Graco Reactor E-10 Instructions-parts List Manual

Instructions - Parts List

For spraying or dispensing 4:1 mix ratio materials, including epoxies, polyurethane foam, and polyurea coatings. Not for use in explosive atmospheres.

Important Safety Instructions

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

313221A

See page 4 for a list of models and maximum working pressures.

Contents

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

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Keep Components A and B Separate . . . 8

Component Identification . . . . . . . . . . . . .9

Controls and Indicators . . . . . . . . . . . . . 10

Motor/Pump Control Function Knob . . . 10

STATUS Indicator . . . . . . . . . . . . . . . . . 10

Motor Power Switch/Circuit Breaker . . . 11 Heater Power Switch/Circuit Breaker . . 11

Heater Temperature Controls . . . . . . . . 11

Fluid Temperature Sensors and Displays .

Air Compressor Power Switch/Circuit

Breaker . . . . . . . . . . . . . . . . . . . . . .12

Air Compressor Controls . . . . . . . . . . . 12

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Startup of Heated Units . . . . . . . . . . . . . . 19

Spraying/Dispensing . . . . . . . . . . . . . . . . 20

Pause (Heated Units) . . . . . . . . . . . . . . . . 21

Pressure Relief Procedure . . . . . . . . . . . 22

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . .22

Maintenance . . . . . . . . . . . . . . . . . . . . . . . 23

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . .24

Troubleshooting . . . . . . . . . . . . . . . . . . . .26

Status Codes . . . . . . . . . . . . . . . . . . . .26

Troubleshooting Chart . . . . . . . . . . . . .29

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Before Beginning Repair . . . . . . . . . . . .35

Recirc/Spray Valves . . . . . . . . . . . . . . .36

Displacement Pump . . . . . . . . . . . . . . .37

Control Module . . . . . . . . . . . . . . . . . . .39

Fluid Heaters . . . . . . . . . . . . . . . . . . . .44

Pressure Transducers . . . . . . . . . . . . . .44

Drive Housing . . . . . . . . . . . . . . . . . . . .45

Cycle Counter Switch Replacement . . .46

Electric Motor . . . . . . . . . . . . . . . . . . . .47

Compressor . . . . . . . . . . . . . . . . . . . . .48

Motor Brushes . . . . . . . . . . . . . . . . . . .49

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Suggested Spare Replacement Parts . .56

Accessories . . . . . . . . . . . . . . . . . . . . . . .56

Dimensions . . . . . . . . . . . . . . . . . . . . . . . .58

Technical Data . . . . . . . . . . . . . . . . . . . . .59

Graco Standard Warranty . . . . . . . . . . . .60

Graco Information . . . . . . . . . . . . . . . . . .60

2 313221A

Related Manuals

The following manuals are for Reactor E-10 - 4:1components and accessories. Some are supplied with your package, depending on its configuration. Manuals are available at www.graco.com.

Fluid Heater Part

No. Description

311210 Instruction-Parts Manual (English)

Fusion Air Purge Plural Component Gun Part

No. Description

309550 Instruction-Parts Manual (English)

Displacement Pump - White Material Part

No. Description

311076 Instruction-Parts Manual (English)

Static Mixer Kit Part

No. Description

313122 Instruction-Parts Manual (English)

313221A 3

Models

The model no., series letter, and serial no. are located on the back of the Reactor E-10. For faster assistance, please have that information ready before calling Customer Service.

Maximum

Working

Pressure, Reactor E10 4:1 Volts

* Electrical

Connection

psi

(MPa, bar)

256765 120

15 A cord

(motor)

15 A cord

(heaters)

15 A cord

(compressor)

2000

(14, 140)

* See page 14 for detailed electrical requirements.

4 313221A

Warnings

The following general warnings are for the setup, use, grounding, maintenance, and repair of this equipment. Additional, more specific warnings may be found throughout the body of this manual where applicable. Symbols appearing in the body of the manual refer to these general warnings.

When these symbols appear throughout the manual, refer back to these pages for a description of the specific hazard.

WARNING

ELECTRIC SHOCK HAZARD

Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power cord before servicing equipment.

• Use only grounded electrical outlets.

• Use only 3-wire extension cords.

• Ensure ground prongs are intact on sprayer and extension cords.

• Do not expose to rain. Store indoors.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDS’s to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

•Gloves

• Hearing protection

SKIN INJECTION HAZARD

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

Get immediate surgical treatment.

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

• Do not put your hand over the spray tip.

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

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

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

313221A 5

Warnings

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Ground all equipment in 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 fire extinguisher in the work area.

PRESSURIZED ALUMINUM PARTS HAZARD

Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical reaction and equipment rupture, and result in death, serious injury, and property damage.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• This equipment is for professional use only.

• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and follow the Pressure Relief Procedure in this manual when equipment is not in use.

• 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.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco replacement parts only.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your Graco 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.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Comply with all applicable safety regulations.

6 313221A

Warnings

WARNING

MOVING PARTS HAZARD

Moving parts can pinch or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or

servicing equipment, follow the Pressure Relief Procedure in this manual. Dis- connect power or air supply.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.

313221A 7

Overview

The Reactor E-10 is a portable, electric-powered, 4:1 mix ratio proportioner, for use with a wide variety of coatings, foams, sealants, and adhesives. Materials must be self-leveling and pourable, and may be applied with impingement mix spray guns, disposable mixer guns, or flush-type mix manifolds.

Reactor E-10 is siphon-fed from 5 gallon pails that can be mounted on the unit.

Severe duty, positive displacement reciprocating piston pumps meter fluid flow to the gun for mixing and applying. When set to recirculation mode, Reactor E-10 will circulate fluids back to the 5 gallon pails.

The Reactor E-10 includes separate thermostatically controlled heaters for each fluid. Digital displays show the temperatures of the two fluids.

An electronic processor controls the motor, monitors fluid pressures, and alerts the operator if errors occur. See STATUS Indicator, page 10, for further information.

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

Slow Recirculation

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

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

• Not used to circulate full tanks up to temperature.

Fast Recirculation

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

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

• Use for flushing.

Pressure Adjust

An air compressor provides and regulates air pressure for the spray gun.

Automatically maintains selected pressure output for dispensing or spraying.

Keep Components A and B Separate

CAUTION

To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (white fluid) and component B (red fluid) parts.

8 313221A

Component Identification

Key for FIG. 1

Component Identification

A Pump A B Pump B C Heater A D Heater B E Compressor F Crossbar G Pail Mounting Bracket H Fluid Pressure Gauges J Recirc/Spray and Overpressure Relief Valves

K Control Panel; see F

IG. 2, page 10

L Electric Motor and Drive Housings M Suction Tubes N Recirculation Tubes P Air Line outlet R Outlet Hose Connections S Recirculation Tube Connections T Fluid Temperature Sensors U Air Filter/Moisture Separator

FIG. 1: Component Identification

313221A 9

Controls and Indicators

TD TD

FIG. 2. Controls and Indicators (heated unit shown)

Motor/Pump Control

• Indicator (ST) blinking: If error occurs, STA-

Function Knob

Use knob (CF) to select desired function.

Icon Setting Function

Stop/Park Stops motor and auto-

matically parks pumps.

Slow Recirc

Fast Recirc Fast recirculation

Pressure Adjust

STATUS Indicator

• Indicator (ST) steady on: Motor Power switch is turned on and control board is working.

Slow recirculation speed.

speed. Adjusts fluid pressure

to gun in spray mode.

Code No. Code Name

1 Pressure imbalance between A and B

2 Unable to maintain pressure setpoint 3 Pressure transducer A failure 4 Pressure transducer B failure 5 Excessive current draw 6 High motor temperature 7 No cycle counter switch input

TI7016a

TUS indicator will blink 1 to 7 times to indicate status code, pause, then repeat. See T

ABLE 1 for a brief description of status

codes. For more detailed information and corrective action, see page 26.

Table 1: Status Codes

(see also the label on back of the control

enclosure)

sides

The default is to shut down if a status code indication occurs. Codes 1 and 2 may be set to disable automatic shutdown if desired; see page 27. The other codes are not settable.

10 313221A

Controls and Indicators

Motor Power Switch/Circuit Breaker

Switch (MP) turns power on to control board and function knob. The switch includes a 20 A circuit breaker.

Heater Power Switch/Circuit Breaker

See FIG. 2. Switch (HP) turns power on to heater thermostats. The switch includes a 20 A circuit breaker.

Heater Temperature Controls

See FIG. 3. Control knobs (HC) set temperature of component A and B heaters. Indicator lights (HL) turn on when thermostats are heating, and off when heater reaches setpoint.

Fluid Temperature Sensors and Displays

See FIG. 2. Fluid temperature sensors (T) monitor actual temperature of component A and B fluid going to spray gun. Temperatures are then displayed (TD).

Unit is shipped set to °F. To change to °C, see page 39.

IG. 3. Heater Temperature Controls

313221A 11

Air Compressor Power Switch/Circuit Breaker

Switch (CP) turns power on to compressor and regulator. The switch includes a 20 A circuit breaker.

Air Compressor Controls

Pressure Gauge (PG) indicates set air pressure by regulator.

Regulator (AR) sets desired air pressure.

Controls and Indicators

FIG. 4

PG CP

12 313221A

Setup

1. Locate Reactor E-10 a. Locate Reactor E-10 on a level

surface.

b. Do not expose Reactor E-10 to

rain.

2. Electrical requirements

Improper wiring may cause electric shock or other serious injury if work is not performed properly. Have a qualified electrician perform any electrical work. Be sure your installation complies with all National, State and Local safety and fire codes.

Connect Reactor E-10 to the correct power source for your model. See TABLE 2. Models with two power cords must be connected to two separate, dedicated circuits. See FIG. 5.

3. Ground system

b. Generator (if used): follow your

local code. Start and stop generator with power cord(s) disconnected.

c. Spray gun: grounded through the

supplied fluid hoses, connected to a properly grounded Reactor E-10. Do not operate without at least one grounded fluid hose.

d. Object being sprayed: follow your

local code.

e. Solvent pails used when flushing:

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

f. To maintain grounding continuity

when flushing or relieving pressure, hold a metal part of spray

gun firmly to the side of a grounded metal pail, then trigger gun.

The equipment must be grounded. Grounding reduces the risk of static and electric shock by providing an escape wire for the electrical current due to static build up or in the event of a short circuit.

a. Reactor E-10: grounded through

power cord.

313221A 13

Table 2: Electrical Requirements

Model Required Power Source Power Cord Connector

Setup

120 V, 1 phase, 50/60 Hz, three 15 ft (4.5 m) power cords, Heated

Table 3: Extension Cord Requirements

Model

Two cord heated models AWG 14 AWG 12

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

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

Required Wire Size

Up to 50 ft (15

m) Up to 100 ft (30 m)

Three NEMA 5-15

To avoid electric shock, always unplug all cords before servicing Reactor E-10.

Ensure no other high amp loads are connected while running Reactor E-10.

To verify separate circuits, plug in Reactor E-10 or a worklight and cycle breakers on and off.

Heater Power

Motor Power

IG. 5. Use Three Separate Circuits

TI12383a

Compressor Power

14 313221A

Setup

4. Connect fluid hoses

Connect fluid supply hoses to outlet hose connections (R, FIG. 6). Fittings are sized to prevent connection errors. Connect other end of hoses to A and B inputs of gun.

5. Connect gun air hose

Connect gun air hose to the gun air input and to the air filter outlet (Z). If you are using more than one hose bundle, join the air hoses with the nipple (305) provided with the hose bundle.

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

6. Turn on air compressor

Turn on air compressor power. Set regulator to desired output pressure as indicated on the gauge.

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

7. Flush before first use

The Reactor E-10 is tested with a plasticizer oil at the factory. Flush out the oil with a compatible solvent before spraying. See page 24.

FIG. 6. Hose Connections

313221A 15

Setup

8. Fill wet-cups

Keep the felt washers in the pump wet-cups saturated with Owens Corning plasticizer; see Owens Corning Distributor. The lubricant creates a barrier between the red fluid and the atmosphere.

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

ing operation. Shut off Motor Power before filling wet-cup.

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

a. Open red and white fluid pails

and position in front of suction tubes.

b. Stand behind unit and hold cross-

bar. Lean unit backwards until the suction tubes are above the supply pails.

Fill wet-cups through slots

in plate, or loosen screws

and swing plate aside.

TI6985a

9. Install suction tube

CAUTION

To prevent cross-contamination of fluids and equipment parts, never interchange component A and component B parts or containers.

Label one pail “A” and the other “B”, using the labels provided. Always doublecheck which material you have before placing suction tubes in pails.

c. Place suction tubes in pails.

16 313221A

Setup

10. Mount pails

a. Insert pail handles on mounting

bracket (G).

b. Install one end of strap (SR)

through eye bolt (EB) on A side of unit. Use second strap for B side.

11. Purge air and flush fluid from

lines

a. Remove both recirculation tubes

(N) from the pails and secure

each one in a dedicated waste container (W).

c. Latch straps (SR) together in

front of pails.

b. Set function knob to Stop/Park

c. Plug in power cord(s). See TABLE

2, page 14.

d. Turn on Motor Power.

313221A 17

e. Set Recirc/Spray valves to

Recirc.

f. Set function knob to Slow Recirc

or Fast Recirc .

g. When clean fluids exit both recir-

culation tubes (P), set function

Setup

knob to Stop/Park .

h. Replace recirculation tubes in

pails.

i. On nonheated units, purge the

hoses through the gun without a static mixer installed.

For heated units, continue with Startup of Heated Units, page 19.

Nonheated units are ready to spray/dispense. Go to Spraying/Dispensing, page

20.

18 313221A

Startup of Heated Units

Equipment surfaces can become very hot. To avoid severe burns:

• Do not operate Reactor E-10 without all covers and shrouds in place.

• Do not touch hot fluid or equipment.

• Allow equipment to cool completely before touching it.

• Wear gloves if fluid temperature exceeds 110°F (43°C).

1. Perform Setup, pages 13-18.

Startup of Heated Units

5. Circulate through heaters until tempera-

ture readouts display desired temperature.

6. Adjust heater control knobs as neces-

sary for a stable spray temperature.

2. Set function knob to Slow Recirc or

Fast Recirc .

3. Turn on Heater Power.

4. Temporarily set heater control knobs to

maximum setting.

313221A 19

Spraying/Dispensing

Air is supplied to spray gun with gun piston safety lock and gun fluid manifold valves A and B closed (if present).

Fusion

Spraying/Dispensing

4. Check fluid pressure gauges to ensure

proper pressure balance. If imbalanced, reduce pressure of higher component by slightly turning Recirc/Spray valve for that component toward Recirc, until gauges show balanced pressures. The pressure imbalance alarm (Status Code

1) is inactive for 10 sec after entering spray pressure mode, to allow time to balance pressures.

n this example, B side pressure is higher, so use the B side valve to balance pressures.

1. Set function knob to Stop/Park .

2. Set Recirc/Spray valves to Spray.

3. Turn function knob to Pressure Adjust

. Keep turning to the right until fluid

pressure gauges show desired pressure.

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

5. Open gun fluid manifold valves A and B

(impingement mix guns only).

On impingement guns, never open fluid manifold valves or trigger gun if pressures are imbalanced.

20 313221A

Pause (Heated Units)

6. Disengage piston safety lock.

Fusion

7. Test spray onto cardboard or plastic

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

3. Set Recirc/Spray valves to Recirc until

temperature readouts come back up.

4. If you stop spraying for more than 2 min-

utes when using an impingement mix gun, close gun fluid valves A and B.

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

Pause (Heated Units)

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

1. Engage piston safety lock.

Fusion

2. Set function knob to Slow Recirc .

313221A 21

Pressure Relief Procedure

1. Engage piston safety lock.

Fusion

2. Set function knob to Stop/Park .

Shutdown

For longer breaks (more than 10 minutes), use the following procedure. If you will be shut down for more than 3 days, first see

Flushing, page 24.

1. Follow all steps of Pressure Relief Pro-

cedure, at left.

2. If using an impingement mix gun, close

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

3. Turn Recirc/Spray valves to Recirc.

Fluid will be dumped to pails. Pumps will move to the bottom of their stroke. Ensure gauges drop to 0.

3. Shut off Heater Power (heated units

only).

4. Shut off Motor Power.

5. Shut off Compressor Power.

6. Remove pails from mounting bracket.

22 313221A

7. Refer to your separate gun manual and

perform the Shutdown procedure.

Maintenance

• Check pump wet-cups fluid level daily, page

16.

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

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

• If using an impingement mix gun, close gun fluid valves A and B when not spraying. Doing this will keep the internal parts of the gun cleaner and prevent crossover. Clean gun mix chamber ports and check valve screens regularly. See gun manual.

Maintenance

• If using an Fusion Air Purge impingement mix gun, always grease the gun after use

until purge air carries grease mist out the front of the gun. Use Part No. 117773 Grease. See gun manual 309550.

313221A 23

Flushing

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

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

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

• Use the lowest possible pressure when flushing.

Flushing

2. Set function knob to Stop/Park .

3. Shut off Heater Power (heated units

only). Allow system to cool.

4. Unlatch straps and remove A and B

pails from mounting bracket. Stand behind unit and hold crossbar. Lean unit backwards to remove suction tubes from A and B fluid pails.

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

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

1. Engage piston safety lock. Close fluid

valves A and B. Leave air on.

Fusion

5. Fill two pails with 1-2 gal. (3.8-7.6 l) of

solvent recommended by your material manufacturer. Insert suction tubes in solvent pails (SP).

24 313221A

Flushing

6. Disconnect recirculation tube (N) and

insert in waste container (W).

7. Turn Recirc/Spray valves to Recirc.

8. Set function knob to Fast Recirc .

Pump solvent through system to waste containers.

To flush gun, refer to gun instruction manual.

Purge Gun Hoses

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

• Turn Recirc/Spray valve A to Spray.

• Open gun into waste container A.

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

• Set function knob to Stop/Park .

• Repeat for B side.

9. When nearly clear solvent comes from

recirculation tubes, set function knob to

Stop/Park . Place recirculation tubes in solvent pails.

10. Set function knob to Fast Recirc .

Circulate solvent through system for 10-20 minutes to ensure thorough cleaning.

11. Set function knob to Stop/Park .

12. Solvent flushing is a two step process.

Go back to step 4, drain solvent, and flush again with fresh solvent.

13. Leave unit filled with solvent, plasticizer,

or reprime with new material.

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

313221A 25

Troubleshooting

Status Codes

Determine the status code by counting the number of times the status indicator (ST) blinks.

TI7016a

Status Code 1: Pressure Imbalance

The unit does not check for pressure imbalance at setpoints less than 250 psi (1.75 MPa, 17.5 bar).

n this example, B side pressure is higher, so use the B side valve to balance pressures.

Turn Recirc/Spray valve only enough to balance pressure. If turned completely, all pressure will bleed off.

3. Check fluid inlet strainers (51a, page 23) and fluid filters at gun.

4. Clean or change restrictor at mixer manifold if using disposable mixer gun kit.

Status Code 2: Pressure Deviation from Setpoint

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

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

Unit senses pressure imbalance between components A and B, and warns or shuts down, depending on settings of DIP switches 1 and 2. To turn off automatic shutdown and/or tighten pressure tolerances for status code 1, see Sta- tus Code 1 and 2 Settings on page 27.

1. Check fluid supply of lower pressure component and refill if necessary.

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

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

To turn off automatic shutdown and/or tighten pressure tolerances for status code 2, see Sta- tus Code 1 and 2 Settings on page 27.

26 313221A

Troubleshooting

Status Code 1 and 2 Settings

OFF

1. Locate switch SW2 on the control board, page 43.

2. Set the four DIP switches to the desired

IG. 7. DIP Switch (SW2) Settings

positions. See FIG. 7 and TABLE 4 on page

27.

Table 4: Status Code 1 and 2 Settings

DIP Switch and Function Left DIP Switch 1

If selected, causes shutdown or displays a warning if there is a pressure imbalance exceeds selection made in DIP Switch 2

DIP Switch 2

If selected, causes shutdown if A and B pressure imbal- ance is greater than

If selected, causes warning if A and B pressure imbalance is greater than

DIP Switch 3

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

DIP Switch 4

Causes warning if deviation of pressure from setpoint is greater than

WARNING SHUTDOWN

500 psi (3.5 MPa, 35 bar) (60% if < 800 psi [5.6 MPa, 56 bar] running)

300 psi (2.1 MPa, 21 bar) (50% if < 800 psi [5.6 MPa, 56 bar] running)

WARNING SHUTDOWN

300 psi (2.1 MPa, 21 bar) (25% if < 800 psi [5.6 MPa, 56 bar])

TI7023a

1 2 3 4

(Default)

TI7024a

Right (default setting)

800 psi (5.6 MPa, 56 bar) (70% if < 800 psi [5.6 MPa, 56 bar] running)

500 psi (3.5 MPa, 35 bar) (60% if < 800 psi [5.6 MPa, 56 bar] running)

500 psi (3.5 MPa, 35 bar) (40% if < 800 psi [5.6 MPa, 56 bar])

Status Code 3: Transducer A Failure

1. Check transducer A electrical connection (J3) at board, page 43.

2. Reverse A and B transducer electrical connections at board, page 43. If error moves to transducer B (Status Code 4), replace transducer A, page 44.

313221A 27

Status Code 4: Transducer B Failure

1. Check transducer B electrical connection (J8) at board, page 43.

2. Reverse A and B transducer electrical connections at board, page 43. If error moves to transducer A (Status Code 3), replace transducer B, page 44.

Troubleshooting

Status Code 5: Excessive Current Draw

Shut off unit and contact distributor before resuming operation.

1. Locked rotor; motor unable to turn. Replace motor, page 47.

2. Short on control board. Replace board, page 42.

3. Worn or hung up motor brush causing arcing of brush at commutator. Replace brushes, page 49.

Status Code 6: High Motor Temperature

Motor is running too hot.

1. Motor temperature too high. Reduce pressure duty cycle, gun tip size, or move Reactor E-10 to a cooler location. Allow 1 hour for cooling.

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

Status Code 7: No Cycle Counter Switch Input

Have not received input from cycle counter switch for 10 seconds after selecting Recirc mode.

1. Check cycle counter switch connection to board (J10, pins 5, 6), page 43.

2. Check that magnet (224) and cycle counter switch (223) are in place under B side motor end cover (227). Replace if necessary.

28 313221A

Troubleshooting Chart

PROBLEM CAUSE SOLUTION

Reactor E-10 does not operate. No power. Plug in power cord.

Cycle Motor Power off ,

then on to reset breaker.

Troubleshooting

Motor does not operate. Power turned on with function

knob set to a run position.

Loose connection on control board.

Worn brushes. Check both sides. Replace

Broken or misaligned brush springs.

Brushes or springs binding in brush holder.

Shorted armature. Replace motor, page 47. Check motor commutator for burn

spots, black pitting, or other damage.

Failed control board. Replace board. See page 42.

Fan not working. Loose fan cable. Check that cable is connected at

Defective fan. Test and replace if necessary,

Pump output low. Plugged fluid inlet strainer. Clear, see page 23.

Plugged disposable mixer. Clean or replace. Leaking or plugged piston valve

or intake valve in displacement pump.

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

Dirty or damaged Recirc/Spray valve.

Plugged fluid inlet strainer. Clear, see page 23. Pump intake valve plugged or

stuck open.

Set function knob to Stop/Park

, then select desired func-

tion. Check connection at J11 (120 V).

See page 42.

brushes worn to less than 1/2 in. (13 mm), see page 49.

Realign or replace, page 49.

Clean brush holder and align brush leads for free movement.

Remove motor. Have motor shop resurface commutator, or replace motor, page 47.

fan and at J9 on control board. See pages 49 and 42.

page 49.

Check valves. See pump manual.

Clean or repair, page 36.

Clean pump intake valve. See page 37.

313221A 29

PROBLEM CAUSE SOLUTION

Troubleshooting

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

Pump intake valve partially plugged.

Air in hose. Fluid is compressible. Purge air from hose. Unequal size hoses or unequal

hose construction.

Pressures are not balanced when

Unequal viscosities. Change temperature setting to running, but pressure is generated and holds on both strokes.

Restriction on one side. Clean mix module or restrictor at

Fluid leak in pump packing nut

Worn throat seals. Replace. See pump manual. area.

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

Leaking Recirc/Spray valve. Repair, page 36.

Leaking piston valve or intake

valve in displacement pump.

Leaking gun shutoff. Repair. See gun manual. Pressure is higher on B side dur-

ing startup of recirculation, especially in High Recirc mode.

This is normal. Component B is

typically higher viscosity than

component A until the material is

heated during recirculation. One gauge shows half as many

Loss of pressure on downstoke. Intake valve is leaking or not clospulses as the other when pumps are cycling.

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

Status indicator (red LED) not lit. Motor Power switch off.

Clean pump intake valve. See page 37.

Use matching hoses, or balance pressures before spraying.

balance viscosities. Change restrictor at mix point to

balance back pressure.

mix manifold. Clean gun check valve screens.

Repair. See pump manual.

No action required.

ing. Clean or replace valve; see page 37.

ing. Clean or replace valve or packings; see page 37.

Cycle Motor Power off ,

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

30 313221A

then on to reset breaker.

Loose indicator cable. Check that cable is connected at

J10 pins 1 (red) and 2 (black) on control board. See page 42.

Failed control board. Replace board. See page 42.

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

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

Check B side inlet strainer and pump intake valve.

Troubleshooting

PROBLEM CAUSE SOLUTION

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.

No temperature display. Loose display cables on control

board. Failed control board (displays get

power from control board).

Check cable connections to each display, page 42.

Remove access panel. Check if board LED is lighted. If not, replace board, page 42.

Inadequate power to control board.

Check that power supply meets requirements.

Loose power cable. Check cable connections, page

42.

Motor Power switch circuit breaker tripped.

Display is powered from Motor Power circuit breaker. Cycle Motor

Power off , then on

to reset breaker.

Wrong temperature displayed. °F/°C switch in wrong position. Set switch, see page 39. Temperature displays do not

match at ambient temperature.

Displays need calibration. Turn calibration screw on back of

displays to correct reading, see page 39.

313221A 31

PROBLEM CAUSE SOLUTION

Troubleshooting

No heat, and heater indicator light is off.

Heater Power shut off, or circuit

breaker tripped.

Cycle Heater Power off ,

then on to reset circuit

breaker.

Bad thermostat. With power on, check for continu-

ity at clicks of heater control knob. To replace thermostat, see

311210.

Bad overtemperature sensor (this

is a high temperature limit fuse

and must be replaced if blown).

With power on, check for continuity at overtemperature sensor. To replace sensor, see 311210.

Loose heater cable connections. Check connections at Heater

Power switch. See F

IG. 12, page

43.

No heat, but heater indicator light is on.

Bad heater cartridge. Check for continuity at heater car-

tridge connections: 16-18.6 ohms for 120 V.

Heater on one side shuts off early or continuously during recirculation.

Y-strainer is plugged on that side. Clean or replace strainer, page

23.

Fluid inlet valve (52) closed. Open valve. B side pump is not priming Running pump too fast. Put finger over recirculation tube

Piston ball check is stuck in open

position.

while running, to build pressure, and release. Repeat as necessary.

Low air output at gun Air valve at gun may be closed. Turn air valve counter-clockwise

to open.

Sprayer air regulator may be

closed.

Pull to unlock and turn air regulator clockwise to open.

Air connections may be loose. Check all connections for leaking

air.

Damaged (leaking) air supply

Replace air supply hose.

hose.

Air intake filter clogged. Clean or replace air intake filter

kit.

Mechanical air unloader stuck

Replace mechanical air unloader.

open.

Electrical air unloader stuck open. Replace electrical air unloader.

32 313221A

Troubleshooting

PROBLEM CAUSE SOLUTION

Air compressor does not run Power is not on. Turn compressor power on.

Voltage to compressor below 105 Vac for 120 Vac.

Try another outlet. Reduce extension cord length or increase

extension cord gauge. Loose power connections. Verify all connections are firm. Excessive head pressure (com-

pressor hums)

Moisture frozen in air supply line.

Wait for air pressure to bleed to

zero.

Electrical air unloader stuck

closed. Replace electrical air

unloader.

Open air regulator; install air line.

Complete Setup on page 13. Compressor thermal switch is

open. Ensure ambient tempera-

Move sprayer to shaded, cooler

area. ture is below 115°F (46°C).

Low compressor performance Worn compressor; replace com-

pressor with Compressor Service

Kit 256779.

313221A 33

Troubleshooting

34 313221A

Repair

Before Beginning Repair

Repairing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly. Have a qualified electrician connect power and ground to main power switch terminals, see page 13. Be sure to shut off all power to the equipment before repairing.

1. Flush if possible, see page 24. If not possible, clean all parts with solvent immediately after removal.

Repair

2. Set function knob to Stop/Park .

3. Shut off Motor Power. Disconnect power supply.

4. Shut off Heater Power. Allow equipment to cool before repairing.

5. Relieve pressure, page 22.

313221A 35

Recirc/Spray Valves

Repair

Heated Models

1. See Before Beginning Repair, page 35.

Relieve pressure, page 22.

2. See FIG. 8. Disassemble Recirc/Spray valves. Clean and inspect all parts for damage. Ensure that the seat (503a) and gasket (503b) are positioned inside each valve cartridge (503).

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

4. Reassemble in reverse order, following all notes in FIG. 8.

506

502

510

501

509

508

507

Torque to 250 in-lb (28 N•m).

Use blue threadlocker on valve cartridge threads into manifold.

Part of item 503.

505

504

503

503a

503b

510

FIG. 8. Recirc/Spray Valves

36 313221A

Repair

Displacement Pump

A side displacement pump repair and parts information is included in manual 311076, which is supplied with your unit.

Use dropcloth or rags to protect Reactor E-10 and surrounding area from spills.

1. See Before Beginning Repair, page 35.

Relieve pressure, page 22.

To Remove Suction Tube

To Remove Intake Valve Only

If pump is not generating any pressure, the intake ball check may be stuck closed with dried material.

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

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

2. Disconnect suction tube.

3. Remove intake valve by hitting ears (E) firmly right-to-left with a non-sparking hammer. Unscrew from pump. See manual 311076 for repair and parts.

1. Loosen nut (34) and remove suction tube (31).

30 32

313221A 37

To Remove Entire Pump Assembly

4. Disconnect suction tube. See page 37. Also disconnect steel outlet tube (16) from heater inlet.

Repair

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

6. Install pump in reverse order of disassembly, following all notes in FIG. 9. Clean strainer (51). Reconnect suction tube and outlet (D) lines.

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

8. Set function knob to Slow Recirc . Purge air and prime. See page 17.

217

218

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

222

207

Lubricate threads with ISO oil or grease.

FIG. 9. Displacement Pump

38 313221A

Repair

Control Module

Change Display Temperature Units (°F/°C)

Unit is shipped with temperature displays set to °F.

1. Shut off Motor Power. Disconnect power supply.

2. Remove access cover (39) from back of control module.

Replace Temperature Display and Sensor (Heated Units Only)

1. See Before Beginning Repair, page 35.

Relieve pressure, page 22.

2. Remove temperature sensor (424):

a. Loosen setscrew (22) on thermowell

housing (21). See FIG. 10 on page 40.

b. Pull sensor (424) out of thermowell

housing.

c. Work sensor and wire out of cable

channel between tanks. It may be easier to remove one tank. See page 36.

3. See FIG. 11. Locate slide switch (FC) at right edge of each temperature display board. Unit is shipped set to °F (down). To change to °C, move both switches to up position.

Calibrate Temperature Displays

1. Remove access cover (39) from back of control module.

2. See FIG. 11. Locate calibration screw (CS) at upper right corner of each temperature display board. Turn screw slightly to correct temperature display.

Temperature displays do not read lower than 50°F (10°C).

3. Remove access cover (39) from back of control module.

4. Disconnect temperature display power cable from J14 or J15 at bottom left of control board (406).

5. Remove four screws from rear panel studs and remove temperature display (403) from front plate (401).

6. Remove screw and nut (409) holding display to plate (403).

7. Pull sensor cable through split in bushing (411).

313221A 39

Repair

8. Reassemble in reverse order. Mount temperature display so Heater Power switch off (0) position is at left when facing control panel.

424

TI7067a

FIG. 10. Temperature Sensor

horizontal. Position knob (416) so pointer (P) faces up. Install knob on shaft so slot (S) engages alignment pin in knob. Push knob onto shaft against detent spring before tightening setscrews (416a).

7. Reconnect potentiometer wires to J2 as shown in F

IG. 12.

Replace Function Knob/Potentiometer

1. See Before Beginning Repair, page 35.

Relieve pressure, page 22.

2. Remove access cover (39) from back of control module.

3. Disconnect potentiometer wires from J2 on control board (406). See FIG. 12.

4. See F and pull function knob (416) off potentiometer (404) shaft.

5. Remove nut (N, part of 404) and detent plate (415).

IG. 11. Remove two setscrews (416a)

6. Install new potentiometer (404) in reverse order. Position potentiometer so slot (S) is

40 313221A

Detail of Function Knob/Potentiometer

415

404

Repair

TI7076a

409

*424

*403

416a

416

*402

416a

421

424*

401

410

410*

404

411

402

408 407

412

413

405

416a

416

416a

N 415

417

406

FIG. 11. Control Module (Heated Model Shown)

313221A 41

* These items are not included on the nonheated display.

TI6979a

Repair

Control Board

Power Bootup Check

There is one red LED (D11) on the board. Power must be on to check. See F

IG. 12 for location. Function is:

• Startup: 1 blink for 60 Hz, 2 blinks for 50 Hz.

• Motor running: LED on.

• Motor not running: LED off.

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

Control Board Replacement

Table 5: Control Board Connectors

(see FIG. 12)

Board

Jack Pin Description

J1 n/a Main power from breaker J2 n/a Function knob J3 n/a Transducer A J4 n/a Motor power (230 V units) J7 1, 2 Motor thermal overload signal J8 n/a Transducer B J9 n/a Fan

J10 1, 2 Status indicator

3, 4 Not used 5, 6 Cycle switch signal

7-8 Jumpered

9-10 Jumpered J11 n/a Motor power (120 V) J14 n/a B temperature display J15 n/a A temperature display

Check motor before replacing board. See Electric Motor, page 47.

1. See Before Beginning Repair, page 35.

Relieve pressure, page 22.

2. Remove access cover (39) at back of control module to expose control board (406).

3. Disconnect all cables and connectors from board. Remove two jumper wires (413) from J10 pins 7-8 and 9-10.

4. Remove screws (408) and remove board from control module.

5. Install new board in reverse order.

Apply thermal compound between the square steel piece on the back of the board and the main aluminum plate. Order Part No. 110009 Thermal Compound.

42 313221A

Repair

Motor

Cycle

Counter

Black Twin Flat Cable

Fan

Status

Indicator

Black Sheath

Red

Black

LINE

Ye l l o w

Red

Black

Jumper

Motor Power

Black

White

On/Off

(20 A

Breaker)

Single Cord Models Only

LINE

Heater Power On/Off (20 A Breaker)

Heater

J11 (120 V Board)

J11

J4 (240 V Board)

CONTROL BOARD

249434 (120 V)

Function

Knob

249432 (240 V)

not used

1 2

3 4 5

J10

6 7 8 9 10

J15J14

1 2 3 4

D11

ONOFF

SW2 (see page 27 to adjust settings)

not used

Black

Red

White

Black Sheath

J3J8

2 pin red connectors2 pin red connectors

Gray SheathGray Sheath

Pressure Transducer A

Calibration

Screw

°C

Temperature

Display B

°F

Temperature Sensor B

Calibration

Screw

°C

Temperature

Display A

Gray Sheath

°F

Temperature Sensor A

Black Phone Cable and Plug

Pressure Transducer B

FIG. 12. Control Module Wiring Connections

313221A 43

Fluid Heaters Pressure Transducers

Fluid heater repair and parts information is included in manual 311210, which is supplied with heated units.

1. See Before Beginning Repair, page 35.

To replace a pressure transducer, see at right.

Relieve pressure, page 22.

2. Remove access cover (39) at back of control module to expose control board (406).

3. Disconnect transducer cables from J3 and J8 at board; see F

IG. 12, page 43. Reverse

A and B connections and check if status code follows the bad transducer, page 27.

Repair

1. See Before Beginning Repair, page 35.

Relieve pressure, page 22.

2. Control section of heater can be repaired in place. Remove heater to clean fluid section. See manual 311210 for heater repair and parts.

4. Reconnect good transducer to proper connector. Disconnect failed transducer from board, and unscrew from base of fluid heater (heated units) or transducer manifold (nonheated units).

5. Install o-ring (60) on new transducer (58), F

IG. 13.

6. Install transducer in heater or manifold. Mark board end of cable with tape (red=transducer A, blue=transducer B).

7. Route cable through channel to control module.

8. Connect transducer cable at board; see FIG. 12, page 43.

44 313221A

Heated Units

IG. 13. Transducers

TI7026a

Repair

Drive Housing

Removal

1. See Before Beginning Repair, page 35.

Relieve pressure, page 22.

2. Remove screws (207) and end covers (221,

227), FIG. 14.

Examine connecting rod (216). If rod needs replacing, first remove the pump (219), page 37.

CAUTION

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

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

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

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

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

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

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

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

If connecting rod (216) or pump (219) were removed, reassemble rod in housing and install pump, page 37.

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

4. Examine crankshaft (210), gear reducer (214), thrust washers (208, 212), and bearings (209, 211, 213).

Installation

1. Apply grease liberally to washers (208,

212), bearings (209, 211, 213), gear reducer (214), crankshaft (210), and inside drive housing (215). Grease is supplied with replacement parts kits.

313221A 45

6. Install drive housing covers (221 on A side, 227 on B side) and screws (207). Pumps must be in phase (both at same position in stroke).

Cycle Counter Switch Replacement

B side drive housing cover (227) includes the cycle counter switch (223), mounted in the cover. When reassembling, be sure to install cover with switch on B side.

223

0.6 in. (15.2 mm) from inside edge

1.0 in. (25.4 mm) from inside bottom edge

TI7028a

Repair

221

222

207

220

218

219

211

(bronze)

215

216

207

209 (bronze)

210

208 (steel)

214

213

(bronze)

217

234

206

207

227

229

201

212

(steel)

213

(bronze)

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

FIG. 14. Drive Housing

46 313221A

Electric Motor

Repair

Test Motor

If motor is not locked up by pumps, it can be tested using a 9 V battery. Open recirculating valves, disconnect J4 or J11 from control board, see FIG. 12, page 43. Touch jumpers from battery to motor connections. Motor should turn slowly and smoothly.

Removal

If replacing a component with electrical cabling, remove one supply tank, page

36.

1. See Before Beginning Repair, page 35.

Relieve pressure, page 22.

e. Thread motor power switch harness out

bottom of control module and cable channel, to free motor.

CAUTION

Motor is heavy. Two people may be required to lift.

5. Remove screws holding motor to bracket. Lift motor off unit.

Installation

1. If replacing motor, install fan assembly and fan mount threaded bushing on new motor.

2. Place motor and fan on unit. Thread motor switch harness into control module.

3. Fasten motor with screws underneath. Do not tighten yet.

2. Remove four screws (207) and shroud (206). See FIG. 14.

3. Remove drive housing/pump assemblies, page 45.

4. Disconnect motor cables as follows:

a. Find control board at back of control

module, see F

IG. 12, page 43.

b. Unplug motor power connector from

J11 (120 V units).

c. Unplug motor temp switch harness from

connector J7.

d. Unplug cable (37) from fan (202). See

IG. 18.

4. Plug 3-pin connector J7 to board.

5. Plug Motor Power switch harness to connector J11 (120 V units).

6. Install drive housing/pump assemblies, page 45. Reconnect inlet assemblies to pumps.

7. Tighten motor mounting screws.

8. Return to service.

313221A 47

Compressor

• To repair compressor, use Compressor Service Kit 256779. Refer to Thomas Compressor manual provided.

• Replace compressor piston assembly, use Kit 256779.

Removing Compressor from Sprayer

1. Relieve pressure, page 22. Disconnect power cord from outlet.

2. Remove filter bracket.

Repair

4. Disconnect air fitting from compressor. Remove compressor from unit. Follow instructions provided with your repair kit.

5. Disconnect electrical connection from solenoid valve.

FIG. 17

IG. 15

3. Remove front and back louvers from unit.

IG. 16

48 313221A

Motor Brushes

Repair

Replace brushes worn to less than 1/2 in. (13 mm). Brushes wear differently on each side of motor; check both sides. Brush Repair Kit 248186 is available; kit includes instruction sheet

406582.

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

1. See Before Beginning Repair, page 35.

Relieve pressure, page 22.

2. See instruction sheet 406582, included with Brush Repair Kit 248186. Remove old brushes and install new ones supplied in kit.

202

TI7030a

FIG. 18. Fan

Fan

1. Disconnect fan cable (75) from fan (202). With Motor Power on, test cable connector for line voltage (120 V).

2. If voltage is correct, fan is defective. Remove screws holding fan to shield (206). Install new fan in reverse order.

3. If voltage is not correct, check fan cable connection at J9 on control board; see F 12, page 43.

IG.

313221A 49

Parts

Part No. 256765, 120 V, 15 A, Heated Proportioner

Parts

32 36

50 313221A

Part No. 121851, Compressor

Parts

Compressor Wiring Diagram

39 39

Attach ground wires to grounding stud on (1).

313221A 51

Airline Diagram

Solenoid Valve

Compressor

Regulator

grounding

stud

Air Filter

Pressure Gauge

Heated Proportioner

Qty

Ref. Part Description

1CART 1 2 PROPORTIONER, E10, 4:1,

120V

3 287672 HEATER, fluid, 120V, E10; see

311210 4 167002 INSULATOR, heat 4 5 100016 WASHER, lock 4 6 108296 SCREW, machine, hex washer

hd; 1/4-20 x 5/8 in. (16 mm) 7 116393 FITTING, straight 1/4 npt 2 8 119891 FITTING, elbow, 1/4 npt x 3/8 in.

tube 9 15G114 TUBE, fluid, w/ferrule, E-10 2 10 117493 SCREW, machine, hex washer

hd; 1/4-20 x 1-1/2 in. (38 mm) 11 157350 ADAPTER 4 12 116504 FITTING, tee, run 2 13 113641 GAUGE, pressure, fluid, sst 2 14 115335 ELBOW, street, 1/4 npt 2 15 MANIFOLD, recirculation, w/

valves 16 249629 HOSE, cpld, 1/4 in. x 48 in.,

moistguard 17 15F692 HOUSING, thermowell 2 18 101118 SCREW, set; 10-24 x 1/4 in. (6

mm) 19 249556 DISPLAY, E-10, heated, 120V,

matrix 20 15G385 COVER, access, display, E10 1 21 COVER, wire 1 22 114238 SCREW, cap, hex hd 4 23 115942 NUT, hex, flange hd 6 24 117623 NUT, cap (3/8-16) 4 25 112853 PLUG, tubing 4 26 205447 COUPLING, hose 2 27 054826 TUBE, plastic 8 28 114601 CONDUIT, flexible, non-metallic 1 29 101765 GROMMET 1 30 115099 WASHER, garden hose 2 31 TUBE 2 32 103413 O-RING 2 33 15B652 WASHER, suction 2 34 15E813 NUT, jam 2 35 STRAINER 2 36 276888 CLIP, drain line 2 37 113956 BOLT, carriage 2 38 106115 WASHER, lock (hi-collar) 3 39 112913 NUT, hex 2 40 154636 WASHER, flat 4 41 116411 SPRING, compression 2 42 116477 WASHER, flat, nylon 4

Ref. Part Description

43 116478 WHEEL, pneumatic 2 44 101242 RING, retaining, ext. 2

45 BOLT, hex, 3/8-16, 0.75 in. 1 46 PANEL, end 1

47 PANEL, end 1 48 117501 SCREW, mach, slot hex wash

49 BRACKET, filter, air 1 50 104641 FITTING, bulkhead 1 51 162453 FITTING, (1/4 npsm x 1/4 npt) 1 52 117629 FILTER, air, 3/8 (auto drain) 1

53 114153 FITTING, elbow, male, swivel 1 54 104984 FITTING, tee, pipe 1 55 114109 FITTING, elbow, male, swivel 3

56 115242 REGULATOR, air, 1/4 npt 1 57 119927 SWITCH, rocker, w/breaker,

58 504235 FITTING, connector, female,

59 114421 BUSHING, strain relief 1

60 115494 SCREW, mach, phillips pan hd 3 61 GAUGE, pressure, 160psi 1

62 15K212 SOLENOID, 2 way normally

63 109575 SCREW, thread forming, hex hd 2

64 121853 VALVE, relief, 100 psi 1 65 113505 NUT, keps, hex hd 1

66 15K040 NUT, regulator, metal 1 67 COMPRESSOR, 120V 1 68 109511 BOLT, eye 2 69 112698 ELBOW, male, swivel 2

▲ 15G719 LABEL, status codes, E-10 1

▲ 15G280 LABEL, warning, E-10 1

▲ 190774 BLANK, label, kit 1

74 75 15G458 CABLE, fan, 46 in. w/plug/board

76 15G218 CORD SET, power, 125V 3 77 LABEL, proportioner, E10, 4:1 1 78 172953 LABEL, designation 1 79 HOSE, nylon, wpr 250 psi 3 80 120023 TERMINAL, dual adapter, unin-

89 109510 STRAP, rubber 4 90 117832 ADAPTER, 9/16-18 JIC x 3/8

91 119998 ADAPTER, 1/2-20 JIC x 1/4 npt 1 92 156971 FITTING, nipple, short 1

▲ Replacement Danger and Warning labels, tags, and

cards are available at no cost.

Parts

Qty

240V, 20A

tube

open, 120V

connection

sulated

npt

52 313221A

Part No. 256539, 120 V Bare Proportioner

Parts

207

208*

209*

210*

211*

†213

217◆

234

‡221

222‡

207‡

220‡

215‡

216

218

219

◆

Ref. Part Description Qty

201 287650 MOTOR, electric; 120 V 1 202 119994 FAN, cooling; 120 V 1 203 115836 GUARD, finger 1 204 RIVET, blind; 5/32 x 3/8 grip 1 205 SCREW, machine, slotted hd;

8-32 x 2 in. (51 mm) 206 249518 SHIELD, proportioner 1 207‡ 115492 SCREW, machine, hex washer

hd; 8-32 x 3/8 in. (10 mm) 208* 116074 WASHER, thrust; steel 2 209* 107434 BEARING, thrust; bronze 2 210* 248231 CRANKSHAFT KIT 2 211* 180131 BEARING, thrust; bronze 2 212† 116073 WASHER, thrust; steel 2 213† 116079 BEARING, thrust; bronze 4 214† 287057 GEAR REDUCER KIT 2 215‡ 287055 DRIVE HOUSING KIT 2 216◆ 287053 CONNECTING ROD KIT 2 217◆ 196762 PIN, straight 2 218 195150 NUT, jam, pump 2 219 PUMP, displacement; A side;

see 311076

206

207

227

233

†212

†213

†214

201

203

205

Ref. Part Description Qty

220‡ 117493 SCREW, machine, hex washer

hd; 1/4-20 x 1-1/2 in. (38 mm) 221‡ 15B254 COVER, drive housing, A side 1 222‡ 15B589 COVER, pump rod 2 223 117770 SWITCH, reed, w/cable 1

224 119875 MAGNET 1 227 249854 COVER, drive housing, B side;

includes item 223 and 228 228 115711 TAPE, mounting, reed switch;

not shown 233 PUMP, displacement pump; B

side 234 BRACKET, bucket 2

* Included in 248231 Crankshaft Kit. † Included in 287057 Gear Reducer Kit. ‡ Included in 287055 Drive Housing Kit.

◆ Included in 287053 Connecting Rod Kit.

201 (Ref)

204 202 75

313221A 53

Part No. 249556, 120 V Heated Display

Parts

409

403

402

421

401

404 402

414

408 407

405 416a

416

416a

404 (Ref)

415

417

406

410

424

Ref. Part Description Qty

401 15F984 PLATE 1 402 119927 SWITCH, motor or heater

power, with circuit breaker

403 249567 MODULE, display, temperature;

includes (1) item 402 and (2)

item 424 404 249494 POTENTIOMETER 1 405 119930 INDICATOR, status, LED 1 406 249434 BOARD, control; 120 V units

only 407 15G230 CABLE, harness 1 408 107156 SCREW, machine, pan hd 7 409 113505 NUT, keps, hex hd 10 410 119898 BULKHEAD FITTING, cable 2 411 101765 GROMMET 1 412 116773 CONNECTOR, plug 1 413 WIRE, jumper 2

411

412

413

Ref. Part Description Qty

414 15G279 LABEL, display 1 415 15G053 PLATE, detent 1

416 249453 KNOB, function; includes item

416a

416a 101118 . SCREW, set; no. 10 x 1/4 in. (6

mm) 417 15G454 LABEL, startup, heated 1 421 15G384 ENCLOSURE 1 424 119869 DISPLAY, temperature, with

sensor

425 DUAL TERMINAL; not shown 2

TI6979a

54 313221A

Part No. 256627 Recirculation Manifold

Parts

507

510

501

506

509

508

502

505

503a 503b

504

503

510

Ref. Part Description Qty

501 15F870 MANIFOLD, recirculation 1 502 189285 LABEL, caution 4 503 239913 VALVE, recirc/spray; includes

items 503a, 503b 503a 15E022 . SEAT 1 503b 111699 . GASKET 1 504 224807 BASE, valve 2 505 187625 HANDLE, valve, drain 2 506 111600 PIN, grooved 2 508 100483 TEE; 3/8-18 npt 2 509 166863 ADAPTER; 3/8 npt x 1/4 npt 1 510 162453 NIPPLE; 1/4 npsm x 1/4 npt 3

313221A 55

Suggested Spare Replacement Parts

Keep the following spare parts on hand to reduce downtime.

All Units Heated Units Only

Part Description

119927 SWITCH, motor or heater power, with cir-

cuit breaker 113641 GAUGE, pressure, fluid; sst 239914 VALVE, recirc/spray; includes seat and

gasket 249494 POTENTIOMETER, control knob 249434 BOARD, control; 120 V units only 246123 TRANSDUCER, pressure

PUMP, displacement; white

PUMP, displacement; red 256779 KIT, repair compressor

Accessories

Part Description

256563 KIT, static mixer; includes Fusion air

purge spray gun; see 313122 256525 HOSE, bundle, 50 ft, 3 hose; see page 54 256407 HOSE, bundle, 6 ft, 3 hose; see page 54

Part Description

119869 DISPLAY, temperature, with sensor 119857 FUSE, heater over-temperature 119797 THERMOSTAT, heater 15F770 HEATER ELEMENT; 120 V units only

56 313221A

Accessories

313221A 57

Dimensions

43.5 in. (1105 mm)

21.25 in. (539.75 mm)

27 in. (685.8 mm)

58 313221A

Technical Data

Maximum fluid working

2000 psi (14 MPa, 140 bar)

pressure Electrical requirements Model 256765: 120 Vac, 1 phase, 50/60 Hz, 3500 W; requires three

separate, dedicated 15 A circuits

Generator Size (for Reac-

Heated: 5000 W minimum

tor E-10 4:1only) Maximum Fluid Tempera-

160°F (71°C)

ture Maximum Ambient Tem-

110°F (43°C)

perature Maximum Output 12 lb/min (5.4 kg/min) at 340 cycles/min Output per Cycle (A side,

0.00352 gal. (0.0133 liter)

white fluid) Output per Cycle (B side,

0.00088 gal. (0.0033 liter)

red fluid) Overpressure Relief Recirc/Spray valves automatically relieve excessive fluid pressure

back to supply tanks Heater Power 120V models: 850 W each; 1700 W total Sound Pressure 78.7 dB(A) in fast circulation mode

84.5 dB(A) at 2000 psi (14 MPa, 140 bar), 0.72 gpm (2.7 lpm)

Sound Power, per ISO 9614-2

88.6 dB(A) in fast circulation mode

94.4 dB(A) at 2000 psi (14 MPa, 140 bar), 0.72 gpm (2.7 lpm)

Fluid Outlets Component A (white fluid): 3/8 npt

Component B (red fluid): 1/4 npt Air Outlet 1/4 npsm(m) Gun Compressed Air

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

/min)

Requirements Weight (empty) approximately 160 lb (72 kg), depending on model Wetted Parts Aluminum, stainless steel, carbon steel, brass, carbide, chrome,

chemically resistant o-rings, PTFE, ultra-high molecular weight poly-

ethylene

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

313221A 59

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

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.

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441

This manual contains English. MM 313221

Graco Headquarters: Minneapolis

www.graco.com

313221A

Graco Reactor E-10 Instructions-parts List Manual

Specifications and Main Features

Frequently Asked Questions

User Manual