Graco A-25 User Manual

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Repair-Parts

A-25

PLURAL COMPONENT PROPORTIONER

3A1570A

Air operated, electrically heated, plural component proportioner

For spraying or dispensing 1:1 ratio polyurethane foam formulations and other 1:1 fast setting materials.

Not for use in explosive atmospheres or hazardous locations.

This model is field-configurable to the following supply voltages: 230 V, 1 Phase 230 V, 3 Phase 380 V, 3 Phase

2000 psi (14 MPa, 138 bar) Maximum Fluid Working Pressure 80 psi (550 kPa, 5.5 bar) Maximum Air Working Pressure

Important Safety Instructions

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

See page 3 for model information, including maximum working pressure and approvals.

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Contents

Proportioner Models . . . . . . . . . . . . . . . . . . . . . . . . 3

Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Important Two-Component Material Information . 7

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

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

Keep Components A and B Separate . . . . . . . . . 7

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

Foam Resins with 245 fa Blowing Agents . . . . . . 7

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

DataTrak Diagnostic Codes . . . . . . . . . . . . . . . . . 9

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

E01: High fluid temperature . . . . . . . . . . . . . . . 10

E02: High zone current . . . . . . . . . . . . . . . . . . . 11

E03: No zone current . . . . . . . . . . . . . . . . . . . . 11

E04: Fluid Temperature Sensor (FTS) or

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

E05: Control board over temperature . . . . . . . . 12

E06: Communication cable unplugged . . . . . . . 12

Communication Diagnostic Codes . . . . . . . . . . 12

E30: Momentary loss of communication . . . . . . 12

E99: Loss of communication . . . . . . . . . . . . . . . 12

Before Beginning Repair . . . . . . . . . . . . . . . . . . . 13

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 13

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Park . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Pumps and Pressures . . . . . . . . . . . . . . . . . . . . 15

Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Hose Heat System . . . . . . . . . . . . . . . . . . . . . . 20

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Disconnect Pump . . . . . . . . . . . . . . . . . . . . . . . 22

Connect Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Remove Air Motor . . . . . . . . . . . . . . . . . . . . . . . 24

Install Air Motor . . . . . . . . . . . . . . . . . . . . . . . . . 24

Recirculation / Over Pressure Relief Block . . . . 25

Air Inlet Filter / Water Separator (Auto Drain) . . 25

Temperature Control Module . . . . . . . . . . . . . . . 26

Primary Heater . . . . . . . . . . . . . . . . . . . . . . . . . 28

Heated Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Fluid Temperature Sensor (FTS) . . . . . . . . . . . . 32

Pump Lubrication System . . . . . . . . . . . . . . . . . 35

Fluid Inlet Strainer Screen . . . . . . . . . . . . . . . . . 36

Temperature Display . . . . . . . . . . . . . . . . . . . . . 36

Replace DataTrak Battery or Fuse . . . . . . . . . . 38

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Recommended Spare Parts . . . . . . . . . . . . . . . . . 39

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Control Panel, 262575 . . . . . . . . . . . . . . . . . . . . 44

Temperature Control . . . . . . . . . . . . . . . . . . . . . 45

Wheel Kit, 262695 . . . . . . . . . . . . . . . . . . . . . . . 45

Fluid Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Fluid Inlet Kit, 262695 . . . . . . . . . . . . . . . . . . . . 46

6 kw Dual Zone Heater, 24J788 . . . . . . . . . . . . 47

A-25 Air Motor Pump Assembly, 262573 . . . . . . 48

Air Tubing Connections . . . . . . . . . . . . . . . . . . . 49

Breaker Module, 262576 . . . . . . . . . . . . . . . . . . 50

Reactor A-25 Wiring Schematic . . . . . . . . . . . . . . 51

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 56

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Proportioner Models

All proportioners can be configured to operate on 380V (4 wire), 230V (3 wire), or 230V 1Ø.

Proportioner Models

Maximum Fluid Working

Pressure

Part No.

262572 2000 psi (14, 138) 80 psi (550, 5.5) --- ---

262614 2000 psi (14, 138) 80 psi (550, 5.5) 24A592

 Only available in Asia.

psi (MPa, bar)

Maximum Air Working

Set Pressure psi (kPa, bar)

Includes:

DataTrak

(cycle count only)

Wheels

Systems

All systems include a proportioner, spray gun, and 60 ft (18.3 m) of heated hose.

Part

P22614 AP2614

CS2614 P22572

AP2572 CS2572

Maximum Working

Pressure

psi (MPa, bar)

2000 (14, 138) 2000 (14, 138)

2000 (14, 138) 2000 (14, 138) 2000 (14, 138)

2000 (14, 138)

Proportioner

262614 262614

262614 262572 262572

262572

Heated Hose Gun

50 ft (15 m) 10 ft (3 m) Model Part

246678 246050 246678 246050

246678 246050 246678 246050 246678 246050

246678 246050

Probler P2 GCP2R1 Fusion Fusion

™



AP CS

Approvals

3172585

246101 CS01RD

Related Manuals

Manuals are available at www.graco.com.

Component manuals in English:

Manual Description

3A1569

309577

309815

309827

3A1570A 3

Reactor A-25 Proportioner, Operation Proportioning Pump, Repair-Parts Feed Pump Kit, Instructions-Parts Feed Pump Air Supply KIt, Instruc-

tions-Parts

Manual Description

309852

309572 309550

312666 313213

313541 312796

Circulation and Return Tube Kit, Instructions-Parts

Heated Hose, Instructions-Parts Fusion Fusion

Probler P2 Spray Gun, Instructions-Parts DataTrak Kits, Installation-Parts

NXT

™

AP Spray Gun, Instructions-Parts

™

CS Spray Gun, Instructions-Parts

Air Motor, Instructions-Parts

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, 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 at main switch before disconnecting any cables and before servicing or installing equipment.

• Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

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.

• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This 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.

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.

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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.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

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 fluid outlet.

• 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.

3A1570A 5

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.

• 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.

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-trichloroethylene, 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.

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.

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.

6 3A1570A

Important Two-Component Material Information

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 thickly. Read material manufacturer’s warnings and material MSDS.

Moisture Sensitivity of Isocyanates

Isocyanates (ISO) are catalysts used in two component foam and polyurea coatings. ISO will react with moisture (such as humidity) to form small, hard, abrasive crystals, which become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts.

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

To prevent exposing ISO to moisture:

• Always use a sealed container with a desiccant

dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container.

• Keep the ISO lube pump reservoir (if installed) filled with Graco Throat Seal Liquid (TSL), Part 206995. The lubricant creates a barrier between the ISO and the atmosphere.

• Use moisture-proof hoses specifically designed for ISO, such as those supplied with your system.

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

• Always lubricate threaded parts with ISO pump oil or grease when reassembling.

Keep Components A and B Separate

Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (isocyanate) and component B (resin) parts.

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Foam Resins with 245 fa Blowing Agents

Some foam blowing agents will froth at temperatures above 90°F (33°C) when not under pressure, especially if agitated. To reduce frothing, minimize preheating in a circulation system.

Important Two-Component Material Information

Changing Materials

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 B (hardener) side. Polyureas often have amines on the B (resin) side.

8 3A1570A

DataTrak Diagnostic Codes

Important Two-Component Material Information

DataTrak can diagnose several problems with the pump. When the monitor detects a problem, the LED will flash and a diagnostic code will appear on the display.

To acknowledge the diagnosis and return to the normal operating screen, press once to wake up the display,

and once more to clear the diagnostic code screen.

Symbol Code Code Name Diagnosis Cause

E-2 Diving Down Leak during downstroke. Worn intake valve.

E-3 Low Battery Battery voltage too low to stop

runaway.

E-6 Blown Fuse Fuse is blown. Replace fuse;

see page 38.

Temperature Control Diagnostic Codes

Low battery. Replace battery; see page 38.

• Faulty solenoid or solenoid

wiring.

• Extreme temperatures

(above 140°F [60°C]).

Temperature control diagnostic codes appear on temperature display.

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

E06 can be cleared by pressing . For other codes,

turn main power OFF then ON to clear.

Code Code Name Alarm Zone

01 High fluid temperature Individual 02 High zone current Individual 03 No zone current Individual 04 FTS or thermocouple disconnected Individual 05 Control board over temperature Individual 06 Communication cable unplugged Individual 30 Momentary loss of communication All 99 Loss of communication All

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

3A1570A 9

Important Two-Component Material Information

E01: High fluid temperature

Causes of E01 Errors

• Thermocouple A or B (361) senses a fluid temperature above 230°F (110°C).

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

• Overtemperature switch (359) senses a fluid temperature above 230°F (110°C) and opens. At 190°F (87°C) the switch closes again.

• Thermocouple A or B (361) fails, is damaged, is not touching the heater element (358), or has a poor connection to the temperature control module.

• Overtemperature switch (359) fails in the open position.

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

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

• Failed heater element where thermocouple is installed.

• Loose wire

between temperature control module and thermocouples A and B (361) or FTS (21) [depending on which zone is displaying E01]. See Table 2, page

26. Ensure that all wires are securely connected to connector B.

4. Remove connector B from temperature control module, and check continuity of overtemperature switch, thermocouples A and B, or FTS by measuring resistance across the pins on the plug end; see Table 1.

Table 1: Sensor Connector Continuity Checks

Pins Description Reading

1 & 2 OT switch nearly 0 ohms 3 & 4 Jumpered nearly 0 ohms 5 & 6 Thermocouple A 4-6 ohms 8 & 9 Thermocouple B 4-6 ohms

11 & 12 FTS approximately 35

ohms per 50 ft (15.2

m) of hose, plus

approximately 10

ohms for FTS at 70°F

(21°C)

10 & 12 FTS open

• Jumper wire covered in heat shrink in the wiring harness near the single over temperature switch connectors on the heater, is loose or incorrectly wired

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.

Check which zone is displaying the E01 error.

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

2. Clean and re-plug connections.

3. Check connections between the temperature control module and overtemperature switch (359), and

IG. 6, page 26).

NOTE: Before doing the following checks, note which zone (A, B, FTS, or all) has high fluid temperature.

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

• If temperature is too high (sensor reading is

229°F [109°C] or above):

6. Check if thermocouples A and B are damaged, or not contacting the heater element, page 30.

7. To test that temperature control module turns off when equipment reaches temperature setpoint:

a. Set temperature setpoints far below displayed

temperature.

b. Turn zone on. If temperature rises steadily,

power module is failing.

c. Verify by swapping with another power module.

See Replacing Temperature Control Assem- bly Modules, page 27.

10 3A1570A

Important Two-Component Material Information

d. If the swapped module does not fix the problem,

the power module is not the cause.

8. Verify continuity of heater elements with an ohmmeter, see page 28.

E02: High zone current

1. Turn main power OFF .

2. Relieve pressure, page 13.

NOTE: Disconnect whip hose.

3. Disconnect hose connector (D) at Reactor.

4. Using an ohmmeter, check between the two terminals of the connector (D). There should be no continuity.

5. Exchange zone module with another one. Turn zone on and check for error (see page 27). If error disappears, replace faulty module.

b. Perform Transformer Primary Check and

Transformer Secondary Check, starting on page 33.

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

E04: Fluid Temperature Sensor (FTS) or thermocouple disconnected

1. Check temperature sensor connections to long green connector (B) on temperature control module, page 26. Unplug and re-plug sensor wires.

2. Test fluid temperature sensor continuity with ohmmeter, page 10.

3. If an error occurred for the hose zone, check FTS connections at each section of hose.

4. If an error occurred for the hose zone, test FTS by plugging directly into machine.

For hose zone: If error still occurs, perform Transformer Primary Check and Transformer Secondary Check,

starting on page 33.

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

E03: No zone current

1. Check for tripped circuit breaker inside electrical cabinet or at power source for that zone. Replace circuit breaker if it trips habitually.

2. Check for loose or broken connection at that zone.

3. Exchange zone module with another one. Turn zone on and check for error (see page 27). If error disappears, replace faulty module.

4. If E03 occurs for all zones, the 238CR contactor may not be closing. Verify wiring from heater control to contactor coil.

a. Hose zone: test hose continuity, page 31.

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5. To verify heater control module is not causing the problem, use a wire to short-circuit the two pins corresponding to the FTS (red and yellow for A or B zone, red and purple for hose). The display will show the control heater module temperature.

6. If an error occurred for the hose zone, temporarily use the current control mode. Refer to Reactor Operation manual.

3A1570A 11

Important Two-Component Material Information

E05: Control board over temperature

NOTE: Each module has an on-board temperature sen-

sor. Heat is turned off if module temperature exceeds 185°F (85°C) within the heater module.

1. Check that fan above electrical cabinet is operating.

2. Check that electrical cabinet door is properly installed.

3. Check for obstructions blocking cooling holes in bottom of electrical cabinet.

4. Clean heatsink fins behind heater control modules.

5. Ambient temperature may be too high. Allow Reactor to cool by moving to a cooler location.

E06: Communication cable unplugged

1. Unplug and re-plug cable that connects heater control module to heater module.

2. Replace communication cable if problem persists.

Communication Diagnostic Codes

E30: Momentary loss of communication

Communications between the display and the motor control board or the temperature control module have been momentarily lost. Normally, when communication is lost, the corresponding display will show E99. The corresponding control board will register E30 (The red LED will flash 30 times). If communications are reconnected, the display can show the E30 for a small time (no more than about two seconds). It should not be possible for E30 to be shown continuously, unless there is a loose connection causing the display and the board to continuously loose and regain communication.

Check all wiring between the display and the control board.

E99: Loss of communication

Communications between the display and the temperature control module has been lost. When communication is lost, the display will show E99.

1. Check all wiring between the display and the temperature control module. Pay close attention to the wire crimping on plug J13 for temperature display and connector for control module.

Step 2 measures line voltage and should be done by a qualified electrician. If work is not performed properly it may cause electric shock or other serious injury.

2. Measure the incoming voltage to the module (it should be ~ 230Vac).

3. If it was only receiving 1 leg of the 230Vac the board may light up, and still not function properly. Correct the incoming voltage problem.

12 3A1570A

Before Beginning Repair

Repairing this equipment requires access to parts that may cause electric shock or other serious injury if work is not performed properly. Electrical troubleshooting must be done by a qualified electrician. Be sure to shut off all power to equipment and lock out power at the source before repairing.

1. Flush if necessary. See Flushing, page 14.

2. Turn main heater power OFF .

3. Relieve pressure. See Pressure Relief Procedure.

Pressure Relief

5. Close gun fluid inlet valves A and B.

ti2421a

6. Close pump inlet supply valves.

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Procedure

The Fusion AP gun is shown.

1. Turn off feed pumps and agitator if used.

2. Park component A pump. Follow Park; see page 14.

3. Close the air inlet valve.

4. Engage gun piston safety lock.

ti2409a

Shutdown

1. Turn main heater power OFF .

2. Follow Park.

3. Check and fill wet-cups (AK, Z). AK

4. Follow gun shutdown procedure. See gun manual.

3A1570A 13

ti16974a

Park

Park the pumps at the end of the day to cycle component A pump to home position, submerging displacement rod.

1. Open the park valve.

Open

2. Trigger the gun until pumps stops at the bottom and relieves pressure.

3. Close the air motor shutoff valve.

4. Close the park valve.

Flushing

Flush equipment only in a well-ventilated area. Do not spray flammable fluids. Do not turn on heaters while flushing with flammable solvents.

• Flush out old fluid with new fluid, or flush out old fluid with a compatible solvent, such as toluene, naptha, or mineral spirits before introducing new fluid.

• Use lowest possible pressure when flushing.

• To flush feed hoses, pumps, and the heater separately from the heated hoses, set PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION. Flush through bleed lines (N).

ti8441a

• To flush entire system, circulate through gun fluid manifold (with manifold removed from gun).

• Always leave hydraulic oil or a non-water based, non-water absorbent fluid in system. Do not use

water.

Only use flush solvents that are compatible with Fluoroelastomer seals. Non-compatible solvents will damage seals and cause hazardous conditions, such as high pressure leaks and pressure switch failure.

14 3A1570A

Troubleshooting

Problems

Try the recommended solutions in the order given for

Before performing any troubleshooting procedures:

1. Relieve pressure, page 13.

2. Turn main power OFF .

3. Allow equipment to cool.

Power

PROBLEM CAUSE SOLUTION

Heat zones do not operate No power Connect power cord

Power cord not connected properly Check connections

No power when disconnect switch is turned on; using 230V, 1 phase or 230V, 3 phase power

External main supply power circuit breaker trips and Reactor disconnect switch fails when switch is turned on.

No temperature display lights at startup

Power terminal jumper still at 380V, 3 phase position, as shipped from factory

Power terminal jumper was left in 230V, 1 phase position. When using 230V, 3 phase or 380V, 3 phase power

No power Connect power cord

Control power fuses blown Check and replace fuses on long ter-

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.

Turn Main Disconnect Switch ON

Place jumpers in correct position; see Operation manual and label inside front lower cabinet.

Place jumpers in correct position; see Operation manual. Replace main power disconnect switch; see page

40.

Turn Main Disconnect Switch ON

minal strip

Troubleshooting

Pumps and Pressures

PROBLEM CAUSE SOLUTION

Pump does not run up and down Motor control valve closed Open air motor shutoff valve

No air supply Air supply line not connected

Open inlet air ball valve Air pressure regulators set at 0 psi Turn up air pressure regulators Air motor shuttle valve is centered. Push button on top of air motor shut-

tle valve.

Pump runs but no fluid pressure Fluid inlet ball valves closed Open fluid inlet ball valves

3A1570A 15

Troubleshooting

PROBLEM CAUSE SOLUTION

Fluid pressure low or dropping Air supply pressure low when spray-

ing

Increase inlet air pressure Increase air compressor size to meet

flow requirements Remove airline quick disconnects Use 3/8 in. (0.95 cm) ID or larger air

supply hose. Use 1/2 in. (12.7 mm) if longer than 25 ft (7.6 m).

Icing in air motor exhausts or mufflers Check inlet filter water separator; see

page 25. Stop spraying while ice melts.

Pump output low, but pressure is normal

One pressure gauge drops when pumps are stalled on both the upstroke and the downstroke

Obstructed gun impingement ports or

Flush and clean gun; see gun manual

filters Leaking pump throat Repair pump; see 309577 Leak between pump and gun Check fluid tubes, heater, and hoses

Pressure Relief/Spray valve leaking back to supply

Spray gun is leaking on one side or

Clean and repair spray gun

plugged on the other side

One pressure gauge drops when pumps are stalled on the downstroke,

Inlet ball check not sealing Clean or replace; see 309577 Inlet check seat o-ring not sealing Repair pump; see 309577

but not the upstroke One pressure gauge drops when

pumps are stalled on the upstroke, but not the downstroke

Piston check ball not sealing Repair pump; see 309577 Piston packing not sealing Repair pump; see 309577 Loose piston stud in pump Repair pump; see 309577 Bad inside sleeve seal Repair o-ring; see 309577

A side rich; lack of B side A side gauge is low B side restriction downstream of

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

A side impingement port is worn.

B side gauge is low B side material supply problem.

Check B side inlet strainer and pump intake valve.

B side rich; lack of A side A side gauge is low A side material supply problem.

Check A side inlet strainer and pump intake valve.

B side gauge is low A side restriction downstream of

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

B side impingement port is worn.

16 3A1570A

Troubleshooting

PROBLEM CAUSE SOLUTION

Fluid pressures not balanced between A and B side

Pump does not reverse direction Obstruction of air motor or pumps Check and clear obstruction Unequal fluid pressure between

UP/DOWN stroke Air motor doesn’t move with air pres-

sure applied

Pump movement speed is erratic Worn air motor seals Replace seals. See Air Motor man-

Fluid viscosities not equal Adjust A and B temperature settings

to balance viscosity. Sometimes nor-

mal if pressure offset is below 200 psi

(14 bar)

Preheat material in drums by recircu-

lating; see Operation manual Inlet Y-strainer screen plugged on low

pressure side Gun port or filter plugged on high

pressure side Pump inlet ball not seating or sticking Clean seating; see pump manual Drum fluid outlet supply hose too

small Low side feed pump not working Turn on or repair feed pump Pressure Relief/Spray valve leaking

back to supply

Feed pumps boost pressure on up stroke.

Damaged air valve Replace or service air valve. See Air

Damaged pilot valve Replace valve. See Air Motor manPark valve left open or leaking

Worn pump seals Replace seals; see Pump manual.

Clean inlet filter screen

Clean or replace; see gun manual

Use 3/4 in. (1.9 cm) ID hose with

short length

Reduce feed pump pressures

Motor manual.

ual.

Electronics

Problem Cause Solution

Plug in power cord. No power.

Display does not illuminate.

Low voltage. Ensure input voltage is within specifi-

Loose wire. Check connections, page 36. Display disconnected. Check cable connections, page 36. Display disconnected. Check cable connections, page 36. Display cable damaged or corroded. Clean connections; replace cable if is

Temperature display does not illuminate.

3A1570A 17

Turn disconnect ON .

cations, page 36.

damaged.

Troubleshooting

Problem Cause Solution

Low voltage. Ensure input voltage is within specifi-

cations, page 36.

Poor display connection. Check cable connections, page 36.

Erratic display; display turns on and off.

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

Replace damaged cable.

damaged. Display cable not grounded. Ground cable, page 37. Display extension cable too long. Must not exceed 100 ft (30.5 m)

Hose display reads OA at startup. FTS disconnected or not installed. Verify proper installation of FTS (see

Operation manual), or adjust FTS to

desired current setting. Poor display connection. Check cable connections, page 36.

Replace damaged cable.

Display does not respond properly to button pushes.

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

damaged. Ribbon cable on display circuit board

Connect cable (page 36) or replace. disconnected or broken.

Broken display button. Replace, page 36.

No hose heat. Loose hose electrical connections. Check connections. Repair as neces-

sary. Circuit breakers tripped. Reset breakers (CB1 or CB2), page

34.

Hose zone not turned on.

Press zone key.

A and B temperature setpoints too low.

Failed temperature control module. Open cabinet. Check if board LED is

Low hose heat. A and B temperature setpoints too

low.

Hose temperature setpoint too low. Check. Increase if necessary to

Flow too high. Use smaller mix chamber. Decrease

Low current; FTS not installed. Install FTS, see operation manual. Hose heat zone not turned on long

enough. Loose hose electrical connections. Check connections. Repair as neces-

Check. Increase if necessary.

blinking. If not, check power wiring

connections to ensure module has

power. If board has power and LED is

not blinking, replace module, page

26.

Increase A and B setpoints. Hose

designed to maintain temperature,

not increase temperature.

maintain heat.

pressure.

Allow hose to heat up, or preheat

fluid.

sary.

18 3A1570A

Heater

PROBLEM CAUSE SOLUTION

Primary heater(s) does not heat.

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

Troubleshooting

Heat turned off.

Press or zone

keys.

Temperature control alarm. Check temperature display for diag-

nostic code, page 9.

Signal failure from thermocouple. See E04: Fluid Temperature Sen-

sor (FTS) or thermocouple disconnected, page 11.

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. Unplug and re-plug long green connector.

Thermocouple not contacting heater element.

Failed heater element. See Primary Heater, page 28. Signal failure from thermocouple. See E04: Fluid Temperature Sen-

Thermocouple wired incorrectly. See E04: Fluid Temperature Sen-

Loosen ferrule nut (N), push in thermocouple (361) so tip (T) contacts heater element (358). Holding thermocouple tip (T) against heater element, tighten ferrule nut (N) 1/4 turn past tight. See page 30 for illustration.

sor (FTS) or thermocouple disconnected, page 11.

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

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

3A1570A 19

Troubleshooting

Hose Heat System

PROBLEM CAUSE SOLUTION

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

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

Hose does not maintain temperature while spraying.

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

Low supply voltage. Verify line voltage. Low line voltage

significantly reduces power available

to hose heat system, affecting longer

hose lengths.

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

designed to maintain temperature,

not to increase it. Ambient temperature is too cold. Increase A and B setpoints to

increase fluid temperature and keep

it steady. Flow too high. Use smaller mix chamber. Decrease

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

perature before spraying. Low supply voltage. Verify line voltage. Low line voltage

significantly reduces power available

to hose heat system, affecting longer

hose lengths.

A and/or B heaters are overheating material.

Check primary heaters for either a

thermocouple problem or a failed ele-

ment attached to thermocouple, page

11.

Faulty thermocouple connections. Verify that all FTS connections are

Hose temperature exceeds setpoint.

Faulty thermocouple connections. Verify that all FTS connections are

Erratic hose temperature.

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

20 3A1570A

snug and that pins of connectors are

clean. Examine connection of ther-

mocouples to long green plug on

heater control board. Unplug and

re-plug thermocouple wires, cleaning

off any debris. Unplug and re-plug

long green connector on heater con-

trol board.

snug and that pins of connectors are

clean. Examine connection of ther-

mocouples to long green plug on

heater control board. Unplug and

re-plug thermocouple wires, cleaning

off any debris. Unplug and re-plug

long green connector.

of hose in same environment as gun.

Verify FTS installation, page 32.

PROBLEM CAUSE SOLUTION

Troubleshooting

Hose does not heat.

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

FTS failed or is not contacting

Check FTS, page 11.

correctly.

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

of hose in same environment as gun. Verify FTS installation, page 32.

Temperature control alarm. Check temperature display or diag-

nostic code, page 32.

Shorted connection or failed hose heating element.

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

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

3A1570A 21

Repair

6. Shut off inlet air ball valve (G)

Unless otherwise noted, all repair procedures must be completed with incoming power switched OFF and locked out at the source. Any electrical repair or troubleshooting required beyond the scope of this manual must be performed by a qualified electrician. Shut off air inlet ball valve and shut off all air supply pressure.

Disconnect Pump

Air motor shaft, yoke, 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 connecting rod during operation.

NOTE: See manual 309577 for pump repair instructions.

1. Turn main heater power OFF .

7. Remove screws (13, 15) and pump covers (63).

13 63

8. Disconnect A side (21) and B side (23) steel outlet tubes from adapters (312).

312

ti17989a

2. Follow Flushing, page 14.

3. Follow Pressure Relief Procedure, page 13.

4. Follow Park instructions, page 14.

5. Shut off both feed pumps and close both inlet supply valves (F).

22 3A1570A

ti17988a

318

317

9. Remove adapter (312) from fluid outlet (M).

10. For A Side pump, disconnect barb fitting (318), elbow fitting (317), and two pipe plugs (324).

NOTE: It is not necessary to cut tubes connected to barb fittings.

312

324

ti17990a

Repair

11. Push retaining wire clip (307) up. Push retaining pin (306) out.

307

306

12. Loosen lock nut (302) by hitting firmly with a

301

302

304

non-sparking hammer.

303

ti17991a

5. For Iso A pump only:

a. Install two pipe plugs (324).

b. Reconnect two tubing lines (N) from ISO Pump

Lube reservoir. Flush and refill reservoir with TSL 206995.

6. Refill Resin B pump wet cup with TSL 206995.

13. Unscrew pump out of pump mounting plate (301).

14. See pump manual for repair procedures and replacement parts.

Connect Pump

1. Ensure locknut (302) is screwed on pump with flat side up. Grease pump mounting threads in plate and pump cylinders (303, 304) with lithium grease. Screw pump into pump mounting plate (301) until top of pump thread is above mounting plate 1/2 to 1 1/2 threads above flush.

NOTE: Pump rod connecting links (302) should be positioned so that pins (306) are in line with each other.

2. Align pump rod hole with link hole. Push retaining pin (306) in. Pull retaining wire clip (307) down to cover pin ends.

3. Tighten locknut (302) by hitting firmly with a non-sparking hammer.

4. Install adapter (312) in fluid outlet. Connect A side (21) and B side (23) steel outlet tubes.

3A1570A 23

Repair

Remove Air Motor

1. Press in tube fitting ferrules and pull out tubing (65) to disconnect air line.

2. Disconnect DataTrak communication cable, if installed.

3. Place wrench on adapter (315) and a another wrench on lock nut (313). Remove lock nut (313).

315

313

ti17992a

FIG. 1

4. Remove four nuts (310) from tie rods (309).

6. Lay air motor on a clean flat work space. Place a wrench on the tie rod flats (309) and hold one of other tie rods with your hand to keep the air motor (308) in place. Remove the tie rods from the air

motor.

309

308

ti17994a

FIG. 3

309

314

301

310

ti17993a

FIG. 2

5. Loosen two screws (314) behind air motor bracket. Carefully lift air motor and tie rods away from the proportioner frame and plate (301).

7. Use a wrench to hold the piston rod in place and remove the adapter (315) with another wrench. See F

IG. 1.

8. See air motor manual for repair instructions.

Install Air Motor

1. Apply medium blue thread lock on adapter (315). Use a wrench to hold the piston rod in place and install the adapter (315) with another wrench. Torque to 32-38 ft-lbs (43-51 N•m). See F

2. Install tie rods (309) in the bottom of the air motor (308). See F

IG. 3.

3. Install tie rods through plate (301). Ensure screws (314) fit in the bracket slots (311). Install screws (314). See F

IG. 2.

4. Tighten nut (313) to 32-38 ft-lbs (43-51 N•m).

5. Evenly torque four tie rod nuts (310) in small increments to 27-32 ft-lbs (37-43N•m). See F

IG. 1.

IG. 2.

24 3A1570A

Repair

Recirculation / Over Pressure Relief Block

Valves can be serviced with the block on the machine (see page 46 for parts view). For thorough cleaning, remove the block assembly as follows.

1. Disconnect two fluid tubes connected to back of recirculation block (3).

2. Loosen and remove two screws (10) in back of recirculation block.

ti17995a

FIG. 4

3. See Fluid Manifold, page 46. Clean and inspect all parts for damage. Ensure that the seat (8a) and gasket (8b) are positioned inside each valve cartridge (8).

4. Apply PTFE pipe sealant to all tapered pipe threads before reassembling.

5. Reassemble in reverse order, following all notes on page 46.

Air Inlet Filter / Water Separator (Auto Drain)

Air Filter Element Removal

1. Close air inlet valve (302) on filter (301).

2. Hold in metal spring clip and twist black cover counterclockwise to remove.

302 301

FIG. 5

3. Unscrew clear drain cover by hand.

4. Unscrew black filter element retainer to remove element.

5. Inspect filter element. Clean or replace.

Air Filter Element Installation

1. Insert cleaned or replacement filter (114228).

2. Hand-screw filter retainer into place.

ti17996a

3. Hand-screw clear drain cover until tight.

4. Reposition black cover and turn. Make sure it “snaps” back into place.

3A1570A 25

Repair

Temperature Control Module

Table 2: Temperature Control Module Connections

Connector Description

DATA (A) Data reporting

HOSE T/C P; FTS (purple)

12 11 HOSE T/C R; FTS (red) 10 HOSE T/C S; FTS (silver

(unshielded bare wire))

9 HEATER T/C B, Y;

SENSOR (B)

DISPLAY (C) Display

COMMUNICATION (D) Communication to power

PROGRAM (E) Software programming

BOOT (F) Software bootloader

POWER/RELAY (G) Circuit board power input and

Thermocouple (yellow)

8 HEATER T/C B, R;

Thermocouple (red) 7 Not used 6 HEATER T/C A, Y;

Thermocouple (yellow) 5 HEATER T/C A, R;

Thermocouple (red)

4, 3 OVERTEMPERATURE B;

Overtemperature switch B

2, 1 OVERTEMPERATURE A;

Overtemperature switch A

boards

contactor control output

ti17997a

ti9843a1

Right Side of

Control Heater Module

Table 3: Temperature Control Module Connections

Connector Description

COMMUNICATION

(H)

POWER (J) Power to heater

Communication to control board

ti9843a4

Bottom of Power Modules

FIG. 6: Temperature Control Module Connections

26 3A1570A

Repair

Test SCR Circuit

1. Test the SCR circuit in the on position:

a. Make sure everything is connected, including

the hose.

b. Turn main power ON .

c. Adjust the hose heat setpoint above the ambi-

ent hose temperature.

d. Turn on heat zone by pressing .

e. Hold down to view electrical current.

Hose current should ramp up to 45A. If there is no hose current, see E03: No zone current, page 11. If hose current exceeds 45A, see E02: High zone current, page 11. If hose current stays several amps below 45A, hose is too long or voltage is too low.

2. Test the SCR circuit in the off position:

Replacing Temperature Control Assembly Modules

NOTICE

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

1. Turn main power off . Disconnect power

supply.

2. Relieve pressure, page 13.

3. Refer to electrical diagrams. See Reactor A-25 Wir- ing Schematic, page 51. Temperature control assembly is on left side inside cabinet.

4. Remove bolts that secure transformer assembly and slide assembly to side in cabinet.

5. Put on static conductive wrist strap.

6. Disconnect all cables and connectors from assembly. See Temperature Control Module, page 26.

a. Make sure everything is connected, including

the hose.

b. Turn main power ON .

c. Adjust the hose heat setpoint below the ambi-

ent hose temperature.

d. Turn on heat zone by pressing .

Using a voltmeter, carefully measure the voltage at the hose connector. You should not get a voltage reading. If you do, the SCR on the temperature control module is bad. Replace the temperature control assembly.

7. Remove nuts and take entire temperature control assembly to workbench.

8. Replace defective module.

9. Install assembly in reverse order.

3A1570A 27

Repair

Primary Heater

Read Warnings on page 4. Wait for heater to cool before repairing.

Heater Element

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 13.

3. Wait for heaters to cool.

4. Remove heater shroud.

5. See F

Heater Rod

IG. 7. Disconnect heater element wires from

heater wire connector. Test with ohmmeter.

Element Wattage Ohms

Line Voltage

The primary heaters output their rated wattage at 230 Vac. Low line voltage will reduce power available and the heaters will not perform at full capability.

1500 30-35

6. To remove heater element, first remove thermocouple (361) to avoid damage, see step 7, page 30.

7. Remove heater element (358) from housing (351). Be careful not to spill any fluid left in housing.

8. Inspect element. It should be relatively smooth and shiny. If there is a crusted, burnt, ash-like material adhered to element or sheath shows pitting marks, replace element.

9. Install new heater element (358), holding mixer (360) so it does not block thermocouple port (P).

10. Reinstall thermocouple, page 30.

11. Reconnect heater element leadwires to heater wire connector.

12. Replace heater shroud.

28 3A1570A

2 5

355

351

353

1 6

361

362 359

356 357

354

Repair

3 6 7

352

Torque to 120 ft-lbs (163 N•m).

Torque to 23 ft-lbs (31 N•m).

Torque to 40 ft-lbs (54 N•m).

Apply 110009 thermal heatsink compound.

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

Apply lubricant to o-rings.

Orient rupture disc housing (369) with exhaust hole pointing towards the bottom of the heater.

FIG. 7. 6 kW Dual Zone Heater

360

358

ti17998a

3A1570A 29

Repair

Thermocouple

Read Warnings on page 4. Wait for heater to cool before repairing.

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 13.

3. Wait for heaters to cool.

4. Remove heater shroud.

5. Disconnect thermocouple wires from B on temperature control module. See Table 2, page 26 and F

IG.

6, page 26.

6. Feed thermocouple wires out of cabinet. Note path as wires must be replaced in the same way.

7. See F

IG. 8. Loosen ferrule nut (N). Remove thermo-

couple (361) from heater housing (351), then remove thermocouple housing (H). Do not remove the thermocouple adapter (356) unless necessary. If adapter must be removed, ensure that mixer (360) is out of the way when replacing the adapter.

8. Replace thermocouple, F

IG. 8.

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 (356).

c. Push in thermocouple (361) so tip (T) contacts

heater element (358).

d. Holding thermocouple (T) against heater ele-

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

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

10. Replace heater shroud.

11. Turn on heaters A and B simultaneously to test. Temperatures should rise at same rate. If one heater is low, loosen ferrule nut (N) and tighten thermocouple housing (H) to ensure thermocouple tip (T) contacts element (358).

Apply PTFE tape and thread sealant.

361

Apply 110009 thermal heatsink compound.

356

301

358

359

360

ti7924a

FIG. 8. Thermocouple

30 3A1570A

Repair

Overtemperature Switch

Read Warnings on page 4. Wait for heater to cool before repairing.

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 13.

3. Wait for heaters to cool.

4. Remove heater shroud.

5. Disconnect one leadwire from overtemperature switch (359), F ter. Resistance must be approximately 0 ohms.

6. If switch fails test, remove wires and screws. Discard failed switch. Apply thermal compound 110009, install new switch in same location on housing (351), and secure with screws (311). Reconnect wires.

NOTE: If wires need replacement, disconnect temperature control module. See Table 2, page 26 and F page 26

IG. 8. Test across switch with ohmme-

IG. 6,

5. If hose fails test, retest at each length of hose, including whip hose, until failure is isolated.

Check FTS Cables

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 13.

3. Disconnect FTS cable (F) at Reactor, FIG. 9.

ti17788a

FIG. 9. Heated Hose

4. Test with ohmmeter between pins of cable connector.

Heated Hose

Refer to the heated hose manual for hose replacement parts.

Pins Result

1 to 2 approximately 35 ohms per 50 ft (15.2 m) of

hose, plus approximately 10 ohms for FTS

1 to 3 infinity

Check Hose Connectors

5. If cable fails test, retest at FTS, page 32.

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 13.

NOTE: Whip hose must be connected.

3. Disconnect hose connector (D) at Reactor, F

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

3A1570A 31

IG. 9.

Repair

Fluid Temperature Sensor (FTS)

Test/Removal

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 13.

3. Remove tape and protective covering from FTS. Disconnect hose cable (F). Test with ohmmeter between pins of cable connector.

Pins Result

1 to 2 approximately 10 ohms

1 to 3 infinity

3 to FTS groundscrew 0 ohms

1 to FTS component A

fitting (ISO)

infinity

4. If FTS fails any test, replace FTS.

5. Disconnect air hoses (C, L), and electrical connectors (D).

6. Disconnect FTS from whip hose (W) and fluid hoses (A, B).

7. Remove ground wire (K) from ground screw on underside of FTS.

8. Remove FTS probe (H) from component A (ISO) side of hose.

Installation

The Fluid Temperature Sensor (FTS) is supplied. Install FTS between main hose and whip hose. See Heated Hose manual 309572 for instructions.

ISO

ti9581c

FIG. 10: Fluid Temperature Sensor and Heated Hoses

32 3A1570A

Repair

Transformer Primary Check

1. Turn main power OFF .

2. Locate the two smaller (10 AWG) wires coming out of transformer. Trace these wires back to contactor and circuit breaker (911). Use an ohmmeter to test for continuity between two wires; there should be continuity.

Transformer Secondary Check

1. Turn main power OFF .

2. Locate the two larger (6 AWG) wires coming out of transformer. Trace these wires back to large green connector under hose control module and circuit breaker (909). Use an ohmmeter to test for continuity between two wires; there should be continuity.

If you are not sure which wire in green plug under hose module connects to transformer, test both wires. One wire should have continuity with the other transformer wire in breaker (909) and the other wire should not.

3. To verify transformer voltage, turn on hose zone. Measure voltage from 178CB-2 to HPOD-1; see

Reactor A-25 Wiring Schematic, page 51.

Model Secondary Voltage

310 ft. 90 Vac*

210 ft. 62 Vac*

* For 230 Vac line voltage.

Replace Transformer

1. Turn main power OFF . Disconnect power

supply.

2. Open Reactor cabinet.

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

4. Disconnect the transformer wires; see Reactor A-25 Wiring Schematic, page 51.

909

911

IG. 11: Circuit Breaker Module

5. Remove transformer from cabinet.

6. Install new transformer in reverse order.

ti17999a

3A1570A 33

Repair

Replace Circuit Breaker Module

1. Turn main power OFF . Disconnect power

supply. Turn circuit breakers on to test.

2. Relieve pressure, page 13.

3. Using an ohmmeter, check for continuity across circuit breaker (top to bottom). If no continuity, trip breaker, reset, and retest. If still no continuity, replace breaker as follows:

a. Refer to electrical diagrams and table below.

Disconnect wires and remove bad breaker.

NOTE: To reference cables and connectors, see the electrical diagrams and parts drawings on page 49 and

51.

b. Install new breaker and reconnect wires.

Ref. Size Component

CB1 50 A Hose Secondary (single)

CB2 40 A Hose Primary (double)

CB3 25 A Heater A (double)

CB4 25 A Heater B (double)

CB1

CB2

CB3 CB4

ti17569a

FIG. 12

34 3A1570A

Pump Lubrication System

Check the condition of the ISO pump lubricant daily. Change the lubricant if it becomes a gel, its color darkens, or it becomes diluted with isocyanate.

Repair

Gel formation is due to moisture absorption by the pump lubricant. The interval between changes depends on the environment in which the equipment is operating. The pump lubrication system minimizes exposure to moisture, but some contamination is still possible.

Lubricant discoloration is due to continual seepage of small amounts of isocyanate past the pump packings during operation. If the packings are operating properly, lubricant replacement due to discoloration should not be necessary more often than every 3 or 4 weeks.

To change pump lubricant:

1. Relieve pressure, page 13.

2. Lift the lubricant reservoir (LR) out of the bracket (RB) and remove the container from the cap. Holding the cap over a suitable container, remove the check valve and allow the lubricant to drain. Reattach the check valve to the inlet hose (ST). See F

IG.

13.

3. Drain the reservoir and flush it with clean lubricant.

FIG. 13. Pump Lubrication System

ti18001a

4. When the reservoir is flushed clean, fill with fresh lubricant.

5. Thread the reservoir onto the cap assembly and place it in the bracket.

6. The lubrication system is ready for operation. No priming is required.

3A1570A 35

Repair

Fluid Inlet Strainer Screen

The inlet strainers filter out particles that can plug the pump inlet check valves. Inspect the screens daily as part of the startup routine, and clean as required.

Isocyanate can crystallize from moisture contamination or from freezing. If the chemicals used are clean and proper storage, transfer, and operating procedures are followed, there should be minimal contamination of the A-side screen.

NOTE: Clean the A-side screen only during daily startup. This minimizes moisture contamination by immediately flushing out any isocyanate residue at the start of dispensing operations.

1. Close the fluid inlet valve at the pump inlet and shut off the appropriate feed pump. This prevents material from being pumped while cleaning the screen.

2. Place a container under the strainer base to catch drain off when removing the strainer plug (C).

Temperature Display

NOTICE

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

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 13.

3. Refer to Reactor A-25 Wiring Schematic, page 51.

4. Put on static conductive wrist strap.

5. Disconnect main display cable (106) at lower left corner of display module; see F

6. Remove screws (116) and cover (105); see F

IG. 15.

3. Remove the screen (A) from the strainer manifold. Thoroughly flush the screen with compatible solvent and shake it dry. Inspect the screen. No more than 25% of the mesh should be restricted. If more than 25% of the mesh is blocked, replace the screen. Inspect the gasket (B) and replace as required.

4. Ensure the pipe plug (D) is screwed into the strainer plug (C). Install the strainer plug with the screen (A) and gasket (B) in place and tighten. Do not overtighten. Let the gasket make the seal.

5. Open the fluid inlet valve, ensure that there are no leaks, and wipe the equipment clean. Proceed with operation.

Ti10974a

FIG. 14. Fluid Inlet Strainer

7. Disconnect cable connector from back of temperature display (102). See F

IG. 15.

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

IG. 15.

9. Remove nuts (103) and plate (101).

10. Disassemble display, see detail in F

IG. 15.

11. Replace board (102a) or membrane switch (102b) as necessary.

12. Reassemble in reverse order, see F

IG. 15. Apply

medium strength thread sealant where shown. Be sure display cable ground wire (G) is secured between cable bushing and cover (105) with screws (107).

36 3A1570A

102

Repair

116

119

G 106

105

107

104

103

Detail of Membrane Switches and Temperature Display Board

Temperature Display

102b

ti18026a

102a

102c

ti18003a

FIG. 15. Display Module

3A1570A 37

Repair

Replace DataTrak Battery or Fuse

4. Remove two screws on back of module to access battery.

The battery and fuse must be replaced in a non-hazardous location.

Use only the following approved replacement batteries. Use of an unapproved battery will void Graco’s warranty and FM and Ex approvals.

• Ultralife lithium # U9VL

• Duracell alkaline # MN1604

• Energizer alkaline # 522

• Varta alkaline # 4922 Use only a Graco-approved replacement fuse. Order

Part 24C580.

Replace Battery

1. Unscrew cable from the back of the reed switch assembly. See F

2. Remove the cable from the two cable clips.

IG. 16.

5. Disconnect the used battery and replace with an approved battery. See F

IG. 18.

Replace Fuse

1. Remove the screw, metal strap, and plastic holder.

2. Pull the fuse away from the board.

3. Replace with a new fuse.

Solenoid Cable Connection

Fuse

Sensor Cable Connection

ti11992a

IG. 16. Disconnect DataTrak

3. Remove DataTrak module from bracket. See F

17. Take module and attached cable to a non-hazardous location.

IG.

Battery

ti11994a

FIG. 18. DataTrak Battery and Fuse Location

ti18004a

IG. 17. Remove DataTrak

38 3A1570A

Accessories

Feed Pump Kits

Pumps, hoses, and mounting hardware to supply fluids to Reactor. Includes 246483 Air Supply Kit. See 309815.

246483 Air Supply Kit

Hoses and fittings to supply air to feed pumps, agitator, and gun air hose. Included in feed pump kits. See

309827.

246978 Circulation Kit

Return hoses and fittings to make circulation system. Includes two 246477 Return Tube Kits. See 309852.

246477 Return Tube Kit

Desiccant dryer, return tube, and fittings for one drum. Two included in 246978 Circulation Kit. See 309852.

TSL (Throat Seal Liquid)

206995 1 qt (1 liter) bottle

206996 1 gal. (3.8 liter) container

P2 Spray Gun

Probler P2 Gun available in round or flat pattern. See

313213.

Y-Strainer Screen

Replacement strainer screen for fluid Y-strainer; 20 mesh.

Part Description

180199 20 mesh; as shipped 255082 80 mesh (2 pack) 255083 80 mesh (10 pack)

114228 Air Filter Element

Replacement air filter element; 5 micron.

262695 Wheel Kit

All hardware and wheels to convert model 262572.

Recommended Spare

24A592 DataTrak with Cycle Count Only Kit

DataTrack and reed switch for NXT Air Motor. See manual 313541.

Heated Hoses

50 ft (15.2 m) and 25 ft (7.6 m) lengths, 1/4 in. (6 mm), 3/8 in. (10 mm), or 1/2 in. (13 mm) diameter, 2000 psi (14 MPa, 140 bar) or 3500 psi (24 MPa, 241 bar). See

309572.

Heated Whip Hoses

10 ft (3 m) whip hose, 1/4 in. (6 mm) or 3/8 in. (10 mm) diameter, 2000 psi (14 MPa, 140 bar) or 3500 psi (24 MPa, 241 bar). See 309572.

Fusion Spray Gun

Air Purge Gun available in round or flat pattern. See

309550. Mechanical Purge Gun available in round or flat pattern. See manual 309856. Clear Shot Gun available in round or flat patter. See manual 312666.

Parts

Keep the following spare parts on hand to reduce downtime.

Part No. Description

262648 Pump, Resin (B) side 246421 Resin (B) Pump Repair Kit for 262648

pump 262647 Pump, ISO (A) side 15C851 ISO (A) Pump Repair Kit for 262647

pump 246963 Wet Cup Kit for 262647 pump 206995 TSL bottle, 1 qt (1 liter) 101078 Y-Strainer; includes 180199 element 180199 Element, Y-Strainer, 20 mesh 114228 Element, air filter, 5 micron 239914 Valve, recirc/spray; includes seat and

gasket

3A1570A 39

Parts

262572, Bare Reactor A-25 262614, Reactor A-25 with DataTrak and Wheels

14 (x4)

83 62

51 11

11 (x6)

9 (x4)

100 (x4)

56 (x4)

91, 92

ti18023a

15 15

40 3A1570A

90 (x6)

Parts

25 (x2)

13 (x2)

Torque pump locking nuts to 66-74 ft-lbs (90-100 N•m).

Apply anaerobic polyacrylate pipe sealant to all non-swiveling pipe threads.

Torque tube ends to 212-265 in-lbs (24-30 N•m).

Connect ground wire (94) from motor lug to ground lug in cabinet.

3A1570A 41

9 (x4)

13 (x2)

ti18024a

Parts

13 (x4)

262572, Bare Reactor A-25 262614, Reactor A-25 with DataTrak and Wheels

Ref Part Description Qty.

1---CART 1 2 262573 PUMP; see page 48 1 3 262577 MANIFOLD, relief; see page 46 1 4 --- PANEL, control, heater;

see page 45

5 24J788 HEATER, system, (6.0kw,

230v); see page 47 6 262575 PANEL, control; see page 44 1 7 262576 MODULE, breaker; see page 50 1 8 24M177 TRANSFORMER, 2790va,

230/62

ti18025a

13 (x4)

ti18007a

9 111799 SCREW, cap, hex hd; M8 x 1.25 8 10 108296 SCREW, mach, hex wash hd;

1/4-20 UNC-2A

11 125621 SCREW, machine, hex washer,

hd; M6 x 1 12 16G917 BRACKET, heater 1 13 114182 SCREW, mach, hex flange; M6

x 1 14 117623 NUT, cap, 3/8-16 4 15 106084 SCREW, mach, pan hd; M5 x

0.8

16 117682 BUSHING, strain relief 1

42 3A1570A

Parts

17 123970 SWITCH, disconnect, 40a 1 18 123971 KNOB, disconnect, operator 1 19 123972 SWITCH, fourth pole 1 20 205447 COUPLING, hose 2 21 16G921 TUBE, fluid, A, heater, inlet 1 22 16G922 TUBE, fluid, A, heater, outlet 1 23 16G923 TUBE, fluid, B, heater, inlet 1 24 16G924 TUBE, fluid, B, heater, outlet 1 25 112125 PLUG, tube 2 26 117666 TERMINAL, ground 1 27 15D795 FILTER, air, 40 micron 1 28 107128 TEE, service 1 29 114110 ELBOW, male, swivel 1 30 162449 NIPPLE, reducing 1 31 158491 NIPPLE 1 32 262660 VALVE, ball, 1/2 npt x 1/2 npt 1 33 114269 GROMMET, rubber 4 34 16G918 COVER, heater 1 35 246995 BOTTLE, assembly, complete 1 36 234366 KIT, fluid inlet, pair; see page 46 1 37† 262695 KIT, wheel; see page 51 2 38 16M152 BRACKET, lube, reservoir 1 44‡ 247791 HARNESS, wire, hose 1 45‡ 261669 KIT, fluid temp sensor, coupler 1 49 167002 INSULATOR, heat 2 50 16J433 HARNESS, wire, display, ext. 1 51 16J434 HARNESS, over temp, a-side,

b-side 52 261821 CONNECTOR, wire, 6awg 1 53‡ --- FLUID, oxide inhibitor 1 54‡ 206994 FLUID, TSL, 8 oz. bottle 1 55‡ 206995 FLUID, TSL, 1 qt. 1 56 186494 CLIP, spring 4 57 --- HOSE, PTFE; 5 ft (1.5 m), 0.25

in. (6.35 mm) ID 58 15G280 LABEL, warning 1 59 189930 LABEL, caution 1 60 189285 LABEL, caution 3 61 15H108 LABEL, pinch point 1 62 15B380 CABLE, hose, control 1 63 16G952 COVER, pump 2 64 --- TUBE, polyethylene, rnd; 3/4

OD; 0.75 ft (0.2 m); see page 49 65 --- TUBE, polyurethane, rnd, black;

5.12 ft (1.56 m); see page 49 66 --- INSERT, control panel 2 67† 24B563 KIT, DataTrak 1 68† 24B659 SWITCH, reed assy 1

69† --- FASTENER, screw, pan head,

m4 x 35mm 79 262581 COVER, electrical, assembly 1 80 --- SCREW, shcs, m5x60 2 83 248208 HOSE, coupled, 4 feet 1 82‡ 15H187 WIRE, jumper, w/quick discon-

nect 84 --- LABEL, product 1 85 16J808 LABEL, warning, disconnect

wiring 88 195874 SCREW, phillips, pan hd; M4 x 8 1 89 16K669 FILTER, electrical 3 90 115266 SCREW, cap, socket hd; M5 x 106

91 --- SCREW, pan hd; M5 x 16 1 92 --- WASHER, #10, external tooth

lock 93 --- TUBE, pe, spiral, wrapping; 1.2

ft (0.4 m) 94 16M086 WIRE, ground, pump 1 95‡ 114601 CONDUIT, flexible, non-metallic 1 96‡ --- SLEEVE, heat-shrink, 2:1; 0.75

ft, 1/2 in. ID, 1/4 in. OD 97‡ 120573 BRIDGE, plug-in, jumper 4 98 16M088 LABEL, error codes 1 99‡ 114958 STAP, tie 10 100 105676 SCREW, pan hd 4

 Replacement Danger and Warning labels, tags, and

cards are available at no cost.

† Only used with 262614.

 Only used with 262572.  Included in Reed Switch Kit 24B659.

‡Not shown.

3A1570A 43

Parts

Control Panel, 262575

116105

102

101

103

108

112

104

115

121

109

110

107

113

106

119

106

113

114

ti18002a

118

113

Flow

111

113

Apply sealant to all non swiveling pipe threads.

Attach ground wire from harness (116) between connector on harness (106) and display cover (105).

Attach harness (106) to J13 on board (102).

Attach harness (119) to J1 on board (102).

Ref. Part Description Qty.

101 16G912 PLATE, display 1 102 24G883 DISPLAY, temperature; includes

102a-102c 102a 24G882 BOARD, circuit 1 102b 246478 SWITCH, membrane 1 102c 112324 SCREW 4 103 117523 NUT, cap (#10) 8 104 16G958 GASKET, display cover 1 105 16G913 COVER, display 1 106 16J432 HARNESS, wire, display 1

112 16F810 NUT, regulator, steel 1 113 114114 FITTING, elbow, male, swivel 4 114 114362 VALVE, ball, air 1 115 110637 SCREW, mach, pan head 2 116 331342 SCREW, screw 10-24 x1/2 in.

ph pn hd 117 114469 FITTING, elbow, m swivel 1 118 116643 VALVE, relief, air, 90 psi (620.5

kPa) 119 16J431 HARNESS, jumper, heater dis-

play 121 16K525 LABEL, control 1

107 --- SCREW, pan head, phillips 2 108 116257 GAUGE, pressure 1 109 100451 COUPLING, 1/8 npt 1 110 114151 FITTING, elbow, male, swivel 1 111 15T536 REGULATOR, air, 3/8 npt 1

44 3A1570A

Temperature Control Wheel Kit, 262695

Parts

151

152

155

154

To B Heater Module

153

To A Heater Module

To Hose Heater Module

154

Ref. Part Description Qty.

151 16G925 PANEL, pod, mounting 1 152 247827 MODULE, heater control 1 153 247828 MODULE, heater 3 154 114183 NUT, hex, flanged, serrated 4 155 247801 CABLE, communication 1

195

193

194

192

191

193

ti18006a

Ref. Part Description Qty.

191† 16H182 AXLE, wheel 2 192† 111841 WASHER, plain 5/8 4 193† 191824 WASHER, space 4 194† 101242 RING, retaining, ext. 4 195† 16G920 WHEEL, semi pneumatic, offset 2

† Only used with 262614. Available as add on wheel kit

262695.

3A1570A 45

Parts

Fluid Manifold

212

214

208b

204

213

206

209

207

Apply sealant and torque to 250 in-lbs (28 N•m).

Use blue thread lock on valve cartridge threads into manifold.

Part of item 208.

Apply lubricant to mating surfaces.

Apply pipe sealant to all NPT threads.

Ref. Part Description Qty.

201 24K993 MANIFOLD, recirculation 1 202 108638 FITTING, pipe, tee 2 203 162453 FITTING, (1/4 npsm x 1/4 npt) 2 204 113641 GAUGE, pressure, fluid, SST 2 205 111600 PIN, grooved 2 206 119789 FITTING, elbow, street, 45 deg, 2 207 116704 ADAPTER, 3/8 JIC x 1/4 npt 1 208 239914 VALVE, drain; includes 208a, 208b 2 208a --- SEAT 2 208b --- GASKET 2 209 119998 ADAPTER, 5/16 JIC x 1/4 npt 1 210 116702 FITTING, union, 1/4 npt x 3/8 JIC 2 212 187625 HANDLE, valve, drain 2 213189285 LABEL, caution 1 214 224807 BASE, valve 2

205

208

ti8459a

208a

201

210

202

203

Fluid Inlet Kit, 262695

255

254

253

252

251

Assemble ball valves in orientation shown.

Apply anaerobic polyacrylate pipe sealant to all NPT connections.

Ref. Part Description Qty.

251 160327 UNION, adapter, 90°; 3/4 npt(m) x

3/4-14 npt(f)

252 101078 Y-STRAINER; 20 m screen 2 253 C20487 NIPPLE, 3/4 npt 2 254 109077 VALVE, ball; 3/4 npt (fbe) 2 255 118459 UNION, swivel; 3/4-14 npt(m)x

3/4-14 npt(f)

180199 ELEMENT, 20 mesh 2

256

ti18027a

 Replacement Danger and Warning labels, tags, and

cards are available at no cost.

46 3A1570A

6 kw Dual Zone Heater, 24J788

353

1 6

355

2 5

351

361

362 359

356 357

354

Parts

3 6 7

352

Torque to 120 ft-lbs (163 N•m).

Torque to 23 ft-lbs (31 N•m).

Torque to 40 ft-lbs (54 N•m).

Apply 110009 thermal heatsink compound.

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

Apply lubricant to o-rings.

Orient rupture disc housing (369) with exhaust hole pointing towards the bottom of the heater.

Ref Part Description Qty.

351 --- HEATER, dual zone 1 352 124132 O-RING 4 353 15H305 FITTING, plug hollow hex

1-3/16 sae

354 121309 FITTING, adapter, sae-orb x

jic 355 15H304 FITTING, plug 9/16 sae 2 356 15H306 ADAPTER, thermocouple,

9/16 x 1/8 357 120336 O-RING, packing 2 358 16A112 HEATER, immersion, (1500w,

230v)

360

358

ti17998a

359 15B137 SWITCH, over temperature 1 360 15B135 MIXER, immersion heater 4 361 117484 SENSOR 2 362 --- SCREW, mach, pnh 2 369 247520 KIT, rupture disc 2

3A1570A 47

Parts

A-25 Air Motor Pump Assembly, 262573

305

307

308

306

314

Ref Part Description Qty.

301 16G915 PLATE, Mounting, Cylinder 1 302 193031 NUT, retaining 2 303 262647 PUMP, displacement, w/lube; iso 1 304 262648 PUMP, displacement; resin 1 305 15J132 LINK, connecting 2

325

3133

315 313

3 7

319

305 311

316

314

306 183210 PIN, str, hdls 2 307 183169 SPRING, retaining 2 308 M12LP0 MOTOR, air, NXT, 6 in., cycle

only; see manual 312796 309 16G929 ROD, tie 4 310 125266 NUT, lock, nylon, m12 4 311 16G926 BRACKET, pump mounting 1

312 117833 ADAPTER, 3/4-16 JIC x 3/8 NPT 2 313 120553 NUT, center lock, 5/8-18 3 314 111799 SCREW, cap, hex hd 4 315 16G914 ADAPTER, rod 1 316 114110 ELBOW, male, swivel 1 317 15K783 ELBOW, street, 90° 1

318 116746 FITTING, barbed, plated 2 319 16G916 PLATE, yoke, pump 1

309

322 15H108 LABEL, pinch point 1 324 100139 PLUG, PIPE 2

301

325 15B565 VALVE, 1/4 npt, park 1

322

310

312 318

302

324

317

304

312

303

Apply PTFE tape and sealant to non-swiveling pipe threads.

Torque to 88.5-124 in.-lbs (10-14 N•m).

Torque to 32-38 ft-lbs (43-51 N•m). Torque nut (313) after assembly of item pin (306) and spring (307).

Install adapters so that pins (306) will be in-line with each other.

Lubricate threads of pump cylinders (303, 304) and plate (301) with lubricant prior to assembly into mounting plate. Assemble pump cylinder 1/2 thread above flush to one and one half thread above flush of mounting pate surface.

Torque to 27-32 ft-lbs (37-43 N•m).

Use blue thread lock (medium).

48 3A1570A

Air Tubing Connections

Parts

503

502

500

501

503

501

Length

Ref.

64 0.75 ft (0.23 m) 503 503 UHMWPE Black 5/32 in. (4 mm) 65 2.66 ft (0.8 m) 501 501 Urethane Black 1/2 in. (12.7 mm) 65 1.66 ft (0.5 m) 502 502 Urethane Black 1/2 in. (12.7 mm) 65 0.75 ft (0.23 m) 500 500 Urethane Black 1/2 in. (12.7 mm)

3A1570A 49

ft (m)

Connection

From To

Material Color

Outside

Diameter

Parts

Breaker Module, 262576

402

403404 (8x)

413 414

410 (4x)

411 412

403

404 (7x)

403

405

401

409 408 407 406

Ref. Part Description Qty.

401 16H309 RAIL, mounting 1 402 112446 BLOCK, clamp end 1 403 120490 COVER, end 3 404 120570 BLOCK, terminal 15 405 255046 BLOCK, terminal ground 1 406 255050 CIRCUIT BREAKER, 25a, 2p 2 407 24M176 CIRCUIT BREAKER, 30a, 2p 1 408 255026 CIRCUIT BREAKER, 1 pole,

50a, c curve 409 255022 RELAY, contactor, 65a, 3p 1 410 120491 BLOCK, terminal 4 411 255043 HOLDER, fuse term.block

5x20mm 412 255023 FUSE, 5a, 5x20mm 2 413 120573 BRIDGE, plug-in, (jumper) 2 414 120485 BRIDGE, plug-in, (jumper) 2 415 16J534 HARNESS, wiring 1

50 3A1570A

Reactor A-25 Wiring Schematic

DSC 1-4

TB13-19

Reactor A-25 Wiring Schematic

230V

1 PHASE

DSC 1-4

230V DELTA

3 PHASE

DSC 1-4

WYE

380V

3 PHASE

BRIDGE

TB13-19

TB14

TB15

BRIDGE

TB18

BRIDGE

TB13-19

BRIDGE

TB13

TB16

BRIDGE

TB17

212

FU2-2

FU2-1

TB10-1

TB10-2

FUSE2

230V

124T1

62V

183CB

50A

FUSE1

187

195

196

207

FTS

HOSE HEATER

238CR

178CB

30A

185

212

180

TB9-1

TB9-2

FU1-2

FU1-1

190

2 BRIDGES

TB19

170

171

172

173

174

175

176

177

178

179

179-1

179-2

179-3

179-4

179-5

3A1570A 51

Reactor A-25 Wiring Schematic

A-POD

APOD-2

APOD-1

211

HEATER

SCR CIRCUIT

LF2

POWER

MODULE

ZONE A

208

238CR

COUPLE A

THERMO-

208

238CR-A1

238CR-A2

TB9-1

204PCB-1

204PCB-3

204PCB-2

210

COUPLE B

THERMO-

TB4-2

TB11-1

204PCB-4

TB5-2

209

179-1

HPOD-2

B-POD

BPOD-2

BPOD-1

H-POD

HPOD-1

179-2

HOSE

POWER

SCR CIRCUIT

HEATER

POWER

MODULE

SCR CIRCUIT

MODULE

ZONE HOSE

ZONE B

198

TB6-2

BRI

TB7-2

TB2-2

TB3-2

DUAL ZONE

B-REAR

A-REAR

191

HARNESS

247801

HEATER

194

212

OVER

TEMP

181

176

180

181

1120-A

TB17

182

183

184

175

185

186

187CB

25A

179

187

188

1122

LF2

197CB

25A

TB16

TB14

178

191 192 193 194 195 196 197 198 199

189

190

206

238CR

TB13

COMMUNICATION

MODULES

TO POWER

TEMPERATURE CONTROL MODULE

200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215

4 COMMON

OPTIONAL

RS485

1 +12V

3 A

2 B

CONNECTION

REPORTING

246122

DATA

FTS HOSE

THERMOCOUPLE B

9 +

8 -

12 +

11 -

10 GROUND

213

179-4

THERMOCOUPLE A

4 NOT USED

6 +

5 -

3 NOT USED

7 NOT USED

214

CONTACTOR

CONTROL

230V AC

4 COMMON

5 COMMON

1 +5V

3 A

DISPLAY

2 OVERTEMP

212

POWER

RS485

2 B

1 +12V

PANEL

52 3A1570A

Reactor A-25 Wiring Schematic

2 2 2 2 2 2 2

(INCOMING POWER)

JUMPER PLACEMENT

1 1 1 1 1 1 1

380V 3-PHASE

NCO

MING PO

TB13-TB19

380V 3-PHASE

DSC-1

INCOMING POWER

(DISREGARD TERMINATION

ID'S SHOWN ON DISCONNECT)

2 2 2 2 2 2 2

1 1 1 1 1 1 1

102GND

230V 3-PHASE

R OPTIO

TB13-TB19

230V 3-PHASE

2 1

TB13-TB19

1 1 1 1 1 1 1

2 2 2 2 2 2 2

230V 1-PHASE

TB13-TB19

230V 1-PHASE

2 2 2 2 2 2 2

1 1 1 1 1 1 1

25A

197CB

1 31 31 3

1 1 1 1

1 1 1 1 1 1 1 1

2 42 42 4

25A

187CB

30A

178CB

50A

183CB

238CR

2 2 2 2

TB9-TB12

USE

2 2 2 2 2 2 2 2

TB1-TB8

3A1570A 53

Reactor A-25 Wiring Schematic

1 1 1 1 1 1 1

2 2 2 2 2 2 2

25A

197CB

25A

187CB

LF3

LF2

B-1

A-1

B-R

A-R

THERMOCOUPLE B

HEATER

1 2

HEATER

1 2

OVERTEMP

THERMOCOUPLE A

30A

178CB

1 3 1 3 1 3

50A

183CB

238CR

2 2 2 2

1 1 1 1

USE

B-1

B-R

A-R

6KW HEATER

A-1

JUMPER PLACEMENT

USE

1 1 1 1 1 1 1 1

2 2 2 2 2 2 2 2

204PCB

123

LF1

2 4 2 4 2 4

B HEATER MODULE

POD B

ECO

2 1

RIMAR

NDA

TO HOSE

1 2

Simplified Schematic, Heater Controls

A HEATER MODULE

USE

2 1

POD A

CONTROL HEATER MODULE

TO FTS

REPORTING

TO OPTIONAL

DATA

TO THERMOCOUPLE B

TO OVERTEMP

TO THERMOCOUPLE A

HOSE HEATER MODULE

2 1

POD HOSE

3KW HEATER

JUMPER PLACEMENT

54 3A1570A

1 1 1 1 1 1 1 1

2 2 2 2 2 2 2 2

Technical Data

Category Data

Maximum Fluid Working Pressure 2000 psi (14 MPa, 138 bar) Maximum Air Supply Pressure 125 psi (0.9 MPa, 9 bar) Maximum Air Working Pressure 80 psi (550 kPa, 5.5 bar) Pressure Ratio 25:1 Air consumption with 02 tip at 1500 psi stall pres-

sure Machine Maximum Power with hose 9000 Watts Voltage Requirement (50/60 Hz)

(230 V Nominal: 195-253 VAC) (380 V Nominal: 338-457 VAC)

Amperage Requirement (Full Load Peak)* 40 amps @ 230 V, 1 Phase

Maximum Heater Fluid Temperature 190 °F (88 °C) Maximum Hose Fluid Temperature 180 °F (82 °C) Maximum Ambient Temperature 120 °F (49 °C) Maximum Output 25 lb/min. (11.4 kg/min.) Output Per Cycle (A and B) 0.025 gal/cycle (0.095 ltr/cycle) Heater Power 6000 Watts Hose Power 2790 Watts Sound Pressure (see NXT air motor manual) 70.2 dB(A) Sound Power (see NXT air motor manual) 80.1 dB(A) Viscosity Range 250-1500 centipoise (typical) Maximum Fluid Inlet Pressure 300 psi (2.1 MPa, 21 bar) or 15% of output pressure Fluid Inlet/Strainer Filter 20 mesh standard Air inlet Filter Mesh 40 Micron Component B (Resin) Inlet 3/4 npt(f) swivel Component A (Isocyanate) Inlet 3/4 npt(f) swivel Recirculation/Block Hose Connections Iso (A) side: #5 JIC (m); Resin (B) side: #6 JIC (m) Maximum Heated Hose Length*** 210 ft of 3/8 ID Weight 310 lb (140.6 kg) Wetted Parts Carbon steel, stainless steel, chrome, aluminum,

28 scfm (0.8m

230 V, 1 Phase 230 V, 3 Phase (Delta) 380 V, 3 Phase (WYE 220 V to Neutral)

32 amps @ 230 V, 3 Phase

18.5 amps @ 380 V, 3 Phase

Fluoroelastomer, PTFE, nylon

/min)

Technical Data

*Full load amps with all devices operating at maximum capabilities with 210 ft (64.1 m) of hose.

***210 ft (64 m) of heated hose will produce the maximum allowable heat capacity. 310 ft (94 m) of heated hose may be used, but will have 25% less heat capacity.

3A1570A 55

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to

the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

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

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

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

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

Original instructions. This manual contains English. MM 3A1750

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Graco A-25 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Proportioner Models

Systems

Related Manuals

Warnings

Important Two-Component Material Information

Isocyanate Conditions

Material Self-ignition

Moisture Sensitivity of Isocyanates

Keep Components A and B Separate

Foam Resins with 245 fa Blowing Agents

Changing Materials

DataTrak Diagnostic Codes

Temperature Control Diagnostic Codes

E01: High fluid temperature

E02: High zone current

E04: Fluid Temperature Sensor (FTS) or thermocouple disconnected

E03: No zone current

E05: Control board over temperature

E06: Communication cable unplugged

Communication Diagnostic Codes

E30: Momentary loss of communication

E99: Loss of communication

Before Beginning Repair

Shutdown

Park

Flushing

Troubleshooting

Problems

Power

Pumps and Pressures

Electronics

Heater

Hose Heat System

Repair

Disconnect Pump

Connect Pump

Remove Air Motor

Install Air Motor

Recirculation / Over Pressure Relief Block

Air Inlet Filter / Water Separator (Auto Drain)

Temperature Control Module

Primary Heater

Heated Hose

Fluid Temperature Sensor (FTS)

Pump Lubrication System

Fluid Inlet Strainer Screen

Temperature Display

Replace DataTrak Battery or Fuse

Accessories

Parts

Control Panel, 262575

Temperature Control Wheel Kit, 262695

Fluid Manifold

Fluid Inlet Kit, 262695

6 kw Dual Zone Heater, 24J788

A-25 Air Motor Pump Assembly, 262573

Air Tubing Connections

Breaker Module, 262576

Reactor A-25 Wiring Schematic

Technical Data

Graco Standard Warranty