Graco 332144C User Manual

Download

Instructions-Parts

Reactor

For spraying or dispensing polyurea coatings and polyurethane foam. For professional use only.

Not approved for use in explosive atmospheres or hazardous locations.

3000 psi (21 MPa, 207 bar) Maximum Working Pressure

Important Safety Instructions

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

E-10hp

332144C

ti21488a

Contents

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Important Isocyanate (ISO) Information . . . . . . . . 6

Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . 6

Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 6

Keep Components ISO and RES Separate . . . . 6

Moisture Sensitivity of Isocyanates . . . . . . . . . . . 6

Foam Resins with 245 fa Blowing Agents . . . . . . 6

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 7

Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Component Identification . . . . . . . . . . . . . . . . . . . 11

Controls and Indicators . . . . . . . . . . . . . . . . . . . . 12

Heater Controls . . . . . . . . . . . . . . . . . . . . . . . . . 12

System Controls . . . . . . . . . . . . . . . . . . . . . . . . 12

Controls and Indicators . . . . . . . . . . . . . . . . . . . 13

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Locate Reactor . . . . . . . . . . . . . . . . . . . . . . . . . 15

Electrical Requirements . . . . . . . . . . . . . . . . . . 15

Ground System . . . . . . . . . . . . . . . . . . . . . . . . . 16

Connect Fluid Hoses . . . . . . . . . . . . . . . . . . . . . 16

Connect Gun Air Hose . . . . . . . . . . . . . . . . . . . 16

Connect Main Air Supply . . . . . . . . . . . . . . . . . 16

Flush Before First Use . . . . . . . . . . . . . . . . . . . 16

Fill Wet-Cups . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Fill Fluid Tanks . . . . . . . . . . . . . . . . . . . . . . . . . 17

Purge Air and Flush Fluid From Lines . . . . . . . 18

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Heatup Guidelines . . . . . . . . . . . . . . . . . . . . . . 20

Heat Management Tips . . . . . . . . . . . . . . . . . . . 20

Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Refill Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 23

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Purge Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Pump Control Status Codes . . . . . . . . . . . . . . . 27

DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . 29

Heat Control Diagnostic Codes . . . . . . . . . . . . . 31

Reactor Electronics . . . . . . . . . . . . . . . . . . . . . . 33

Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Proportioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Before Beginning Repair . . . . . . . . . . . . . . . . . . 39

Remove Supply Tank . . . . . . . . . . . . . . . . . . . . 39

Replace Recirc/Spray Valves . . . . . . . . . . . . . . 40

Displacement Pump . . . . . . . . . . . . . . . . . . . . . 41

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Pressure Transducers . . . . . . . . . . . . . . . . . . . . 50

Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Replace Cycle Counter Switch . . . . . . . . . . . . . 52

Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Tank Fluid Level Sensors . . . . . . . . . . . . . . . . . 55

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

System Packages . . . . . . . . . . . . . . . . . . . . . . . 57

E-10hp Proportioners . . . . . . . . . . . . . . . . . . . . 58

Suggested Replacement Parts . . . . . . . . . . . . . . . 74

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 78

2 332144C

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 symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear 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.

• Connect only to 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 MSDSs 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.

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

SKIN INJECTION HAZARD

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

• Engage trigger lock when not spraying.

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

• Do not put your hand over the spray tip.

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

•Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

332144C 3

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. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are antistatic or conductive.

• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

THERMAL EXPANSION HAZARD

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

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

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

PRESSURIZED ALUMINUM PARTS HAZARD

Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents.

• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for compatibility.

4 332144C

Warnings

WARNING

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.

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

• Do not leave the work area while equipment is energized or under pressure.

• Turn off all equipment and follow the Pressure Relief Procedure 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. Alterations or modifications may void agency approvals and create safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• 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, cut 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 and disconnect all power sources.

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.

332144C 5

Important Isocyanate (ISO) Information

Isocyanates (ISO) are catalysts used in two component materials.

Isocyanate Conditions

Spraying or dispensing 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

Some materials may become self-igniting if applied too thick. Read material manufacturer’s warnings and material MSDS.

Keep Components ISO and RES

Moisture Sensitivity of Isocyanates

Exposure to moisture (such as humidity) will cause ISO to partially cure; forming 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.

NOTICE

Partially cured ISO will reduce performance and the life of all wetted parts.

• Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container.

• Keep the ISO pump wet cup or reservoir (if installed) filled with appropriate lubricant. The lubricant creates a barrier between the ISO and the atmosphere.

• Use only moisture-proof hoses compatible with ISO.

• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.

• Always lubricate threaded parts with an appropriate lubricant when reassembling.

NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature.

Separate

Foam Resins with 245 fa Blowing Agents

Some foam blowing agents will froth at temperatures Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination:

• Never interchange ISO and RES wetted parts.

• Never use solvent on one side if it has been con-

taminated from the other side.

6 332144C

above 90°F (33°C) when not under pressure, especially

if agitated. To reduce frothing, minimize preheating in a

circulation system.

Changing Materials

NOTICE

Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime.

• 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.

• When changing between epoxies and urethanes or polyureas, disassemble and clean all fluid components and change hoses. Epoxies often have amines on the RES (hardener) side. Polyureas often have amines on the RES (resin) side

Important Isocyanate (ISO) Information

332144C 7

Systems

Part

APT100

P2T100

APT900

APT901

APT902

P2T900

P2T901

P2T902

24T900

24T901

24T902

Maximum

Working

Pressure,

psi

(MPa, bar)

3000

(21, 207)

3000

(21, 207)

3000

(21, 207)

3000

(21, 207)

3000

(21, 207)

3000

(21, 207)

3000

(21, 207)

3000

(21, 207)

3000

(21, 207)

3000

(21, 207)

3000

(21, 207)

Gun

Unheated

Proportioner

Volts

Model

120 V 24T100 25R000 ---

230 V 24R900 25R000

230 V 24R900 25R000 Europe

230 V 24R900 25R000

230 V 24R900 25R000 Europe

230 V 24R900 25R000

230 V 24R900 ---

Hose

35 ft (10.6 m)

Cord

Adapter

North

America

Australia/

Asia

North

America

Australia/

Asia

North

America

Model Part

Fusion

PROBLER

Fusion

PROBLER

Air Purge

--- ---

249810

GCP2RA

249810

GCP2RA

230 V 24R900 --- Europe --- ---

230 V 24R900 ---

Australia/

Asia

--- ---

Models

The model no., series letter, and serial no. are located on the back of the cart. For faster assistance, please have that information ready before calling Customer Service.

Maximum Bare Proportioner Part, Series Volts

* Electrical

Connection

24T100, A 120 V 20 A cord

(motor)

20 A cord

(heaters)

24R900, A 230 V 15 A cord

(motor)

15 A cord

(heaters)

* See page 15 for detailed electrical requirements.

8 332144C

Working

Pressure,

psi (MPa, bar) Approvals

3000

(21, 207)

3000

(21, 207)

9902471

Conforms to ANSI/UL

Std. 499 Certified to

CAN/CSA Std.

C22.2 No. 88

Related Manuals

The following manuals are for Reactor E-10hp components and accessories. Some are supplied with your package, depending on its configuration. Manuals are also available at www.graco.com.

Displacement Pump

Part No. Description

311076 Instruction-Parts Manual (English)

Fusion Air Purge Spray Gun

Part No. Description

309550 Instruction-Parts Manual (English)

Probler P2 Spray Gun

Part No. Description

313213 Instruction-Parts Manual (English)

Probler P2 Recirculation Kit

Part No. Description

406842 Instruction-Parts Manual (English)

Lift Ring Kit

Part No. Description

332977 Instruction-Parts Manual (English)

332144C 9

Overview

The Reactor E-10hp is a portable, electric-powered, 1:1 mix ratio proportioner for use with:

•Polyurea

• Polyurea hybrid coatings

• Polyurethane foam

Material may be applied with impingement mix spray guns.

The Reactor E-10hp is gravity-fed from 6 gal. (22.7 liter) supply tanks mounted on the unit.

Severe duty, positive displacement reciprocating piston pumps meter fluid flow to the gun for mixing and applying. When set to recirculation mode, Reactor E-10hp will circulate fluids back to the supply tanks.

The Reactor E-10hp uses primary heating rods and boost heating rods, for each fluid, and an insulated hose bundle with circulation return hoses. This allows the hoses and gun to be preheated to the desired temperature before spraying. The boost heating rods are used during circulation mode to reduce heatup time. Digital displays show the temperatures of the two fluids.

Electronic controls monitor fluid pressures, drive the motor, and alerts the operator if errors occur. See Motor/Pump Status Codes, page 14, for further information.

The Reactor E-10hp has two recirculation speeds, slow and fast, and an adjustable pressure output.

Slow Recirculation

• Slow circulation results in a higher temperature transfer in the heater, so hoses and gun heat up quicker.

• Good for touchup or low flow spraying, up to moderate temperature.

• Not used to circulate full tanks up to temperature.

• Use with 245 fa blowing agent foams, to minimize heat returned to tank and reduce frothing.

Fast Recirculation

• Use to support higher flow rates or higher temperatures by preheating the tanks.

• Agitates fluid within tanks, to avoid heating only the fluid at the top of the tank.

• Use for flushing.

Pressure Adjust

Automatically maintains selected pressure output for dispensing or spraying.

10 332144C

Component Identification

Key for FIG. 1

A Supply Tank (ISO) B Supply Tank (RES) CPump (ISO) DPump (RES) E Heater (under shroud) F Fluid Pressure Gauges G Recirc/Spray and Overpressure Relief Valves H Tank Level Sensors (bottom of tanks) J Control Panel; see F K Electric Motor and Drive Housings L Insulated Hose Bundle (includes circulation return

hoses)

M Fusion Air Purge Spray Gun

. 2, page 12

Component Identification

N Desiccant Dryer P Recirculation Tubes Q Air Line Inlet (quick-disconnect fitting) R Outlet Hose Connections S Return Hose Connections T Fluid Temperature Sensors (located on heater

assembly, under shroud) U Hose Rack and Control Shield V Fluid Inlet Ball Valves (each side) W Fluid Inlet Strainers (each side) X Power Cords (not shown) Y Fluid Temperature Gauges (each side) Z Air Filter/Moisture Separator

. 1: Component Identification

332144C 11

ti21488a

Controls and Indicators

See Controls and Indicators identification table, page

13.

Heater Controls

NOTICE

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

FIG. 2. Heater Controls and Indicators

System Controls

I I

STATUS

AXAW

. 3. System Controls and Indicators

12 332144C

Controls and Indicators

Key Name Description

Heater Controls

AA ISO Setpoint Increase Increases the temperature setpoint by one degree in the units selected

within the setpoint limits. Press target key prior to adjusting.

AB ISO Setpoint Decrease Decreases the temperature setpoint by one degree in the units

selected within the setpoint limits. Press target key prior to adjusting.

AC RES Setpoint Increase Increases the temperature setpoint by one degree in the units selected

within the setpoint limits. Press target key prior to adjusting.

AD RES Setpoint Decrease Decreases the temperature setpoint by one degree in the units

selected within the setpoint limits. Press target key prior to adjusting.

AE ISO Heater On/Off Key Turns heater on or off for ISO zone. Also clears heater zone diagnostic

codes, see page 31.

AF RES Heater On/Off Key Turns heater on or off for RES zone. Also clears heater zone diagnostic

codes, see page 31.

AG Actual Temperature Key Press to display actual temperature. Press and hold to display electrical

current.

AH Target Temperature Key Press to display target temperature. Press and hold to display heater

control circuit board temperature. AJ Temperature Scale Key °F Press to change temperature scale to degrees Fahrenheit. AK Temperature Scale Key °C Press to change temperature scale to degrees Celsius. AL Temperature Display Show actual temperature or target temperature of heater zones,

depending on selected mode. Defaults to actual at startup. Range is

32-170°F (0-77°C) for ISO and RES.

Heater Indicators

AM ISO Heater Activity

AN RES Heater Activity

AO Actual Temperatures Active Actual temperatures are displayed. AP Target Temperatures Active Target temperatures are displayed. AR Fahrenheit Units Active Indicates that temperatures are displayed in °F. AS Celsius Units Active Indicates that temperatures are displayed in °C.

System Controls

AT Heater Power Enables heater control. The switch includes a 20 A circuit breaker. AU Motor Power Enables motor. The switch includes a 20 A circuit breaker. AV Motor Pump Control Function Knob Selects operation mode / pressure setpoint. See Motor/Pump Control

System Indicators

AW Boost Heat Indicator Indicates boost heat is active. AX Tank Level Indicator See Tank Level Sensor LED, page 14. AY System Status Indicator Flashes an error code if alarm or deviation is active. See Motor/Pump

LEDs flash when heater zones are on. The duration

of each flash shows the extent that the heater is

turned on.

LEDs flash when heater zones are on. The duration

of each flash shows the extent that the heater is

turned on.

Function Knob, page 14.

Status Codes, page 14.

332144C 13

Controls and Indicators

Motor/Pump Control Function Knob

Use knob (AV) to select desired function

Icon Setting Function

Stop/Park

Slow Recirc Slow recirculation speed.

Fast Recirc Fast recirculation speed.

Pressure Adjust

Stops motor and automatically parks pumps.

Adjusts fluid pressure to gun in spray mode.

Motor/Pump Status Codes

If error occurs, status indicator (AY) will blink 1 to 19 times to indicate status code, pause, then repeat, or will blink other active error codes. See T description of status codes.

Table 1: Motor/Pump Status Codes

No. Name

1 Pressure imbalance between ISO and RES sides

2 Pressure deviation from setpoint

3 Pressure transducer ISO failure

4 Pressure transducer RES failure

5 Excessive current draw

6 High motor temperature

7 No cycle counter switch input

8 High cycle rate deviation (more than 1.0 GPM)

High cycle rate shutdown (more than 1.1 GPM)

9 Low tank level

10 Not used

11 Locked motor rotor

12 Motor controller bus overvoltage

13 Motor controller bus undervoltage

14 Motor controller high temperature

15-19 Motor controller fault

ABLE

1 for a brief

Heater Control Diagnostic Codes

Heater control diagnostic codes appear on the temperature display. These alarms turn off heat.

Table 2: Heater Control Diagnostic Codes

Code Name Alarm Zone

01 High fluid temperature Individual

02 High zone current Individual

03 No zone current with heater on Individual

04 Thermocouple not connected Individual

05 High controller temperature Individual

06 No communications with zone

pod

09 Display is missing Individual

99 No communication with heater

control module

Individual

Tank Level Sensor LED

The tank level sensor LED (AX) is triggered when chemical is not present in either tank.

Table 3: Tank Level Indicator (AX)

Chemical Status

> 1 gallon Off

< 1 gallon Flashing

NOTE: The default is to shut down if a status code indi-

cation occurs.

14 332144C

Setup

Locate Reactor

1. Locate Reactor on a level surface.

2. Do not expose Reactor to rain.

Electrical Requirements

Improper wiring may cause electric shock or other serious injury if work is not performed properly. All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

1. Connect Reactor to the correct power source for your model. See nected to two separate, dedicated circuits. See F

2. Some models include cord adapters for use outside North America. Connect the appropriate adapter to the unit’s power cord before connecting to your power source.

Table 4

. Power cords must be con-

To avoid electric shock, always unplug both cords before servicing Reactor and wait one minute.

Heater Power

Ensure no other high amp loads are connected while running Reactor.

To verify separate circuits, plug in Reactor or a worklight and cycle breakers on and off.

FIG. 4: Use Two Separate Circuits

Motor Power

Setup

TI7061a

Table 4: Electrical Requirements

Model

230 V, 1 phase, 50/60 Hz, two 15 ft (4.5 m) power cords

120V, 50/60 Hz, two 15 ft (4.5 m) power cords

Required Power Source

Two separate, dedicated circuits rated at minimum of 15 A each

Two separate dedicated circuits rated at minimum of 20 A each

Power Cord Connectors Supplied Local Adapters

NEMA 6-15P

Two IEC 3-20 C20

Euro CEE74

Plugs

YP-39 AS3112

Two NEMA

5-20P Plugs

(North America)

(Australia/Asia)

Table 5: Extension Cord Requirements

Required Wire Size

Model

Up to 50 ft (15 m) Up to 100 ft (30 m)

All models AWG 12 AWG 10

NOTE: Cords must be 3-conductor grounded, rated for your environment.

(Europe)

332144C 15

Setup

Ground System

The equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode. Improper grounding can cause electric shock. Grounding provides an escape wire for the electric current.

Reactor:

Generator (if used):

stop generator with power cord(s) disconnected.

Spray gun:

connected to a properly grounded Reactor. Do not operate without at least one grounded fluid hose.

Object being sprayed:

Solvent pails used when flushing:

code. Use only metal pails, which are conductive, placed on a grounded surface. Do not place pail on a nonconductive surface, such as paper, plastic, or cardboard, which interrupts grounding continuity.

To maintain grounding continuity when flushing or relieving pressure:

firmly to the side of a grounded gun.

grounded through power cord.

follow your local code. Start and

grounded through the supplied fluid hoses,

follow your local code.

follow your local

hold a metal part of spray gun

metal

pail, then trigger

2. Connect recirculation hoses from gun recirculation ports to connections (S).

(ISO)

Air

FIG. 5

(RES)

Connect Gun Air Hose

1. Connect gun air hose to the gun air input and to the air filter outlet (Z). If you are using more than one hose bundle, join the air hoses with the nipple provided with the hose bundle.

2. On units with Fusion guns, connect the supplied ball valve and quick-disconnect coupler to the gun air hose, then connect the coupler to the gun air fitting.

Connect Fluid Hoses

Connect Main Air Supply

1. Connect fluid supply hoses to outlet hose connections (R, F Fittings are sized to prevent connection errors. Connect other end of hoses to ISO and RES inputs of gun.

NOTE: Probler guns use recirc accessory kit 24E727.

. 5). Red hoses for ISO, blue for RES.

Connect the main air supply to the quick disconnect fitting (Q) on the unit. Air supply hose must be at least 5/16 in. (8 mm) ID up to 50 ft (15 m) or 3/8 in. (10 mm) ID up to 100 ft (30 m).

NOTE: Air Filter/Moisture Separator (Z) is equipped with an automatic moisture drain.

Flush Before First Use

The Reactor is tested with a plasticizer oil at the factory. Flush out the oil with a compatible solvent before spraying. See Flushing, page 25.

16 332144C

Setup

Fill Wet-Cups

Keep the felt washers in the pump wet-cups saturated with Graco ISO pump oil, Part No. 217374. The lubricant creates a barrier between the ISO and the atmosphere.

Pump rod and connecting rod move during operation. Moving parts can cause serious injury such as pinching or amputation. Keep hands and fingers away from wet-cup during operation. Shut off Motor

Power before filling wet-cup.

Fill wet-cups through slots in plate, or loosen screws and swing plate aside.

1. Lift hose rack. Remove tank cover and pour ISO into tank (red side, with desiccant filter in cover).

Replace cover .

RES

ISO

Add thin coating of grease lubricant to tank o-ring

if lid is difficult to assemble to tank.

NOTE: Desiccant filter is blue when fresh, and turns pink when saturated. Be sure shipping plugs are removed from openings on desiccant filter.

2. Remove tank cover and pour resin into RES tank

(blue side). Replace cover .

Fill Fluid Tanks

NOTICE

To prevent cross-contamination of fluids and equipment parts, never interchange (isocyanate) and (resin) parts or containers.

Have at least two 5 gal. (19 liter) pails to transfer fluid from drums to supply tanks. Label one pail “ISO” and the other “RES”, using the red and blue labels provided. Always double-check which material you have before pouring it in the supply tanks. Pouring is easier if pails are not filled to the top.

Open only one supply tank at a time, to avoid splashing material from one tank into the other when filling.

NOTE: Using a drill and mixing blade, mix filled or separated materials in the pail before adding to the tanks. Material left in the tanks overnight may need to be remixed in the tanks.

332144C 17

Setup

STATUS

Purge Air and Flush Fluid From Lines

To avoid fire and explosion:

• Flush equipment only in a well-ventilated area.

• Ensure main power is off and heater is cool before flushing.

• Do not turn on heater until fluid lines are clear of solvent.

1. Remove both recirculation tubes (P) from the tanks and secure each one in a dedicated waste container.

5. Turn on Motor Power. System status indicator (AY) should turn on.

6. Set Recirc/Spray valves to Recirc.

ti21495a

7. Set function knob to Slow Recirc or Fast Recirc

ti21489a

2. Set function knob to Stop/Park .

3. Plug in power cords(s). See Table 2, page 15.

4. Open both pump fluid inlet valves (V, shown in open position).

ti21917a

8. When clean fluids exit both recirculation tubes (P),

set function knob to Stop/Park .

ti21490a

9. Replace recirculation tubes in supply tanks.

18 332144C

Startup

d. Press to display actual temperatures.

Heated fluid can cause equipment surfaces to become very hot. To avoid severe burns:

• Do not operate Reactor without all covers and shrouds in place.

• Do not touch hot fluid or equipment.

• Allow equipment to cool completely before touching it.

1. Perform Setup, page 15.

2. Set function knob to Slow Recirc or Fast Recirc

. See Heatup Guidelines, page 20, then con-

tinue with steps 3-6.

ti21489a

3. Turn on Heater Power.

5. Circulate through heater until temperature readouts display desired temperature. See Table 6.

6. Adjust heat controls as necessary for a stable spray temperature.

Table 6: Approximate heatup time for starting a cold

machine with 5 gallons (19 liters) per side

120 V 230 V

Fluid Spray Target

Temperature

35 ft (10.7 m) Hose

(1 bundle)

125°F (52°C) 15 minutes 10 minutes 170°F (77°C) 40 minutes 20 minutes

NOTE: Heatup times are based on 70°F (21°C) starting material temperature and 70°F (21°C) ambient temperature.

NOTE: Different fluids will absorb heat at different rates. When refilling a warm machine, heatup times will be less.

4. Set temperatures:

a. Press or to change temperature

scale.

b. Press to display target temperatures.

c. To set heat zone target temperature,

press or until display shows

desired temperature. Repeat for zone.

332144C 19

Startup

Heatup Guidelines

The fluids must be circulated from the pumps through the heater, hoses, and back to the tanks to ensure warm fluids are supplied to the gun.

Slow Recirculation

• Slow Recirc results in a higher temperature transfer in the heater, so hoses and gun heat up quicker.

• Good for touchup or low flow spraying, up to moderate temperature.

Fast Recirculation

Fast Recirc keeps heaters on full-time to bring fluid tanks up to temperature. The higher your flow rate, the more heat needed in the tanks before spraying.

•

For 230 V systems:

fluid temperature gauges (Y) are within 45°F (25°C) of target outlet temperature.

•

For 120 V systems:

fluid temperature gauges (Y) are within 30°F (17°C) of target temperature.

Use Fast Recirc until pump inlet

Heat Management Tips

• Heaters perform better with lower flow rates or smaller mix modules.

• Triggering the gun for short periods helps maintain efficient heat transfer, keeping material at the desired temperature. Triggering the gun for a long period may not allow enough heating time, depending on material temperature in tanks.

• If temperature displays fall below acceptable limits,

set function knob to Slow Recirculation and circulate again to bring temperatures back up.

• Each 35 ft (10.7 m) hose bundle adds about 5 minutes to heatup time, with most materials. Maximum recommended hose length is 105 ft (32 m).

• For a quicker start, do initial heatup circulation with the tanks 1/4 to 1/3 filled, then add more material.

•

Volume in tanks:

example, 2.5 gal. (10 l) in each tank will heat up almost twice as fast as 5 gal. (20 l).

• Mixes fluid within tanks, to avoid heating only the fluid at the top of the tank.

• Use for flushing.

Use only what you need. For

20 332144C

Spraying

NOTE: Air is supplied to spray gun with gun piston

safety lock or trigger safety lock engaged and gun fluid manifold valves closed (if present).

Fusion

Probler

Spraying

4. Check fluid pressure gauges to ensure proper pressure balance. If imbalanced, reduce pressure of higher component by slightly turning Recirc/Spray valve for that component toward Recirc, until gauges show balanced pressures. The pressure imbalance alarm (Status Code 1) is inactive for 10 seconds after entering spray pressure mode, to allow time to balance pressures.

In this example, RES side pressure is higher, so use the RES side valve to balance pressures.

ti21493a

1. Set function knob to Stop/Park . Verify system

status indicator LED is on.

2. Set Recirc/Spray valves to Spray

ti21490a

ti21491a

3. Turn function knob to Pressure Adjust . Keep

turning to the right until fluid pressure gauges show desired pressure.

ti21492a

NOTE: Watch gauges for 10 seconds to be sure pressure holds on both sides and pumps are not moving.

5. Open gun fluid manifold valves (impingement mix guns only).

Fusion

Probler

NOTE: On impingement guns, never open fluid manifold

valves or trigger gun if pressure are imbalanced.

6. Disengage piston safety lock or trigger safety lock.

Fusion

Probler

7. Test spray onto cardboard or plastic sheet. Verify that material fully cures in the required length of time, and is the correct color. Adjust pressure and temperature to get desired results. Equipment is ready to spray.

332144C 21

Pause

To bring the hose and gun back to spray temperature after a brief break, use the following procedure.

1. Engage piston safety lock or trigger safety lock.

Probler

ti21494a

Fusion

2. Set function knob to Slow Recirc .

3. Set Recirc/Spray valves to Recirc until temperature readouts come back up.

Refill Tanks

Material can be added to the tanks at any time. See Fill Fluid Tanks, page 17.

NOTE: If you are operating at high temperatures or flow

rates, follow Pause instructions to bring tanks up to temperature.

NOTICE

To prevent cross-contamination of fluids and equipment parts, never interchange ISO and RES parts or containers.

Open only one supply tank at a time, to avoid splashing material from one tank into the other when filling.

If you stop spraying for more than 2 minutes when using an impingement mix gun,

close gun fluid valves. Doing this will keep the internal parts of the gun cleaner and prevent crossover.

Fusion

Probler

ti21495a

22 332144C

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

1. Engage piston safety lock or trigger safety lock.

Fusion

Probler

Shutdown

NOTE: For longer breaks (more than 10 minutes) use

the following procedure. If you will be shutdown for more than 3 days, first see Flushing, page 25.

1. Shut off Heater Power.

2. Shut off Motor Power.

3. Follow all steps of Pressure Relief Procedure, page 23.

4. Close gun fluid valves ISO and RES. Doing this will keep the internal parts of the gun cleaner and prevent crossover.

2. Set function knob to Stop/Park .

ti21490a

3. Turn Recirc/Spray valves to Recirc. Fluid will be dumped to supply tanks. Pumps will move to the bottom of their stroke. Ensure gauges drop to 0.

ti21495a

Fusion

Probler

5. Refer to your separate gun manual and perform Shutdown procedure.

332144C 23

Maintenance

• Check pump wet-cups fluid level daily, page 17.

• Throat u-cup is not adjustable. Do not overtighten packing nut/wet-cup.

• Keep component ISO from exposure to moisture in atmosphere, to prevent crystallization.

• Wipe supply tank lid o-ring, inner rim, and inner tank walls daily to prevent ISO crystallization. Keep film of grease on o-ring and inside of lid.

• Check desiccant filter weekly. Filter is blue when fresh, and turns pink when saturated.

• Remove plug (X) and clean fluid inlet strainer (S) as needed. Always clean the fluid inlet strainers after flushing.

ti21836a

• Generally, flush if you will shutdown for more than three days. Flush more often if material is moisture sensitive and humidity is high in the storage area, or if material may separate or settle out over time.

•

If using an impingement mix gun,

valves when not spraying. Doing this will keep the internal parts of the gun cleaner and prevent crossover. Clean gun mix chamber ports and check valve screens regularly. See gun manual.

Fusion

•

If using an Fusion Air Purge impingement mix gun,

always grease the gun after use until purge air carries grease mist out the front of the gun. Use Part No. 117773 Grease. See gun manual.

close gun fluid

Probler

24 332144C

Flushing

STATUS

To avoid fire and explosion:

• Flush equipment only in a well-ventilated area.

• Ensure main power is off and heater is cool before flushing.

• Do not turn on heater until fluid lines are clear of solvent.

• Generally, flush if you will be shut down for more than 3 days. Flush more often if material is moisture sensitive and humidity is high in the storage area, or if material may separate or settle out over time.

• Flush out old fluid with new fluid, or flush out old fluid with a compatible solvent before introducing new fluid.

Flushing

3. Shut off Heater Power. Allow system to cool.

4. Remove recirculation tubes (P) from supply tanks and place in original containers or waste containers.

5. Turn Recirc/Spray valves to Recirc.

• Use the lowest possible pressure when flushing.

• Always leave some type of fluid in system. Do not use water.

• For long term storage, flush out the solvent with a storage fluid such as Bayer Mesamoll plasticizer or, at minimum, clean motor oil.

1. Engage piston safety lock or trigger safety lock. Close fluid valves ISO and RES. Leave air on.

Fusion

Probler

2. Set function knob to Stop/Park .

ti21490a

ti21495a

6. Set function knob to Fast Recirc . Pump material from supply tanks until no more comes out.

ti31496a

7. Set function knob to Stop/Park .

ti21490a

8. Wipe out any remaining material from the supply tanks. Fill each supply tank with 1-2 gal. (3.8-7.6 l) of solvent recommended by your material manufacturer.

332144C 25

Flushing

STATUS

9. Set function knob to Fast Recirc . Pump solvent through system to waste containers.

ti31496a

10. When nearly clear solvent comes from recirculation

tubes, set function knob to Stop/Park . Return

recirculation tubes to supply tanks.

ti21490a

11. Set function knob to Fast Recirc . Circulate solvent through system for 10-20 minutes to ensure

thorough cleaning.

ti31496a

12. Set function knob to Stop/Park .

13. Solvent flushing is a two step process. Go back to step 4, drain solvent, and flush again with fresh solvent.

14. Leave unit filled with solvent, plasticizer, clean motor oil, or refill supply tanks with new material and reprime.

NOTE: Never leave the unit dry unless it has been disassembled and cleaned. If fluid residue dries in the pumps, the ball checks may stick the next time you use the unit.

NOTE: To flush gun, refer to gun instruction manual.

Purge Hoses

Disconnect hoses from gun and secure back into the tanks for thorough cleaning with solvent.

• Turn Recirc/Spray valve ISO to Spray.

• Open gun into waste ISO container.

• Set function knob to Slow Recirc until hose is flushed.

• Set function knob to Stop/Park .

• Repeat for RES side.

26 332144C

Troubleshooting

Pump Control Status Codes

Determine the status code by counting the number of times the system status indicator blinks. The status indicator will blink 1-19 times to indicate a status code.

Multiple active status codes are separated by a longer duration pause.

Status Code 1: Pressure Imbalance

NOTE: The unit does not check for pressure imbalance

at setpoints less than 300 psi (2.1 MPa, 21 bar).

NOTE: The unit does not check for pressure imbalance for 10 sec after entering pressure mode.

Unit senses pressure imbalance between components ISO and RES, and warns or shuts down, depending on settings of DIP switches 1 and 2. To turn off automatic shutdown and/or tighten pressure tolerances for status code 1, see DIP Switch Settings, page 29.

1. Reduce pressure of higher component by slightly turning Recirc/Spray valve for that component toward Recirc, until gauges show balanced pressures.

In this example, RES side pressure is higher, so use the RES side valve to balance pressures.

To turn off automatic shutdown and/or change pressure tolerances for status code 2, see DIP Switch Settings, page 29.

Deviation can occur if power is turned on if function knob (AV) is not set to Park/Off. Leave knob in Park/Off mode until status indicator LED turns on.

Status Code 3: Pressure Transducer ISO Failure

1. Check transducer ISO electrical connection (J11) at board, page 45.

2. Reverse ISO and RES transducer electrical connections at board, page 45. If error moves to transducer RES (Status Code 4), replace transducer ISO, page

50.

Status Code 4: Pressure Transducer RES failure

1. Check transducer RES electrical connection (J12) at board, page 45.

2. Reverse ISO and RES transducer electrical connections at board, page 45. If error moves to transducer ISO (Status Code 3), replace transducer RES, page

50.

Status Code 5: Excessive Current Draw

1. Shut off unit and retry operation. Brushes may not be fully seated.

2. If pressure imbalance continues, see Proportioner

Troubleshooting, page 36.

Status Code 2: Pressure Deviation from

2. Check fan operation. Elevated temperature can cause excessive current draw.

3. Locked rotor; motor unable to turn. Replace motor, page 53.

Setpoint

4. Short on control board. Replace board, page 44.

NOTE: The unit does not check for pressure deviation at setpoint less than 400 psi (2.8 MPa, 28 bar).

Unit senses pressure deviation from setpoint, and warns or shuts down, depending on settings of DIP switches 3 and 4. If equipment cannot maintain enough pressure for a good mix with an impingement mix gun, try using a smaller mix chamber or nozzle.

332144C 27

5. Worn or hung up motor brush causing arcing of brush at commutator. Replace brushes, page 54.

6. Disconnect motor connections from the control board. Cycle power.

a. If status code 5 is still present, replace the

board.

b. If status code 5 is not active, test motor. See

Test Motor, page 53.

Troubleshooting

Status Code 6: High Motor Temperature

Motor is running too hot.

1. Reduce pressure duty cycle, gun tip size, or move Reactor to a cooler location. Allow 1 hour for cooling.

2. Check fan operation. Clean fan and motor housing.

3. Check J9 overtemperature connector on control board.

Status Code 7: No Cycle Counter Switch Input

Have not received input from cycle counter switch for 10 seconds after selecting Recirc mode or unit is unable to park within 15 seconds of entering park mode.

1. Verify that recirc valves are open and unit is set to Recirc mode.

2. Check cycle counter switch connection to board (J10), see F

. 12, page 45.

3. Check J6 connections on control board. See Table 8, page 45.

Level Sensor

LED

Green - on Sensor is powered Green - off Sensor is not powered Yellow - on Sensor detects material Yellow - off Sensor does not detect material

Status

Status Code 11: Locked Motor Rotor

Verify that pumps are not seized and move freely. The motor is unable to turn. Replace motor, page 53.

Shut off unit and contact distributor before resuming operation.

Status Code 12: Motor Controller Overvoltage

Too much voltage connected to control board. See Technical Data, page 75, for power requirements.

3. Check that magnet (224) and cycle counter switch (223) are in place under RES side motor end cover (229). Replace if necessary.

Status Code 8: High Cycle Rate

System is spraying more than 1 gpm. System will shutdown if spraying more than 1.1 gpm.

1. Reduce pressure and/or gun tip size.

Status Code 9: Low Tank Level

The tank level sensors sense ISO and RES material density inside the tank, and warns or shuts down, depending on settings of DIP switch 5. See DIP Switch Settings, page 29.

1. Add material to supply tank, if necessary.

2. Check that the tank level sensor is in contact with the surface of the tank. Replace if necessary. See Tank Fluid Level Sensors, page 55.

Cycle power and check status indicator to see if error is still active.

Status Code 13: Motor Controller Undervoltage

Not enough voltage connected to control board. See Technical Data, page 75, for power requirements.

Cycle power and check status indicator to see if error is still active.

Status Code 14: Motor Controller High Temperature

The motor control board is too hot.

Shutdown and move Reactor to a cooler location. Allow 1 hour for cooling.

Status Code 15-19: Motor Controller Faults

Cycle power. If error is still present, replace board. See, page 44.

28 332144C

DIP Switch Settings

To avoid electric shock, always unplug both power cords before servicing Reactor and wait one minute.

1. Turn power off and unplug power cords from wall outlets.

2. Remove screws and display cover (26).

Troubleshooting

ti21923a

3. Locate the DIP switch on the control board.

FIG. 6: DIP Switch

4. Set DIP switches to the desired positions. See DIP Switch Settings and Functions, page 30

5. Replace display cover (26) and plug in unit.

6. Cycle power switch to activate changes to DIP switch.

332144C 29

Troubleshooting

DIP Switch Settings and Functions

DIP Switch and Function OFF ON

DIP Switch 1

If selected, displays a status code or displays a status code and causes shutdown if the pressure imbalance exceeds selection made in DIP Switch 2.

DIP Switch 2

Select pressure imbalance limits, that if exceeded, will cause a deviation and a shutdown (if enabled).

DIP Switch 3

If selected, causes shutdown or displays a status code due to deviation of pressure from setpoint exceeds selection made in DIP Switch 4.

DIP Switch 4

Causes deviation if pressure setpoint is greater than:

DIP Switch 5

Causes shutdown or displays a status code for low fluid level in tanks.

DIP Switch 6

Enables or disables boost heat.

DIP Switch 7

DIP Switch 8

DEVIATION DEVIATION AND

See Dip Switch 1 and 2 Settings table, page 30

DEVIATION

300 psi (2.1 MPa, 21 bar)

(25% if < 800 psi [5.6 MPa, 56 bar])

DEVIATION

DISABLE

Not used

SHUTDOWN

500 psi (3.5 MPa, 35

bar)

(40% if < 800 psi [5.6 MPa, 56 bar])

SHUTDOWN

ENABLE

Default DIP Switch Settings

DIP Switch 1 and 2 Settings

DIP Switch 1

Off Off

Off

30 332144C

DIP Switch 2

Off

Deviation Shutdown

300 psi (2.1 MPa, 21 bar)

500 psi (3.5 MPa, 35 bar)

300 psi (2.1 MPa, 21 bar)

500 psi (3.5 MPa, 35 bar)

---

500 psi (3.5 MPa, 35 bar)

800 psi (5.6 MPa, 56 bar)

Troubleshooting

Heat Control Diagnostic Codes

Heat control diagnostic codes appear on the temperature display.

These alarms turn off heat. Codes E03 and E04 can be

cleared by pressing .

1. To clear other codes:

2. Shut off Heater Power.

3. Shut off Motor Power.

• Failed heater element where thermocouple is installed.

• Loose wire

E01 Checks

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

NOTE: Before checking the thermocouple, note which zone (ISO or RES) has high fluid temperature.

1. Check that connector B is firmly plugged into heater control module. See Temperature Control Mod- ules Connections, page 47.

2. Clean and re-plug connections.

4. Turn on Motor Power and Heater power to clear.

Code Code Name Alarm

Zone

01 High fluid temperature Individual

02 High zone current Individual

03 No zone current Individual

04 Thermocouple not con-

nected

Individual

Corrective

Action page

E01: High Fluid Temperature

• Thermocouple ISO or RES (310) senses a fluid temperature above 260°F (71°C).

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

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

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

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

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

3. Check connections between the temperature control module and overtemperature switch, and between the temperature control module and thermocouples. Ensure all wires are securely connected to connector B on heater control module. See Table 7, page 32.

332144C 31

Troubleshooting

4. Remove connector B from heater control module and check continuity of thermocouples by measuring resistance across pins on the plug end.

Table 7: Connector B Resistance Measurements

120V 230V

Connector Pin Connector Pin

B1 1, 2 B1 1, 2 Overtemperature Switch nearly 0 ohms B2 1 B1 5 Thermocouple ISO, R (red) B2 2 B1 6 Thermocouple ISO, Y (yellow) B2 4 B1 8 Thermocouple RES, R (red) B2 5 B1 9 Thermocouple RES, Y (yellow) B2 3 B1 3-4,7,10 Unused N/A

If temperature [127°C] or above):

6. Check if thermocouples are damaged, or not contacting the heater element, see F

7. Check if temperature control module turns off when equipment reaches temperature setpoint:

too high (sensor reading is 260°F

. 16, page 49.

Description

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

E03: No zone current

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

1. Check for tripped circuit breaker on Reactor or at power source of that zone. Replace circuit breaker if it trips habitually.

Reading

4-6 ohms

a. Set temperature setpoints far below displayed

temperature.

b. Turn zone on. If temperature rises steadily,

power board is failing.

c. Verify by exchanging with another power mod-

ule. See Replace Temperature Control Mod- ules, page 46.

d. If the exchanged module does not fix the prob-

lem, the power module is not the cause.

8. Verify continuity of heater elements with an ohmmeter, see page 48.

E02: High zone current

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

1. See Before Beginning Repair, page 39.

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 46). If error disappears, replace faulty module.

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

E04: Thermocouple disconnected

1. Check temperature sensor connections to green connectors (B) on temperature control module. See Temperature Control Modules Connections, page 47.

2. Unplug and re-plug sensor wires.

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

32 332144C

Troubleshooting

Reactor Electronics

Before performing any troubleshooting procedures:

1. Shut off Heater Power.

PROBLEM CAUSE SOLUTION

Temperature display does not illuminate.

Display disconnected. Check cable connections, page 45.

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

Blown fuse. Replace fuse (73) in fuse holder on

Failed circuit board. Display is failing. Replace.

Loose display cables on control board.

Failed control board (displays get power from control board).

Inadequate power to control board. Check that power supply meets

Loose power cable. Check cable connections, F

Heater power switch circuit breaker tripped.

2. Shut off Motor Power.

3. Relieve pressure, page 23.

4. Allow equipment to cool.

5. 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.

damaged.

DIN rail assembly located under electronics cover (55).

Check cable connections to each display, F

. 23 on page 72.

Remove access panel. Check if board LED is lighted. If not, replace board, page 44.

requirements.

. 23 on

page 72.

Display is powered from heater power circuit breaker. Cycle heater

power off , then on

to reset breaker.

Erratic display; display turns on and off.

Low voltage. Ensure input voltage is within specifi-

cations, page Technical Data, page

75.

Poor display connection. Check cable connections, F

. 23 on

page 72. Replace damaged cable.

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

damaged.

332144C 33

Troubleshooting

PROBLEM CAUSE SOLUTION

Display does not respond properly to button pushes.

Poor display connection. Check cable connections, FIG. 23 on

page 72. Replace damaged cable.

Display cable damaged or corroded. Clean connections, F

72. Replace damaged cable.

Ribbon cable on display circuit board disconnected or broken.

Connect cable, F or replace.

Broken display button. Replace, page 42.

Fan not working. Loose wire. Check fan wire.

Defective fan. Replace, page 54.

. 23 on page

. 23 on page 72,

34 332144C

Troubleshooting

Heaters

Before performing any troubleshooting procedures:

1. Shut off Heater Power.

PROBLEM CAUSE SOLUTION

Primary heater(s) does not heat. Heat turned off.

Temperature control alarm. Check temperature display for diag-

Signal failure from thermocouple. See E04: Thermocouple discon-

2. Shut off Motor Power.

3. Relieve pressure, page 23.

4. Allow equipment to cool.

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

Press or zone

keys.

nostic code, page 31.

nected, page 32.

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

Failed heater element. Check resistance of heater elements.

See Test Heater Element, page 48.

Dirty thermocouple connections. Examine connection of thermocou-

ples to long green plug on heater control board. Unplug and re-plug thermocouple wires, cleaning off any debris. For 120V, unplug and re-plug long green connector. For 230V, unplug and re-plug green connector(s) B.

Thermocouple not contacting heater element.

Failed heater element. See Heaters, page 35.

Signal failure from thermocouple. See E04: Thermocouple discon-

Thermocouple wired incorrectly. See E04: Thermocouple discon-

Loosen ferrule nut (N), push in thermocouple (310) so tip (T) contacts heater element (307). Holding thermocouple tip (T) against heater element, tighten ferrule nut (N) 1/4 turn past tight. See page 49 for illustration.

nected, page 32.

nected, page 32. Power up zones

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

332144C 35

Troubleshooting

Proportioner

Before performing any troubleshooting procedures:

1. Shut off Heater Power.

PROBLEM CAUSE SOLUTION

Reactor does not operate. No power. Plug in both power cords.

2. Shut off Motor Power.

3. Relieve pressure, page 23.

4. Allow equipment to cool.

Cycle Motor Power and Heater

Power off , then on

to reset both breakers.

Motor does not operate. Power turned on while function knob

set to a run position.

Loose connection on control board. Check connection at motor power

Worn brushes. Check both sides. Replace brushes

Broken or misaligned brush springs. Realign or replace, page 54.

Brushes or springs binding in brush holder.

Shorted armature. Replace motor, page 53.

Check motor commutator for burn spots, black pitting, or other damage.

Failed control board. Replace board. See page 44.

Pump output low. Plugged fluid inlet strainer. Clear, see page 24.

Leaking or plugged piston valve or intake valve in displacement pump.

Set function knob to Stop/Park ,

once status LED turns on. Then select desired function.

connections on bottom board. See F

. 12, page 45.

worn to less than 1/2 in. (13 mm), see page 54.

Clean brush holder and align brush leads for free movement.

Remove motor. Have motor shop resurface commutator, or replace motor, page 53.

Check valves. See pump manual.

36 332144C

PROBLEM CAUSE SOLUTION

Troubleshooting

One side doesn’t come up to pressure in spray mode.

Low fluid in tank. Refill.

Dirty or damaged Recirc/Spray valve. Clean or repair, page 40.

Plugged fluid inlet strainer. Clear, see page 24.

Pump intake valve plugged or stuck open.

Clean pump intake valve. See page

41.

Material is too viscous to pump. Warm material before adding to

tanks.

Pressure is higher on one side when setting pressure with function knob.

Pump intake valve partially plugged. Clean pump intake valve. See page

41.

Air in hose. Fluid is compressible. Purge air from hose.

Pressures are not balanced when running, but pressure is generated and holds on both strokes.

Unequal size hoses or unequal hose construction.

Unequal viscosities. Change temperature setting to bal-

Use matching hoses, or balance pressures before spraying.

ance viscosities.

Change restrictor at mix point to balance back pressure.

Restriction on one side. Clean mix module or restrictor at mix

manifold.

Clean gun check valve screens.

Fluid leak in pump packing nut area. Worn throat seals. Replace. See pump manual.

Pressure doesn’t hold when stalled against gun in spray mode.

Leaking Recirc/Spray valve. Repair, page 40.

Leaking piston valve or intake valve

Repair. See pump manual.

in displacement pump.

Leaking gun shutoff. Repair. See gun manual.

Pressure is higher on RES side during startup of recirculation, especially in High Recirc mode.

This is normal. RES is typically higher viscosity than ISO until the material is heated during recircula-

No action required.

tion.

One gauge shows half as many pulses as the other when pumps are cycling.

Loss of pressure on downstoke. Intake valve is leaking or not closing.

Clean or replace valve; see page 40.

Loss of pressure on upstoke. Piston valve is leaking or not closing.

Clean or replace valve or packings; see page 40.

Status indicator not lit. Function knob is not set to Park/Off

Turn function knob to Park/Off.

when power is applied.

Loose indicator cable. Check that cable is connected at J3

on top motor control board. See page

45.

Failed control board. Replace board. See page 44.

Shorted pressure transducer or potentiometer input.

See Control Board LEDs, page 44 for troubleshooting.

332144C 37

Troubleshooting

PROBLEM CAUSE SOLUTION

ISO side rich; lack of RES side. ISO side gauge is low. RES side restriction downstream of

gauge. Check gun check valve screen, mix module, or mix manifold restrictor.

RES side gauge is low. RES side material supply problem.

Check RES side inlet strainer and pump intake valve.

RES side rich; lack of ISO side. ISO side gauge is low. ISO side material supply problem.

Check ISO side inlet strainer and pump intake valve.

RES side gauge is low. ISO side restriction downstream of

gauge. Check gun check valve screen, mix module, or mix manifold restrictor.

Tank level sensor does not sense empty tank (indicator LED on control panel never blinks).

Material build up. Flush and clean inside of tanks.

Clean outside of sensor and recessed area on tank.

LED wires disconnected inside con-

Reconnect LED wires.

trol panel.

Tank level sensor does not sense full tank (indicator LED on control panel always blinking).

Tank level sensor sensitivity is too high.

Tank level sensor is too far away from tank.

Reset tank fluid level sensor sensitivity, page 56.

Check position of both tank level sensors. See Tank Fluid Level Sen- sors, page 55.

Sensor wires disconnected. Reconnect sensor wires in display

panel.

Tank level sensor sensitivity is too low.

Reset tank fluid level sensor sensitivity, page 56.

38 332144C

Repair

Before Beginning Repair

Repairing this equipment requires access to parts which 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 page 15. Be sure to shut off all power to the equipment before repairing.

1. Flush if possible, see page 25. If not possible, clean all parts with solvent immediately after removal, to prevent isocyanate from crystallizing due to moisture in the atmosphere.

2. Set function knob to Stop/Park .

ti21490a

Remove Supply Tank

1. See Before Beginning Repair, page 39.

2. Relieve pressure, page 23.

3. Flush, page 25.

4. Place waste container under y-strainer.

5. Close fluid valve (V).

ti21893a

3. Shut off Motor Power.

4. Shut off Heater Power. Allow system to cool.

5. Relieve pressure, page 23.

6. Disconnect heater and motor power cords.

6. Remove filter drain hex nut (N) and drain material.

7. Remove recirculation tubes (P) and place in waste containers.

332144C 39

Repair

8. Disconnect swivel elbow at pump fluid inlet.

9. Remove six screws (28) holding tank (27) to cart frame.

ti21837a

10. Loosen nut and slide tank level sensor (S) away from the tank.

11. Pivot top of tank to side and remove the tank, with fluid inlet fittings, off the cart.

Replace Recirc/Spray Valves

1. See Before Beginning Repair, page 39.

2. Relieve pressure, page 23.

3. See F

4. Ensure that the seat (453a) and gasket (453b) are

5. Apply PTFE pipe sealant to all tapered pipe threads

6. Reassemble in reverse order, following all notes in

. 7. Disassemble Recirc/Spray valves.

Clean and inspect all parts for damage.

positioned inside each valve cartridge (453).

before reassembling.

. 7.

456

455

12. Reinstall in reverse order. Torque screws (28) to 125 in.-lbs (14 N•m).

Torque to 250 in-lb (28 N•m).

Use blue threadlocker on valve cartridge threads into manifold.

Part of item 453.

FIG. 7: Recirc/Spray Valves

453

453a 453b

ti21838a

454

40 332144C

Repair

Displacement Pump

NOTE: Use dropcloth or rags to protect Reactor and

surrounding area from spills.

1. See Before Beginning Repair, page 39.

2. Relieve pressure, page 23.

3. Close both fluid valves (V).

ti21893a

NOTE: Use dropcloth or rags to protect Reactor and surrounding area from spills.

8. Remove pump rod cover (222). Push clip up in back and push pin (217) out. Loosen locknut (218) by hitting firmly right-to-left with a non-sparking hammer. Unscrew pump. See manual 311076 for pump repair and parts.

9. Install pump in reverse order of disassembly, following all notes in F

. 8. Clean strainer (51). Recon-

nect fluid inlet (C) and outlet (D) lines.

10. Tighten fluid outlet fitting (D), then tighten locknut (218) by hitting firmly with a non-sparking hammer.

11. Set function knob to Slow Recirc . Purge air and prime. See Purge Air and Flush Fluid From

Lines, page 18.

217

4. Open filter drain hex nut (N) on y-strainer.

Remove Intake Valve Only

NOTE: If pump is not generating any pressure, the

intake ball check may be stuck closed with dried material.

If the pump is not generating pressure on the downstroke, intake ball check may be stuck open.

Either of these conditions can be serviced with the pump in place.

5. Disconnect fluid inlet (C) and swing it aside.

6. Remove intake valve by hitting ears (E) firmly, right-to-left, with a non-sparking hammer. Unscrew from pump. See displacement pump manual for repair and parts.

Remove Entire Pump Assembly

7. Disconnect fluid inlet (C) and outlet (D) lines. Also disconnect steel outlet tube (46) from heater inlet.

Flat side faces up. Tighten by hitting firmly with non-sparking hammer.

Lubricate threads with ISO oil or grease.

FIG. 8: Displacement Pump

218

222

ti21839a

TI7025a

332144C 41

Repair

Control Panel

Replace Temperature Display

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. See Before Beginning Repair, page 39.

2. Remove screws (21) and display cover (26).

Replace Function Knob/Potentiometer

1. See Before Beginning Repair, page 39.

2. Remove screws (21) and back cover (26).

3. Disconnect potentiometer wires from J5 on motor control board (354). See F

4. See F

. 9. Remove two setscrews (356a) and pull

function knob (356) off potentiometer (357) shaft.

5. Remove nut (N, part of 357) and detent plate (358).

6. Install new potentiometer (357) in reverse order. Position potentiometer so slot (S) is horizontal. Position knob (356) so pointer (P) faces up. Install knob on shaft so slot (S) engages alignment pin in knob. Push knob onto shaft against detent spring before tightening setscrews (356a).

7. Reconnect potentiometer wires to J5.

. 12, page 45.

ti21923a

3. Put on static conductive wrist strap.

4. Disconnect main display cable (81) from upper right

corner of temperature display (353). See F

. 10.

5. Remove jumper (373) from back of display (353). Set aside and install jumper on new display.

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

. 10.

7. Remove nuts (360) from plate (351).

8. Disassemble display (353), see detail in F

9. Reassemble in reverse order, see F

. 10.

. 10. Apply

medium strength thread sealant where shown.

358

356

356a

FIG. 9: Function Knob/Potentiometer

357

ti21840a

42 332144C

360

Repair

353

373

351

357

FIG. 10: Control Panel

352

363

ti21841a

354

332144C 43

Repair

Motor Control

Power Bootup Check

NOTE: Power must be on to check. See FIG. 11 or loca-

tion. Function is:

• Motor ready: LED on.

• Motor not ready: LED off.

• Status code (motor not running): LED blinks status code.

• Multiple status codes are separated by a longer LED off duration.

Control Board LEDs

If LEDs on bottom board are on and the top board LEDs are off, the following may have occurred:

• A pressure transducer shorted out.

• A short occurred between the power and ground pin of the potentiometer.

Board LED State Description

Top R4 Red: on Hardware or software

failure

G1 Green: on Power on

Bottom D4 Red: on Hardware or software

failure

D16 Green: on Power on

Replace Control Board

NOTE: Check motor before replacing board. See Test Motor, page 53.

1. See Before Beginning Repair, page 39.

2. Remove access cover (26) on back of cart to expose control board (354).

354

ti21923a

3. Disconnect all cables and connectors from board (354). See Table 8, page 45.

4. Remove six nuts (363) and remove board from control board (354). See F

. 10, page 43.

J98

J12

J11

J10

D16

(under C52)

(bottom side

5. Install new board in reverse order.

of board)

FIG. 11

44 332144C

Table 8: Control Board Connectors (see FIG. 12)

Top Board Connectors Bottom Board Connectors

Board

Jack Pin Description Connector Description

J1 n/a Not Used Female Quick

Power

Connect Terminals

J2 n/a Not Used Plug Housing with

Motor Power

Male Blades J3 n/a Error LED J4 n/a Tank Level LED J5 n/a Function Knob J6 1 Brown - ISO Sensor V+

2 Blue - ISO Sensor V3 Black - ISO Sensor Signal 4 Brown - RES Sensor V+ 5 Blue - RES Sensor V-

6 Black - RES Sensor Signal J8 n/a Boost Power Relay J9 n/a Motor Overtemperature

J10 n/a Cycle Switch J11 n/a ISO Pressure Transducer J12 n/a RES Pressure Transducer

Repair

Bottom

FIG. 12: Wiring Connections

Top

J98

J12

J11

J10

332144C 45

Repair

Replace Temperature Control Modules

NOTICE

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

1. See Before Beginning Repair, page 39.

2. Remove heater shroud (89) and electronics cover (55).

4. Disconnect all cables and connectors from temperature control module (59).

ti21844a

FIG. 13

5. Remove hex nut (56) and replace defective module.

6. Install new module in reverse order. Connect all cables and connectors.

3. Put on static conductive wrist strap.

ti21845a

46 332144C

Repair

Temperature Control Modules Connections

Table 9: Heater Control Module Connections

Description

Connector

DATA (A) Not used

Sensor (B) See Table 11

DISPLAY (C) Display

COMMUNICATION

(D)

PROGRAM (E) Software programming

BOOT (F) Software bootloader

120V 230V

Communication to power boards

Table 11: Sensor B Connections

120V 230V

B1 1, 2 B1 1, 2 Overtemperature Switch B2 1 B1 5 Thermocouple ISO, R (red) B2 2 B1 6 Thermocouple ISO, Y (yellow) B2 4 B1 8 Thermocouple RES, R (red) B2 5 B1 9 Thermocouple RES, Y (yellow) B2 3 B1 3-4,7,10 Unused

Table 9: Heater Control Module Connections

Description

Connector

120V 230V

POWER/RELAY (G) Circuit board power input

and contactor control output

Table 10: Temperature Power Module Connections

Connector Description

COMMUNICATION

(H)

Communication to control board

POWER (J) Power to heater

DescriptionConnector Pin Connector Pin

120 V 230 V

CB1 B2

FIG. 14: Temperature Control Module Connections

ti9843a4

ti21843a

B1C

332144C 47

Repair

Heater

Test Heater Element

1. See Before Beginning Repair, page 39.

2. Wait for heater to cool.

3. Remove heater shroud (90) and electronics cover (55).

4. Disconnect heater element wires from heater wire connector. Test with ohmmeter. Replace heater element if the resistance reading does not fall within the range.

Heater

Voltage

120 1500 500 24-32

230 2000 620 73-94

Wattage Per

Zone

Element Wattage Ohms

1000 12-16

1380 32-43

Remove Heater Element

1. To remove heater element, first remove thermocouple (310) to avoid damage, see step 7, page 49.

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

3. Inspect element.

FIG. 15

ti21845a

NOTE: 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.

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

5. Reinstall thermocouple, page 49.

6. Reconnect heater element leadwires to heater wire connector.

7. Replace heater shroud (90) and electronics cover (55).

Line Voltage

The primary heaters output their rated wattage at either 120 Vac or 230 Vac, depending on system. Low line voltage will reduce power available and the heaters will not perform at full capability.

48 332144C

Repair

Thermocouple

1. See Before Beginning Repair, page 39.

2. Wait for heaters to cool.

3. Remove heater shroud (90) and electronics cover (55). See F

4. Loosen and remove temperature control module bracket mounting fasteners (56). Move control module up and out of the way to access thermocouple.

5. Disconnect thermocouple wires from B on temperature control module. See Temperature Control Modules Connections, page 47.

6. Clip cable ties as necessary. Note path as wires must be replaced in the same way.

7. See F mocouple (310) from heater housing (301), then remove thermocouple housing (H). Do not remove the thermocouple adapter (305) unless necessary. If adapter must be removed, ensure that mixer (309) is out of the way when replacing the adapter.

. 15, page 48.

. 16. Loosen ferrule nut (N). Remove ther-

8. Replace thermocouple, F

. 16.

a. Remove protective tape from thermocouple tip

(T).

b. Apply PTFE tape and thread sealant to male

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

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

heater element (307).

d. Holding thermocouple (T) against heater ele-

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

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

10. Replace heater shroud (90) and electronics cover

(55). See F

. 15, page 48.

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

309

FIG. 16. Thermocouple

310

305

301

Apply PTFE tape and thread sealant.

Apply 110009 thermal heatsink compound.

307

308

ti7924a

332144C 49

Repair

Overtemperature Switch

1. See Before Beginning Repair, page 39.

2. Wait for heaters to cool.

3. Remove heater shroud (90) and electronics cover (55). See F

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

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

NOTE: If wires need replacement, disconnect from heater control module. See F

. 15, page 48.

. 16. Test across switch with ohm-

. 24 on page 73.

a. Remove supply tank, page 39.

b. Follow transducer cable on cart frame and cut

zip ties. Disconnect transducer from pump outlet manifold.

c. Install o-ring (553) on new transducer (554).

Apply lubricant to o-ring (553).

d. Install transducer (554) in manifold. Mark end of

cable with tape (red = ISO, blue = RES).

e. Route cable back through cart frame to the con-

trol board. See F

. 12, page 45.

f. Install supply tank.

554

553

Pressure Transducers

1. See Before Beginning Repair, page 39.

2. Remove back cover (26).

354

ti21923a

3. Disconnect transducer cables from J11 and J12 connectors. Reverse ISO and RES transducer connections and check if status codes follows the bad transducer.

. 17. Transducer

ti21846a

4. Replace transducer if the transducer fails test.

50 332144C

Repair

Drive Housing

Removal

1. See Before Beginning Repair, page 39.

2. Remove screws (207) and end covers (229), see F

. 18.

NOTE: Examine connecting rod (216). If rod needs replacing, first remove the pump (219), page 41.

NOTICE

To prevent equipment damage, do not drop gear reducer (214) and crankshaft (210) when removing drive housing (215). These parts may stay engaged in motor end bell (MB) or may pull away with drive housing.

3. Disconnect pump inlet and outlet lines. Remove screws (220) and pull drive housing (215) off motor (201) Connecting rod (216) will disengage from crankshaft (210).

4. Install gear reducer (214) and crankshaft (210) into motor end bell (MB).

NOTE: Crankshaft (210) must be in line with crankshaft at other end of motor. Pumps will move up and down together.

NOTE: If connecting rod (216) or pump (219) were removed, reassemble rod in housing and install pump, page Displacement Pump, page 41.

5. Push drive housing (215) onto motor (201). Install screws (220).

6. Install drive housing covers (229) and screws (207). Pumps must be in phase (both at same position in stroke).

4. Examine crankshaft (210), gear reducer (214), thrust washers (208, 212), and bearings (209, 211,

213).

Installation

1. Apply grease liberally to washers (208, 212), bearings (209, 211, 213), gear reducer (214), crankshaft (210), and inside drive housing (215). Grease is supplied with replacement parts kits.

NOTE: RES side crankshaft (210) includes the cycle counter magnet (224). When reassembling, be sure to install crankshaft with magnet on RES side.

If replacing crankshaft, remove magnet (224). Reinstall magnet in center of offset shaft on new crankshaft. Position shaft in Park position.

2. Install bronze bearings (211, 213) in drive housing (215), as shown.

3. Install bronze bearings (209, 211) and steel washer (208) on crankshaft (210). Install bronze bearing (213) and steel washer (212) on gear reducer (214).

332144C 51

Repair

Replace Cycle Counter Switch

NOTE: RES side drive housing cover (229) includes the

cycle counter switch (223), mounted in the cover. When reassembling, be sure to install cover with switch on RES side.

201

208 (steel)

209 (bronze)

223

0.6 in. (15.2 mm) from inside edge

1.0 in. (25.4 mm) from inside bottom edge

TI7028a

233

221

223

211 (bronze)

210

224

215

220

229

207

214

213 (bronze)

216

Crankshaft must be in line with crankshaft at other end of motor, so pumps move up and down in unison.

FIG. 18. Drive Housing

213 (bronze)

219

212

(steel)

ti21847a

52 332144C

Repair

Electric Motor

Test Motor

If motor is not locked up by pumps, it can be tested using a 9 V battery.

1. Open recirculating valves.

2. Disconnect motor connections from control board, see F

. 12, page 45. Touch jumpers from battery to motor connections. Motor should turn slowly and smoothly.

Removal

NOTE: See wiring schematic, page 45.

1. See Before Beginning Repair, page 39.

2. Relieve pressure, page 23.

3. Remove four screws (91), shroud (89), and mounting brackets (233). See F

. 18.

NOTICE

To prevent dropping the motor, two people may be required to lift.

10. Remove screws (15) holding motor (201) to bracket. Lift motor off unit.

11. If replacing motor, remove shroud mounting bolts (207) and brackets (233) and set aside.

Installation

1. If replacing motor, install fan assemblies (16) and shroud mounting brackets (233) on new motor (201).

2. Place motor (201) and fans (16) on unit. Thread motor switch harness through grommets in cart and into the back of the display. See F

3. Fasten motor (201) with screws (15) underneath. Do not tighten yet.

4. Plug motor temp switch harness to connector J9 and grounding cable from grounding screw.

5. Plug in motor power connector.

. 24 on page 73.

4. Remove fans (16) and disconnect cable (80). See

. 20.

5. Remove drive housing/pump assemblies, page 51.

6. Remove display control cover (26). Disconnect motor cables as follows:

a. Unplug motor power connector before ferrite

(88).

b. Unplug motor temp switch harness from con-

nector J9 and remove grounding cable from grounding screw.

7. Remove RES supply tank. See Remove Supply Tank, page 39.

8. Cut zip ties.

9. Thread motor power switch harness and over temp switch out bottom of control module and cable channel, to free motor.

6. Secure all cables to cart frame with zip ties.

7. Install display control cover (26).

8. Install supply tank.

9. Install drive housing/pump assemblies, page 51. Reconnect inlet assemblies to pumps.

10. Torque screws (15) to 150 in.-lbs (17 N•m).

11. Return to service.

332144C 53

Repair

Motor Brushes

NOTE: Replace brushes worn to less than 1/2 in. (13

mm). Brushes wear differently on each side of motor; check both sides. Brush Repair Kit 287735 is available; kit includes instruction sheet 406582.

NOTE: Motor commutator should be smooth. If not, resurface commutator or replace motor.

1. See Before Beginning Repair, page 39.

2. Relieve pressure, page 23.

3. Remove four screws (91) and motor shroud (89). See F

. 18.

4. Remove fans (16) and disconnect cable (80). See

. 20.

5. Loosen pump inlet and outlet connections.

6. Remove the display control cover (26). Disconnect motor cables as follows:

a. Unplug motor power connector.

9. See instruction sheet 406582, included with Brush Repair Kit 287735.

ti21916a

FIG. 19: Motor Brushes

Fans

1. Disconnect fan cable (80) from fan (16). With Motor Power on, test cable connector for line voltage (120 V or 230 V).

If voltage is 120 V or 230 V,

Remove screws holding fan to shield (17). Install new fan in reverse order.

If voltage is not 120 V or 230 V,

connection at terminal blocks 1 and 2; see F on page 72.

fan is defective.

check fan cable

. 23

b. Unplug motor temp switch harness from con-

nector J9. Disconnect grounding cable from grounding screw.

7. To replace the front motor brush:

a. Remove the two bolts and access cover plate.

See F

. 19.

b. Remove old brushes and install new ones sup-

plied in kit.

8. To replace the rear motor brush:

a. Remove motor mounting bolts. Slide the motor

forward and lean on the cart frame.

a. Remove the two bolts and access cover plate.

See F

. 19.

b. Remove old brushes and install new ones sup-

plied in kit.

. 20. Fans

ti21848a

54 332144C

Repair

Tank Fluid Level Sensors

Adjust

Adjust position of tank fluid level sensor (57) so that the sensor contacts the surface of the tank.

1. Loosen sensor jam nuts and press sensor (57) against the tank.

2. Spin on inner jam nut until flush, then tighten inner jam nut one more turn.

3. Retighten outer jam nut.

6. Route new tank level sensor cable through grommet on bottom of cart and through the grommet on bottom of control panel. Connect new level sensor (57) to J6.

7. Install the display control cover (26).

8. Zip tie tank level sensor cable with other low voltage cables.

9. Reinstall supply tank. See page 39.

10. Adjust position of level sensor assembly (57). See Adjust.

11. Set sensitivity. See Reset Sensitivity, page 56.

12. Check operation of both sensors.

a. Hold one hand inside both tanks for 5 seconds,

near inner wall, where the tank level sensor is located.

b. The tank level indicator LED on the control

panel will stop flashing when it senses both of your hands.

ti21849a

Replace

1. Loosen jam nuts and remove level sensor assembly (57).

2. Remove supply tank, see page 39.

3. Cut zip ties securing the sensor cable to the cart.

4. Remove the display control cover (26).

ti21923a

5. Disconnect level sensor connector from J6 on control board. See F

. 12, page 45.

c. The tank level indicator LED will flash if either

tank sensor indicates that it is low. Alternately, remove each hand away from inner wall for 5 seconds. The tank level indicator LED on the control panel will flash.

Table 12: Sensor LED Identification

LED Status

Green - on Sensor is powered Green - off Sensor is not powered Yellow - on Sensor detects material (immediate, no

5 second display)

Yellow - off Sensor does not detect material

ti21963a

FIG. 21: Sensor LEDs

332144C 55

Repair

Reset Sensitivity

The tank fluid level sensor sensitivity may need to be adjusted when:

• A new tank has a different insulation density than the previous tank.

• Material build-up is on the inside or outside of the tank. Adjust sensitivity rather than thoroughly cleaning the tank.

• Level sensor sensitivity comes out of alignment through misuse or harsh environment.

• Material density is less than normally pumped materials.

1. Ensure tank is completely empty.

2. Remove shroud (89) to expose the sensors.

3. Ensure sensor (57) and tank are properly installed. See Adjust, page 55.

7. Slowly turn the adjustment screw (S) counterclockwise an additional 1/2 turn.

NOTE: The yellow LED should stay turned off.

8. Fill tank with desired material and verify that sensor detects material. The yellow LED will turn on when material reaches the one gallon mark.

If the yellow LED does not turn on after two gallons of the material, then the material density may be too low and is not detected by the sensor. Turn the adjustment screw clockwise in 1/8 turn increments until sensor detects the material and the yellow LED turns on.

NOTE: If the adjustment screw is turned a total 1/2 turn, then it will not detect an empty tank.

9. Reinstall the shroud (89).

4. Locate the adjustment screw (S) above the green and yellow LEDs.

NOTE: The adjustment screw on some tank level sensors is covered by white tape. Remove the white tape to access the adjustment screw.

ti21963a

FIG. 22: Adjustment Screw

5. Use a small flathead screwdriver and slowly turn the adjustment screw (S) clockwise until the yellow LED turns on.

6. Slowly turn the adjustment screw (S) counterclockwise until the yellow LED barely turns off.

56 332144C

Parts

System Packages

Parts

System

Package

104

101

15G962

103

Proportioner Hose Gun Power Cord Adapter

101

see page 58

102

see page 71

15G958

103

16W239

104

Part No. Region

102

APT100 24T100 25R000 249810 ✖✖

P2T100 24T100 25R000 GCP2RA* ✖✖

APT900 24R900 25R000 249810 16W239 North America

APT901 24R900 25R000 249810 15G958 Europe

APT902 24R900 25R000 249810 15G962 Australia/Asia

P2T900 24R900 25R000 GCP2RA* 16W239 North America

P2T901 24R900 25R000 GCP2RA* 15G958 Europe

P2T902 24R900 25R000 GCP2RA* 15G962 Australia/Asia

* Probler packages use recirc accessory kit 24E727.

✖

Not included.

332144C 57

Parts

E-10hp Proportioners

24T100, 120 V, Proportioner 24R900, 230 V, Proportioner

26 21

102

30, 30a

58 332144C

ti21853b

Parts

ti21855b

332144C 59

Parts

ti21854a

60 332144C

Parts

Apply sealant to all non-swiveling pipe threads.

Apply sealant to threads of nut cap.

Apply lubricant to thread and axle of cart.

Apply even distribution of thermal grease on bottom of metal surface of solid state relays.

Torque to 125 in.-lbs (14 N•m).

Torque to 150 in.-lbs (17 N•m).

Assemble nut to finger tight only.

24T100, 120 V, Proportioner 24R900, 230 V, Proportioner

Ref. Part Description

1 --- CART 2 24T950 BRACKET, tank mount 3 24T951 BRACKET, crossbar 4 24T952 BRACKET, gusset, cart 5 24T953 BRACKET, motor mount 6 110996 NUT, hex, flange head 7 101765 GROMMET 8 119975 GRIP, vinyl, gray; 1.25 in. 9 154636 WASHER, flat 10 116411 SPRING, compression 11 116477 WASHER, flat, nylon 12 116478 WHEEL, pneumatic 13 101242 RING, retaining, ext. 14 24T954 PROPORTIONER, see page 65 15 117493 SCREW, mach, hex washer hd; 1/4-20 16 24K985 FAN, cooling, 120 VAC

24K986 FAN, cooling, 230 V 17 115836 GUARD, finger 18 120094 SCREW, pan hd, phil, zinc 19 24U009 HEATER, assy; 120V, 1000W; see page 67

24T955 HEATER, assy; see page 67 20 167002 INSULATOR, heat 21 108296 SCREW, mach, hex wash hd 22 24T960 MANIFOLD, outlet/recirc; see page 70 23 24T962 DISPLAY, control; see page 68 24 117623 NUT, cap; 3/8-16 25 24U005 DIODE, light-emitting,120 V

24T970 DIODE, light-emitting, 230 V 26 24R648 COVER, display

Orient SSR with terminals 1 and 2 towards the top.

Orient fan to flow down and connector plug towards the back.

Orient heater module with fins outwards.

Assemble sensor flush to tank surface.

Install clamp-on ferrite near termination of transducer wires. See F

. 24, page 73.

Install clamp-on ferrite on black and red motor power wires.

. 24, page 73.

See F

Quantity

24T100,

120 V

24R900,

230 V

11 11 11 11 11

18 18

33 22 44 22 44 22 22 11 44 2

2 22 88 1

1 22

10 10

11 11 44 1

1 11

332144C 61

Parts

Ref. Part Description

27 24T973 TANK 28 111800 SCREW, cap, hex hd 29 127148 SCREW, set, 7/16-14, 1/2, black 30 24T975 LID; includes o-ring (30a) 30a 24T975 O-RING 31 24K976 MUFFLER,1/4 NPT 32 101044 WASHER, plain 33 119973 CABLE, sst lanyard; 14 in. 35 24K984 DRYER, desiccant, mini in-line 36 162453 FITTING; 1/4 npsm x 1/4 npt 37 100176 BUSHING, hex 38 24K977 FILTER, regulator, air; with 3/8 npt auto drain; includes

64a

38a 114228 ELEMENT, 5 micron; polypropylene; not shown 39 157350 ADAPTER 40 104641 FITTING, bulkhead 41 169970 FITTING, line air; 1/4-18 npt 42 116704 ADAPTER, 9/16-18 JIC x 1/4 NPT 43 117506 FITTING, swivel, 1/4 npt x #6 JIC 44 --- MANIFOLD, assembly, outlet; see page 71 45 556765 FITTING, #6 JIC 1/4PM 46 24T977 TUBE, pump outlet, ISO 47 24T978 TUBE, heater outlet, ISO 48 24T979 HOSE, coupled, recirc, ISO 49 24T980 TUBE, recirculation 50 24T981 HOSE, coupled, recirc, RES

Quantity

24T100,

120 V

24R900,

230 V

12 12

22 22 22 11 11 22 11 11 11

11 11 11 11 44 22 22 22 22 22 11 22 11

62 332144C

Ref. Part Description

51 114225 TRIM, edge protection 52 119992 FITTING, pipe, nipple, 3/4 x 3/4 npt 53 24T982 MANIFOLD, inlet, RES; see page 69 54 24T986 MANIFOLD, inlet, ISO; see page 69 55 24T987 COVER, electronics 56 115942 NUT, hex, flange head 57 24T988 SENSOR, tank level 58 24T990 PANEL, heater control mount 59 247828 MODULE, heater 60 24T989 PANEL, logic control mount 61 24T308 MODULE, heater control,120 V

24T307 MODULE, heater control, 230V

64 24U006 RELAY, SSR, 120 V

24T991 RELAY, SSR, 230 V 65 112144 SCREW, mach, pan hd 66 126811 BLOCK, clamp end 67 24U007 CONNECTOR, contactor; 120 V

24T992 CONNECTOR, contactor; 230 V 68 126817 COVER, end 69 126818 BLOCK, terminal 3-wire 70 126810 RELAY, cradle

Quantity

24T100,

120 V

24R900,

230 V

11 22 11 11 11

12 12

22 22 22 11 1

2 44 44 1

1 11 22 11

Parts

332144C 63

Parts

Ref. Part Description

71 24T993 RELAY, 12V 72 255043 HOLDER, fuse terminal block; 5 x 20mm 73 255023 FUSE, 5A, 5 x 20 mm 74

†

127239 CONNECTOR, 5 pin 127240 CONNECTOR, 10 pin

†

120748 CONNECTOR, 2 pin 76 127237 CONNECTOR, 6 pin 77 116171 BUSHING, strain relief

16W761 BUSHING, strain relief

†

78✖ 79✖ 80✖ 81✖ 82✖

24T994 HARNESS, POWER; see FIG. 23 on page 72.

†

24T995 CABLE, communication, heater control module

†

24T996 CABLE, FAN, 29 in. (736.6 mm)

†

24T997 CABLE, control, display

†

24T998 CABLE, harness, overtemperature 83 24T999 CONNECTOR, jumper 84 24U008 CORD, 20A, 120 V

24U000 CORD, 16A, 230 V 85 113505 NUT, keps, hex hd

†

88✖

125835 CLIP, ferrite bead 89 24U001 COVER, proportioner, lower 90 24U002 COVER, proportioner, upper 91 115492 SCREW, mach, slot hex wash hd 92 24U003 GUARD, splash, hose rack 93 24U004 RACK, hose 94 120008 PLUG, tube 95 120150 ISOLATOR, pad, rubber 96 119999 BOLT, shoulder 97 110533 WASHER, flat, nylon,1/4 98▲ 15G280 LABEL, safety, warning, multiple 99▲ 189930 LABEL, electric shock 104 217374 LUBRICANT, ISO pump

Quantity

24T100,

120 V

24R900,

230 V

11 22 22 1

1 21 11 2

2 11 11 22 11 11 22 2

2 22 22 11 11

10 10

11 11 44 22 22 44 11 22 11

▲

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

✖

Not shown.

†See F

. 23 on page 72.

--- Not available for purchase.

64 332144C

24T954, 120 V and 230 V Bare Proportioner

233

207

212

(steel)

229

207

201

208 (steel)

210

209 (bronze)

211 (bronze)

215

220

213

214

(bronze)

213 (bronze)

223

221

7 10

207

Parts

91 (ref)

89 (ref)

216

218

222

207

217

Apply lubricant to all gear teeth, motor pinion, and motor endbell on both sides of motor.

Apply lubricant to rectangular cavity on connecting link.

Apply lubricant to threads of pump cylinder before assembly into housing. Align top of cylinder flush within 0.06 to inside bottom of pump mounting hole.

Torque fasteners to 140-160 in.-lbs (15-18 N•m).

Assemble nut to finger tight only.

219

ti21847a

223

0.6 in. (15.2 mm) from inside edge

1.0 in. (25.4 mm) from inside bottom edge

TI7028a

Torque fasteners to 30-35 in.-lbs. Applies only when fasteners are assembled in plastic housings (215).

Switch mounts to cover opposite brush end of motor only.

Housing must be installed on motor with crankshafts aligned with each other.

Assemble magnet to center of offset crankshaft on switch cover side of motor and adjust for park location.

Affix switch to motor cover with double-sided tape. Cut to 2 in. (50.8 mm). Mount cover on side opposite brush end of motor.

332144C 65

Parts

Ref. Part Description Qty

201 24T758 MOTOR, electric

‡

207

208* 116074 WASHER, thrust 209* 107434 BEARING, thrust 210* 300001 KIT, crankshaft 211* 180131 BEARING, thrust 212 213 214 215 216◆ 287053 KIT, repair, connecting, rod 217◆ 196762 PIN, straight 218 195150 NUT, jam, pump 219 24L006 PUMP, displacement 220

221 222 223 117770 SWITCH, reed with cable 224 24K982 MAGNET, disc, 0.38 dia.,

227 115711 TAPE, foam, 1/2 wide 229 300003 KIT, cover 233 16W162 BRACKET, shroud tab

115492 SCREW, mach, slot hex wash

†

116073 WASHER, thrust

†

116079 BEARING, thrust

†

244242 GEAR, reducer (first stage)

‡

287055 HOUSING, drive

‡

117493 SCREW, mach, hex washer

‡

300002 KIT, cover; includes switch

‡

15B589 COVER, pump rod

0.100 thick; not shown

2 2 2 2 2 4 2 2 2 2 2 2 8

1 2 1 1

1 1 2

* Included in 300001 Crankshaft Kit (210).

† Included in 244242 Gear Reducer Kit (214).

‡ Included in 287055 Drive Housing Kit (215).

◆

Included in 287053 Connecting Rod Kit (216).

66 332144C

24U009, 120 V Heater 24T955, 230 V Heater

304

2 5

310

305

311

308

306

Parts

307

316

302

1 5

303

Torque to 120 ft-lbs (163 N•m).

Torque to 23 ft-lbs (31 N•m).

Apply 110009 thermal heat sink compound.

Apply sealant and tape to all non-swiveling and threads without o-rings.

Ref. Part Description Qty.

301 --- BLOCK, heater 1 302 15H302 FITTING, reducer 1-3/16 SAE x 1/2

npt

303 16V432 FITTING, adapter, #6 JIC x npt,

mxm 304 15H304 FITTING, plug, 9/16 SAE 2 305 15H306 ADATPER, thermocouple, 9/16 x

1/8 306 120336 O-RING, packing 2 307 24T958 HEATER, fire rod, 230 V, 24T955

only

24U012 HEATER, fire rod, 120 V, 24U009

only

309

316

312

ti21850a

301

Apply lubricant to o-rings before assembling in heater housing.

Tighten NPT fitting from sensor to heater housing as shown. Remove tape from probe tip prior to inserting. Insert probe until tip bottoms on heater element. Tip must touch heating element. Insert ferrule and tighten ferrule nut to sensor probe. Orient sensor as shown and torque 1/4 turn past tight.

Ref. Part Description Qty.

308 15B137 SWITCH, overtemperature 1 309 16U940 MIXER, heater 4

310 117484 SENSOR, 2 311 --- SCREW, mach; #6-32 2

312 124132 O-RING 4 316 24T959 HEATER, fire rod, 230 V; 24T955

only

24U014 HEATER, fire rod, 120 V; 24U009

only

--- Not available for purchase.

332144C 67

Parts

24T962, Display

360

353

373

361

359

366

388

363

351

365

355

356

Ref. Part Description Qty.

351 24T963 PLATE, display, front 352 24T964 ENCLOSURE, control 353 24T966 DISPLAY, heat two zone 354 24T967 CONTROL, board, assy 355 24K983 SWITCH, rocker, w/breaker, 240v,

20a

356 24L001 KNOB, control, w/ball plunger 357 24L002 POTENTIOMETR, adjustment,

pressure

358 15G053 PLATE, detent, display 359 300005 FILTER, board 360 117523 NUT, cap (#10) 361 127157 SCREW, mach, captive, #8 363 127158 NUT, captive, #8 364 24T968 DIODE, light-emitting, red

364

358

367

363

357

Ref. Part Description Qty.

365 24T971 DIODE, light-emitting, yellow

366 --- CLAMP, cable

367 113505 NUT, keps, hex hd

368 101765 GROMMET

373 127019 CONNECTOR, jumper, e-stop

1 1

--- Not available for purchase.

1 2 4 8 8 1

354

352

ti21841a

1 2 6 3 1

68 332144C

Fluid Inlets

24T986, ISO Inlet 24T982, RES Inlet

Parts

407

401

406

405

404

ti21851a

Align Y-strainer as shown

Apply sealant to all npt threads. Do not apply to JIC threads.

Apply thermal lubricant to thermometer probe.

Torque fitting of bent tube to 45-50 ft-lbs (61-67 N•m).

Align bent tube to fitting within 2°.

Align thermometer dial as shown.

402

403

24T986 24T982

6 6

ti21852a

Ref. Part Description Qty.

401 101078 STRAINER, Y 402 15D757 HOUSING, thermometer, Viscon HP 403 102124 THERMOMETER, dial 404 24T983 VALVE, ball, 3/4 npt, mxf, T-handle 405 24T984 FITTING, adapter JIC-12 X 3/4 npt,

1 1 1 1 1

mxm

406 24T985 TUBE, assy, inlet 407 160327 FITTING, union adapter, 90°

332144C 69

1 1

Parts

24T960, Fluid Manifold

452

464

460

461

456

455

454

453

451

4 6

458

459

Apply sealant to assembled non-swiveling pipe threads.

Apply sealant and PTFE tape to threads.

Apply sealant to valve threads. Torque to 240-260 in.-lbs (27-29 N•m).

Apply lubricant to mating surfaces of valve base and handle.

Apply lubricant to o-rings on fittings. Torque to 16-20 ft-lbs (22-27 N•m).

Align handles as shown when open.

462

463

Ref. Part Description

451 24T961 MANIFOLD, fluid 452 102814 GAUGE, pressure, fluid 453 239914 VALVE, drain 453a 15E022 SEAT 453b 111699 GASKET 454 224807 BASE, valve 455 187625 HANDLE, valve, drain 456 111600 PIN, grooved 457 16V434 FITTING, 90 elbow, JIC-6 x

SAE-ORB

458 119789 FITTING, elbow, street, 45° 459 162453 FITTING; 1/4 npsm x 1/4 npt

457

Qty.

ti21838a

Ref. Part Description

460 127130 FITTING, straight, JIC-5 x

461 127128 FITTING, 45° elbow, JIC-5, mxf,

2 2

462 127131 FITTING, straight, JIC-6 x

1 1

463 127129 FITTING, 45° elbow, JIC-6, mxf,

464▲ 189285 LABEL, warning, hot surface

2 2

▲

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

SAE-ORB

swivel

SAE-ORB

SWIVEL

2 2

Qty.

70 332144C

25R000, Insulated Hose Bundle with Recirculation Lines

Parts

501

502

503 (Ref)

505 503

Ref. Part Description Qty

501 24R996 HOSE, fluid (component ISO),

moisture guard; 1/4 in. (6 mm) ID; no. 5 JIC fittings (mxf); 35 ft (10.7 m)

502 24R997 HOSE, fluid (component RES); 1/4

in. (6 mm) ID; no. 6 JIC fittings (mxf); 35 ft (10.7 m)

502 (Ref)

304

TI6991a

Ref. Part Description Qty

503 15G342 HOSE, air; 1/4 in. (6 mm) ID; 1/4

npsm (fbe); 35 ft (10.7 m)

504 buy

locally

505 156971 NIPPLE; 1/4 npt; for joining air line

TUBE, foam, insulated; 1-3/8 in. (35 mm) ID; 31 ft (9.5 m)

to another hose bundle

Outlet Manifold

554

553

551

552

ti21846a

Apply lubricant to o-rings.

Orient housing with exhaust hole pointing down.

Ref. Part Description Qty

551 24T976 MANIFOLD, fluid, pump, outlet 1 552 247520 HOUSING, rupture disc 1 553 111457 PACKING, o-ring 1 554 24K999 TRANSDUCER, pressure, control 1

332144C 71

Parts

+

+ + + + +

+



)

)

5(/ $ <

+ ++ ++

++

++ ++

%22675(6

5(6665

7



7

+

+ +

+ +

0$,1 5(6



+



WLD

+

+

+

-

)DQ

&

&

&

0$,1 +($7 ,62

%2267 +($7 ,62

+

+

+

+



&R Q W D F W R U



&

-

+ + + +

0$,1 +($75(6

%2267 +($75(6

&

&

 9  9

0$,1 ,62

0$,1 5(6

%2267 ,62

%22675(6

%2267 ,62

0$,1 ,62





+ +



665 ,62



+



+

+

FIG. 23: Power Harness (78) Wire Identification

72 332144C

&

Parts

+

+

%52:1

+

WLD

+($7(5

5((' 6 (1625

+

*1'

*5((1

7$1

%/$ &.

+HDWHU

7$1

%/$ &.

0RWRU

*5((1

%/8(

+

+

02725 276:,7&+

7$1. /9/ 6(1625

02725 3:5

%52:1

7$1

75$16'8&(5 ,62

5('% 2267 +($7 / ('

5('0 2725 /(' <(//2:7$1./('

%/8(

%52:1

02725 +($7(5

%/8(

%/$ &.

7$1

%/$ &.

%52:1

02725

%/8(

+

%/8(

+

75$16'8&(5 5(6

%/$ &.

%/8(

FIG. 24

332144C 73

Suggested Replacement Parts

Part Description

24K984 DRYER, desiccant 24K983 SWITCH, motor or heater power, with circuit

breaker 101078 Y-STRAINER; includes 180199 element 180199 ELEMENT, Y-strainer, 20 mesh 114228 ELEMENT, air filter, 5 micron; polypropylene 239914 VALVE, recirc/spray; includes seat and gas-

ket 24L002 POTENTIOMENTER, control knob 24K999 TRANSDUCER, pressure 24L006 PUMP, displacement; fits either side 249855 REPAIR KIT, displacement pump; includes

seals, balls, bearings, intake seat) 24T975 O-RING, tank lid

Dimensions

Accessories

Part Description

24E727 Probler Recirc Kit 24U342 Lift Ring Kit

36 in.

(914 mm)

46 in.

(1168 mm)

29 in.

(736 mm)

74 332144C

Technical Data

Reactor E-10hp US Metric

Maximum fluid working pressure 3000 psi 20.6 MPa, 206 bar

Maximum spray pressure: 120 V 2200 psi 15.2 MPa, 152 bar

Maximum spray pressure: 230 V 2500 psi 17.2 MPa, 172 bar

Maximum fluid temperature 170°F 77°C

Maximum ambient temperature 120°F 48°C

Maximum output 1 gal./min 3.8 liters/min

Output per cycle (ISO and RES) 0.0038 gallons/cycle 0.014 liters/cycle

Air inlet 1/4 in. quick-disconnect industrial type pin fitting

Air outlet 1/4 npsm(m)

Overpressure relief Recirc/Spray valves automatically relieve excessive fluid pressure back to

supply tanks

Gun compressed air requirements

Maximum hose length 105 ft 32 m

Tank capacity each (nominal) 6 gal. 22.7 liters

Weight (empty) 239 lb 108 kg

Recommended Mix Chamber Sizes

Fusion

Probler

Electrical Requirements

120 V 120 VAC, 1 phase, 50/60 Hz, 3840 W; requires two separate,

230 V 230 VAC, 1 phase, 50/60 Hz, 5520 W; requires two separate,

Generator Size

120 V 5000 W minimum

230 V 7500 W minimum

Heater Power

Air Purge

120 V

230 V

Sound Pressure

In fast recirculation mode 71.3 dB(A)

Measure at 2500 psi (17 MPa, 172 bar), 1 gpm (3.8 lpm)

Sound Power*

In fast recirculation mode 79.9 dB(A)

Measure at 2500 psi (17 MPa, 172 bar), 1 gpm (3.8 lpm)

Fusion Gun (purge air and operating air): 4 scfm (0.112 m

000, AW2222 (00 and 01 at reduced spray pressure)

AA (00 and 01 at reduced spray pressure)

dedicated 20 A circuits. Full load peak amperage 16 A per circuit.

dedicated 15 A circuits. Full load peak amperage 12 A per circuit.

3000 W during recirculation, 2000 W during pressure spray mode

4000 W during recirculation, 2760 W during pressure spray mode

85.6 dB(A)

93.3 dB(A)

/min)

332144C 75

Technical Data

Reactor E-10hp US Metric

Fluid Outlets

ISO Side -5 JIC male

RES Side -6 JIC male

Fluid Circulation Returns

ISO side -5 JIC male

RES side -6 JIC male

Hose Markings

ISO side Red

RES side Blue

Wetted Parts

Wetted parts on all models Aluminum, stainless steel, carbon steel, brass, carbide, chrome, chemically

resistant o-rings, PTFE, ultra-high molecular weight polyethylene

Notes

Sound power measured per ISO-9614-2.

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

76 332144C

Notes

332144C 77

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 reconnaissen 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.

t avoir convenu que la

Graco Information

For the latest information about Graco products, visit www.graco.com.

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505

All written and visual data contained in this document reflects the latest product information available at the time of publication.

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

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

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

Original instructions.

This manual contains English. MM 332144

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revised March 2014

Graco 332144C User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Warnings

Important Isocyanate (ISO) Information

Isocyanate Conditions

Material Self-ignition

Moisture Sensitivity of Isocyanates

Foam Resins with 245 fa Blowing Agents

Changing Materials

Systems

Models

Related Manuals

Overview

Component Identification

Controls and Indicators

Heater Controls

System Controls

Controls and Indicators

Setup

Locate Reactor

Electrical Requirements

Ground System

Connect Gun Air Hose

Connect Fluid Hoses

Connect Main Air Supply

Flush Before First Use

Fill Wet-Cups

Fill Fluid Tanks

Purge Air and Flush Fluid From Lines

Startup

Heatup Guidelines

Heat Management Tips

Spraying

Pause

Refill Tanks

Pressure Relief Procedure

Shutdown

Maintenance

Flushing

Purge Hoses

Troubleshooting

Pump Control Status Codes

DIP Switch Settings

Heat Control Diagnostic Codes

Reactor Electronics

Heaters

Proportioner

Repair

Before Beginning Repair

Remove Supply Tank

Replace Recirc/Spray Valves

Displacement Pump

Control Panel

Motor Control

Heater

Pressure Transducers

Drive Housing

Replace Cycle Counter Switch

Electric Motor

Motor Brushes

Fans

Tank Fluid Level Sensors

Parts

System Packages

E-10hp Proportioners

24T954, 120 V and 230 V Bare Proportioner

24U009, 120 V Heater 24T955, 230 V Heater

24T962, Display

Fluid Inlets

24T960, Fluid Manifold

25R000, Insulated Hose Bundle with Recirculation Lines

Outlet Manifold

Suggested Replacement Parts

Dimensions

Accessories

Technical Data

Notes

Graco Standard Warranty