Graco A-25 User Manual

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

2 3A1570A

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.

4 3A1570A

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.

3A1570A 7

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.

ti17716a

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.

+ 39 hidden pages