Graco 3A1570A User's Manual
Contents
1. Ref Size Component CB1 50A Hose Secondary single CB2 40 A Hose Primary double 25 Heater A double CB4 25A Heater B double Jo o 1 olo o OL O mi O O O O O Ol O m o f CB1 CB2 CB3 CB4 FIG 12 34 3A1570A Repair Pump Lubrication System MU Check the condition of the ISO pump lubricant daily Change the lubricant if it becomes a gel its color dark ens or it becomes diluted with isocyanate Gel formation is due to moisture absorption by the pump lubricant The interval between changes depends on the environment in which the equipment is operating The pump lubrication system minimizes exposure to mois ture but some contamination is still possible Lubricant discoloration is due to continual seepage of small amounts of isocyanate past the pump packings during operation If the packings are operating properly lubricant replacement due to discoloration should not be necessary more often than every 3 or 4 weeks RT ti18001a To change pump lubricant Fic 13 Pump Lubrication System 1 Relieve pressure page 13 2 Lift the lubricant reser2. 94 9 4 15 63 A Torque pump locking nuts to 66 74 ft Ibs 90 100 Nem A Apply anaerobic polyacrylate pipe sealant to all non swiveling pipe threads Torque tube ends to 212 265 in Ibs 24 30 Nem A Connect ground wire 94 from motor lug to ground lug in cabinet 3A1570A 13 x2 Parts ti18024a 41 Parts 13 ae k 5 262572 Bare Reactor A 25 262614 Reactor A 25 with DataTrak and Wheels Ref 42 Part 262573 262577 24 788 262575 262576 24M177 Description CART PUMP see page 48 MANIFOLD relief see page 46 PANEL control heater see page 45 HEATER system 6 0kw 230v see page 47 PANEL control see page 44 MODULE breaker see page 50 TRANSFORMER 2790va 230 62 2 lk 1 1 1 1 bw a ES 13 x4 12 Qty 9 10 11 12 13 14 15 16 111799 108296 125621 169917 114182 117623 106084 117682 ti18025a 83 es e a U WM G ti18007a SCREW cap hex hd M8 x 1 25 SCREW mach hex wash hd 1
3. Length Connection Outside Ref ft m From To Material Color Diameter 64 0 75 ft 0 23 m 503 503 UHMWPE Black 5 32 in 4 mm 65 2 66 ft 0 8 m 501 501 Urethane Black 1 2 in 12 7 mm 65 1 66 ft 0 5 m 502 502 Urethane Black 1 2 in 12 7 mm 65 0 75 ft 0 23 m 500 500 Urethane Black 1 2 in 12 7 mm 3A1570A 49 Parts Breaker Module 262576 404 8x 403 410 4x 404 7x 403 Q A2 25 ai 25 A B 238CR 1 3 Sm pA 5 ch 22 83 55 55 0898 403 9 E Ess 55 58 9 5 n n n Olt 6 Kw Pe PPP P AS Y ILI 312
4. perature display Code Code Name Alarm Zone These alarms turn off heat E99 clears automatically L ali dli when communication is regained Codes E03 through 92 Migh zone current 03 No zone current Individual E06 can be cleared by pressing o For other codes 04 FTS or thermocouple disconnected Individual 05 Control board over temperature Individual 06 Communication cable unplugged Individual turn main power OFF then ON to clear 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 3A1570A 9 Important Two Component Material Information E01 High fluid temperature Causes of E01 Errors Thermocouple A or B 361 senses a fluid tempera ture above 230 F 110 C e Fluid temperature sensor FTS senses a fluid tem perature above 230 F 110 C e Overtemperature switch 359 senses a fluid tem perature above 230 F 110 C and opens At 190 F 87 C the switch closes again e 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 posi tion The temperature control module fails to turn off any heat zone Zone power wires or thermocouples are switched from one zone to another Failed
5. VA 85902 r gt av S8rSY lt y o AW 1dSIC 1 684 NDAWHO p O 29 49852 2 aodpoZT O gt 2041409 NOWNOD SL 19 59852 CIO Ast 1 dW3133AD 2 4 7 aasn LON aasn 10N p o v lt S S 108272 g lt 8 19 SSINAYH N oo oi o lt 4 3SUH 514 lt 7 all o sanam OL lt O 9 NOILYJINNWWOD S8rsa C VIVI 4 oe ve NOLLOANNOD N LLdI 7081409 38n1VN3dW3L INOW N3ADd 425 OEN Id d Yr gial 8 1 i 6 1 D Zo 9181 IN N Id d ot 181 Zell 49852 S d io m mE lt Ql IN IN V 08iT m Ele ele We Ole 602 80 10 90 50 YO 20 20 10 00 661 861 151 961 561 r61 561 61 161 061 681 5 981 81 5 281 181 081 3A1570A 52 Reactor A 25 Wiring Schematic 1200 oar aou is 3SVHd I A0E2 LE O10100 O 10 10 ASVHd A08E QGI3AUd 9 IN3K39V ld CLOANNOISIC NO SI NOILVNIWYSL 03793451 amp 3 ADd SNIWDONI e NAV Te STE SIS 2 82761
6. LN O 3 I OLOR OO m HE H IH Q SO O d j O N N N N N N 21 40 6713 1 A Cy x o Pe HE Be 10 2 4 6 23808 E 411 c thou hb 413 414 412 g BERE 402 49 408 407 Ref Part Description Qty 401 16H309 RAIL mounting 1 402 112446 BLOCK clamp end 1 403 120490 COVER end 3 404 120570 BLOCK terminal 1 405 255046 BLOCK terminal ground 1 406 255050 CIRCUIT BREAKER 25 2p 2 407 24M176 CIRCUIT BREAKER 30a 2 1 408 255026 CIRCUIT BREAKER 1 pole 1 50a c curve 409 255022 RELAY contactor 65a 3p 1 410 120491 BLOCK terminal 4 411 255043 HOLDER fuse term block 2 5x20mm 412 255023 FUSE 5a 5x20mm 413 120573 BRIDGE plug in jumper 414 120485 BRIDGE plug in jumper 415 16J534 HARNESS wiring 50 3A1570A Reactor A 25 Wiring Schematic Reactor A 25 Wiring Schematic 61 181 394144 21 350138 ASVHd 1 A082 350138 390148 v 61 14 1 3d T 980 390158 DUA 3SVHd 05 DUA x E 5 6 1 7 61 5 61 2 641 1 61 6 1 84 LLI 9LT G T ELT eL UI 0 1 51 3A1570A Reactor A 25 Wiring Schematic yal 8 d ldnn3 ZOWXJHL 31daN0I OWX3HL 831V3H 3NHZ vna 3 IT A Ld 3SUH 1103419 AIS 3 IL AJADd SAL V3H LINDAID AIS o
7. Display cable damaged or corroded Clean connections replace cable if is damaged Display cable not grounded Ground cable page 37 Display extension cable too long Must not exceed 100 ft 30 5 m Hose display reads OA at startup FTS disconnected or not installed Verify proper installation of FTS see Operation manual or adjust FTS to desired current setting Display does not respond properly to button pushes Poor display connection Check cable connections page 36 Replace damaged cable Display cable damaged or corroded Clean connections replace cable if is damaged Ribbon cable on display circuit board disconnected or broken Connect cable page 36 or replace Broken display button Replace page 36 No hose heat Loose hose electrical connections Check connections Repair as neces sary Circuit breakers tripped Reset breakers CB1 or CB2 page 34 Hose zone not turned on Press zone o key A and B temperature setpoints too low Check Increase if necessary Failed temperature control module Open cabinet Check if board LED is blinking If not check power wiring connections to ensure module has power If board has power and LED is not blinking replace module page 26 Low hose heat A and B temperature setpoints too low Increase A and B setpoints Hose designed to maintain temperature not increa
8. A Torque to 88 5 124 in Ibs 10 14 Nem Torque to 32 38 ft Ibs 43 51 Nem Torque nut 313 after assembly of item pin 306 and spring 307 Install adapters so that pins 306 will be in line with each other A Lubricate threads of pump cylinders 303 304 and plate 301 with lubricant prior to assembly into mounting plate Assemble pump cylinder 1 2 thread above flush to one and one half thread above flush of mounting pate surface A Torque to 27 32 ft lbs 37 43 Nem A Use blue thread lock medium 48 Ref 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 322 324 325 Part Description 16G915 PLATE Mounting Cylinder 193031 NUT retaining 262647 PUMP displacement w lube iso 262648 PUMP displacement resin 15J132 LINK connecting 183210 PIN str hdls 183169 SPRING retaining M12LPO MOTOR air NXT 6 in cycle only see manual 312796 16G929 ROD tie 125266 NUT lock nylon m12 16G926 BRACKET pump mounting 117833 ADAPTER 3 4 16 JIC x 3 8 NPT 120553 NUT center lock 5 8 18 111799 SCREW cap hex hd 16G914 ADAPTER rod 114110 ELBOW male swivel 15K783 ELBOW street 90 116746 FITTING barbed plated 16G916 PLATE yoke pump 15H108 LABEL pinch point 100139 PLUG PIPE 15B565 VALVE 1 4 npt park Qty a NN NN F ON RA 3A1570A Air Tubing Connections Parts
9. 841 181 2191 681 voc 906 82 8 998 7 83881 53 3A1570A Reactor A 25 Wiring Schematic gt 8 M 1 3SOH OL 3A1570A IN3W32V ld 431V3H MJE IN3A39V d 811V3H MA9 51044909 USLVSH DIZOWSYDS B HEATER MHDULE HOSE HEATER MODULE M wave p gt DI v 1 DL JAIdNODOWSSHL OL 513 DL SINGOW 331V3H JUM1NU2 RUC i OL paldnduls 54 Technical Data Technical Data Category Data Maximum Fluid Working Pressure 2000 psi 14 MPa 138 bar Maximum Air Supply Pressure 125 psi 0 9 MPa 9 bar Maximum Air Working Pressure 80 psi 550 kPa 5 5 bar Pressure Ratio 25 1 Air consumption with 02 tip at 1500 psi stall pres sure 28 scfm 0 8m min Machine Maximum Power with hose 9000 Watts Voltage Requirement 50 60 Hz 230 V Nominal 195 253 VAC 380 V Nominal 338 457 VAC 230 V 1 Phase 230 V 3 Phase Delta 380 V 3 Phase WYE 220 V to Neutral Amperage Requirement Full Load Peak 40 amps 230 V 1 Phase 32 amps 230 V 3 Phase 18 5 amps 380 V 3 Phase Maximum Heater Fluid Temperature 190 F
10. For hose zone lf 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 dis played 203 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 disap pears replace faulty module 4 f 203 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 3A1570A Important Two Component Material Information 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 dis played 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 Test fluid temperature sensor continuity with ohm meter page 10 3 error occurred for the hose zone check FTS connections at each section of hose 4 lf an error occurred for the
11. 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 nor mal Obstructed gun impingement ports or filters Flush and clean gun see gun manual One pressure gauge drops when pumps are stalled on both the upstroke and the downstroke 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 plugged on the other side Clean and repair spray gun One pressure gauge drops when pumps are stalled on the downstroke but not the upstroke Inlet ball check not sealing Clean or replace see 309577 Inlet check seat o ring not sealing Repair pump see 309577 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
12. ing Schematic page 51 Temperature control assembly is on left side inside cabinet 4 Remove bolts that secure transformer assembly and slide assembly to side in cabinet 5 Puton static conductive wrist strap 6 Disconnect all cables and connectors from assem bly See Temperature Control Module page 26 7 Remove nuts and take entire temperature control assembly to workbench 8 Replace defective module 9 Install assembly in reverse order 27 Repair Primary Heater AN N 77 Read Warnings on page 4 Wait for heater to cool before repairing Heater Element 1 Turn main power OFF Disconnect power supply 2 Relieve pressure page 13 3 Wait for heaters to cool 4 Remove heater shroud 5 See 7 Disconnect heater element wires from heater wire connector Test with ohmmeter Heater Rod Element Wattage Ohms 1500 30 35 6 To remove heater element first remove thermocou ple 361 to avoid damage see step 7 page 30 7 Remove heater element 358 from housing 351 Be careful not to spill any fluid left in housing 8 Inspect element It should be relatively smooth and shiny If there is a crusted burnt ash like material adhered to element or sheath shows pitting marks replace element 9 Install new heater element 358 holding mixer 360 so it does not block thermocouple port P 10 Reinstall thermocouple page 30 11 Reconnect hea
13. 1 5 m 0 25 in 6 35 mm ID LABEL warning LABEL caution LABEL caution LABEL pinch point CABLE hose control COVER pump TUBE polyethylene rnd 3 4 OD 0 75 ft 0 2 m see page 49 TUBE polyurethane rnd black 5 12 ft 1 56 m see page 49 INSERT control panel KIT DataTrak SWITCH reed assy P N 1 697 79 80 83 827 84 85A 88 89 90 91 92 93 94 95 96 97 98 997 100 262581 248208 15H187 16J808 195874 16K669 115266 16M086 114601 120573 16M088 114958 105676 FASTENER screw pan head m4 x 35mm COVER electrical assembly SCREW shcs m5x60 HOSE coupled 4 feet WIRE jumper w quick discon nect LABEL product LABEL warning disconnect wiring SCREW phillips pan hd M4 x 8 FILTER electrical SCREW cap socket hd M5 x 10 SCREW pan hd M5 x 16 WASHER 10 external tooth lock TUBE pe spiral wrapping 1 2 ft 0 4 m WIRE ground pump CONDUIT flexible non metallic SLEEVE heat shrink 2 1 0 75 ft 1 2 in ID 1 4 in OD BRIDGE plug in jumper LABEL error codes STAP tie SCREW pan hd Parts Replacement Danger and Warning labels tags and cards are available at no cost X Only used with 262614 Only used with 262572 Included in Reed Switch Kit 24B659 Not shown 43 Parts Control Panel 262575 A Apply sealant to all
14. 88 C Maximum Hose Fluid Temperature 180 F 82 C Maximum Ambient Temperature 120 F 49 C Maximum Output 25 Ib min 11 4 kg min Output Per Cycle A and B 0 025 gal cycle 0 095 Itr cycle Heater Power 6000 Watts Hose Power 2790 Watts Sound Pressure see NXT air motor manual 70 2 dB A Sound Power see NXT air motor manual 80 1 dB A Viscosity Range 250 1500 centipoise typical Maximum Fluid Inlet Pressure 300 psi 2 1 MPa 21 bar or 15 of output pressure Fluid Inlet Strainer Filter 20 mesh standard Air inlet Filter Mesh 40 Micron Component B Resin Inlet 3 4 npt f swivel Component A Isocyanate Inlet 3 4 npt f swivel Recirculation Block Hose Connections Iso A side 4 amp 5 JIC m Resin B side 46 JIC m Maximum Heated Hose Length 210 ft of 3 8 ID Weight 310 Ib 140 6 kg Wetted Parts Carbon steel stainless steel chrome aluminum Fluoroelastomer PTFE nylon Full load amps with all devices operating at maximum capabilities with 210 ft 64 1 m of hose 210 ft 64 m of heated hose will produce the maximum allowable heat capacity 310 ft 94 of heated hose may be used but will have 25 less heat capacity 3A1570A 55 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be
15. Hose temperature exceeds setpoint A and or B heaters are overheating material Check primary heaters for either a thermocouple problem or a failed ele ment attached to thermocouple page 11 Faulty thermocouple connections Verify that all FTS connections are snug and that pins of connectors are clean Examine connection of ther mocouples to long green plug on heater control board Unplug and re plug thermocouple wires cleaning off any debris Unplug and re plug long green connector on heater con trol board Erratic hose temperature Faulty thermocouple connections Verify that all FTS connections are snug and that pins of connectors are clean Examine connection of ther mocouples to long green plug on heater control board Unplug and re plug thermocouple wires cleaning off any debris Unplug and re plug long green connector FTS not installed correctly FTS should be installed close to end of hose in same environment as gun Verify FTS installation page 32 20 3A1570A Troubleshooting PROBLEM CAUSE SOLUTION Hose does not heat FTS failed or is not contacting correctly Check FTS page 11 FTS not installed correctly FTS should be installed close to end of hose in same environment as gun Verify FTS installation page 32 Temperature control alarm Check temperature display or diag nostic code page 32 Hoses near Reactor are wa
16. transformer Trace these wires back to large green 1 Turn main power OFF Disconnect power connector under hose control module and circuit breaker 909 Use an ohmmeter to test for continu supply ity between two wires there should be continuity 2 Open Reactor cabinet If you are not sure which wire in green plug under hose module connects to transformer test both wires One wire should have continuity with the other transformer wire in breaker 909 and the 4 other wire should not 3 Remove bolts holding transformer to cabinet floor Slide transformer forward Disconnect the transformer wires see Reactor A 25 Wiring Schematic page 51 5 Remove transformer from cabinet 6 Install new transformer in reverse order ti17999a Fic 11 Circuit Breaker Module 3A1570A 33 Repair Replace Circuit Breaker Module aA 1 Turn main power OFF Disconnect power supply Turn circuit breakers on to test 2 Relieve pressure page 13 3 Using an ohmmeter check for continuity across cir cuit breaker top to bottom If no continuity trip breaker reset and retest If still no continuity replace breaker as follows a Referto electrical diagrams and table below Disconnect wires and remove bad breaker NOTE To reference cables and connectors see the electrical diagrams and parts drawings on page 49 and 51 b Install new breaker and reconnect wires
17. 5 Inspect filter element Clean or replace Air Filter Element Installation 1 Insert cleaned or replacement filter 114228 2 Hand screw filter retainer into place 3 Hand screw clear drain cover until tight 4 Reposition black cover and turn Make sure it snaps back into place 25 Repair Temperature Control Module Table 2 Temperature Control Module Connections Connector Description DATA A Data reporting PIN 12 HOSE T C P FTS purple 11 HOSE T C R FTS red 10 HOSE T C S FTS silver unshielded bare wire 9 HEATER T C B Y Thermocouple yellow SENSOR B 8 HEATER T C B F Thermocouple red 7 Not used 6 HUE T C A Y hermocouple yellow 5 4 38 HEATER T C A R Thermocouple red OVERTEMPERATURE B Overtemperature switch B 2 1 OVERTEMPERATURE A Overtemperature switch A DISPLAY C COMMUNICATION D Display Communication to power boards PROGRAM E Software programming BOOT F POWER RELAY G Software bootloader Circuit board power input and contactor control output Table 3 Temperature Control Module Connections Connector Description COMMUNICATION Communication to control H board POWER J Power to heater 26 ti17997a ti9843a1 Right Side of Control Heater Module ti9843a4 Bottom of Power Modules Fic 6 Temperature Control Modul
18. 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 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 Clean inlet filter screen Gun port or filter plugged on high pressure side Clean or replace see gun manual Pump inlet ball not seating or sticking Clean seating see pump manual Drum fluid outlet supply hose too small Use 3 4 in 1 9 cm ID hose with short length Low side feed pump not working Pressure Relief Spray valve leaking back to supply Turn on or repair fe
19. Power cord not connected properly Check connections No power when disconnect switch is turned on using 230V 1 phase or Power terminal jumper still at 380V 3 Place jumpers in correct position see phase position as shipped from fac Operation manual and label inside 230V 3 phase power tory front lower cabinet External main supply power circuit Power terminal jumper was left in Place jumpers in correct position see breaker trips and Reactor disconnect 230V 1 phase position When using Operation manual Replace main switch fails when switch is turned on 230V phase or 380 phase power disconnect switch see page power 40 No temperature display lights at No power Connect power cord startup Turn Main Disconnect Switch ON Control power fuses blown Check and replace fuses on long ter minal strip 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
20. 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 24 788 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 3A1570A Proportioner Models Proportioner Models proportioners can be configured to operate on 380V 4 wire 230V 3 wire or 230V 10 Maximum Fluid Working Maximum Air Working cludes Pressure Set Pressure DataTrak Part No psi MPa bar psi kPa bar cycle count only Wheels Approvals 262572 2000 psi 14 138 80 psi 550 5 5 C US LISTED 262614 2000 psi 14 138 80 psi 550 5 5 24A592 Intertek 3172585 Only available in Asia Systems All systems include a proportioner spray gun and 60 ft 18 3 m of heated hose Maximum Working Heated Hose Gun Pressur
21. See 309550 Mechanical Purge Gun available in round or flat pattern See manual 309856 Clear Shot Gun available in round or flat patter See manual 312666 3A1570A Accessories P2 Spray Gun Probler P2 Gun available in round or flat pattern See 313213 Y Strainer Screen Replacement strainer screen for fluid Y strainer 20 mesh Part Description 180199 20 mesh as shipped 255082 80 mesh 2 pack 255083 80 mesh 10 pack 114228 Air Filter Element Replacement air filter element 5 micron 262695 Wheel Kit All hardware and wheels to convert model 262572 Recommended Spare Parts Keep the following spare parts on hand to reduce down time Part No Description 262648 Pump Resin B side 246421 Resin B Pump Repair Kit for 262648 pump 262647 Pump ISO A side 15C851 ISO A Pump Repair Kit for 262647 pump 246963 Wet Cup Kit for 262647 pump 206995 TSL bottle 1 qt 1 liter 101078 Y Strainer includes 180199 element 180199 Element Y Strainer 20 mesh 114228 Element air filter 5 micron 239914 Valve recirc spray includes seat and gasket 39 Parts Parts 262572 Bare Reactor A 25 262614 Reactor A 25 with DataTrak and Wheels ti18023a 40 3A1570A L
22. Thermocouple B 4 6 ohms 11 amp 12 FTS approximately 35 ohms per 50 ft 15 2 m of hose plus approximately 10 ohms for FTS at 70 F 21 C 10812 FTS 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 tempera ture 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 Totest that temperature control module turns off when equipment reaches temperature setpoint a Settemperature 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 3A1570A 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 ohmme ter 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 termi nals of the connector D There should be no conti nuity 5 Exchange zone module with another one Turn zone on and check for error see page 27 If error disap pears replace faulty module
23. Two Component Material Information Important Two Component Material Information Isocyanate Conditions wee Spraying or dispensing materials containing isocyanates creates potentially harmful mists vapors and atomized particulates 22 t 441 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 Keep Components A and B Separate P 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 Moisture Sensitivity of Isocyanates Isocyanates ISO are catalysts used in two component foam and
24. corresponding display will show E99 The corresponding control board will register E30 The red LED will flash 30 times If communications are recon nected the display can show the E30 for a small time no more than about two seconds It should not be pos sible 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 tempera ture control module has been lost When communication is lost the display will show E99 1 Check all wiring between the display and the tem perature 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 3A1570A Before Beginning Repair W Repairing this equipment requires access to parts that may cause electric shock or other serious injury if work is not performed properly Electrical troubleshootin
25. 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 Warnings 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 an
26. heater element where thermocouple is installed Loose wire Jumper wire covered in heat shrink in the wiring har ness near the single over temperature switch con nectors on the heater is loose or incorrectly wired Checks aA 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 tem perature control module see FIG 6 page 26 2 Clean and re plug connections 3 Check connections between the temperature control module and overtemperature switch 359 and 10 between temperature control module and thermo couples 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 mod ule and check continuity of overtemperature switch thermocouples A and B or FTS by measuring resis tance across the pins on the plug end see Table 1 Table 1 Sensor Connector Continuity Checks Pins Description Reading 1 amp 2 OT switch nearly 0 ohms 3 amp 4 Jumpered nearly 0 ohms 5 amp 6 Thermocouple A 4 6 ohms 8 amp 9
27. 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 crystal lization 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 e Always lubricate threaded parts with ISO pump oil or grease when reassembling Foam Resins with 245 fa Blowing Agents Some foam blowing agents will froth at temperatures above 90 F 33 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
28. specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable ELECTRIC SHOCK HAZARD This equipment must be grounded Improper grounding setup or usage of the system can cause electric shock D 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 Do 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 2 PERSONAL PROTECTIVE EQUIPMENT om 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 Equipmen
29. 14183 NUT hex flanged serrated 155 247801 CABLE communication 3A1570A P Parts Wheel Kit 262695 194 ti18006a Ref Part Description Qty 1917 16H182 AXLE wheel 1921 111841 WASHER plain 5 8 1937 191824 WASHER space 1941 101242 RING retaining ext 1957 16G920 WHEEL semi pneumatic offset 2 BRD T Only used with 262614 Available as add on wheel kit 262695 45 Parts Fluid Manifold Fluid Inlet Kit 262695 A 212 ti18027a A Assemble ball valves in orientation shown 202 A Apply anaerobic polyacrylate pipe sealant to all NPT connections ti8459a 207 A Apply sealant and torque to 250 in Ibs 28 Nem A Use blue thread lock on valve cartridge threads into manifold A Part of item 208 Ref Part Description Qty 251 160327 UNION adapter 90 3 4 npt m x 2 3 4 14 npt f AX Apply lubricant to mating surfaces 252 101078 Y STRAINER 20 m screen A Apply pipe sealant to all NPT threads 253 C20487 NIPPLE 3 4 npt 254 109077 VALVE ball 3 4 npt fbe 255 118459 UNION swivel 3 4 14 npt m x 3 4 14 npt f 256 180199 ELEMENT 20 mesh 2 Ref Part Description 201 24K993 MANIFOLD recirculation 202 108638 FITTING pipe tee 203 162453 FITTING 1 4 npsm x 1 4 npt 204 113641 GAUGE pressure fluid SST 205 111600 PIN grooved 206 119789 FITTING elbow street 45 deg 207 116704 ADAPTER 3 8 JIC x 1 4 npt 208 239914 VALVE drain includes 208a 208b 20
30. 4 20 UNC 2A SCREW machine hex washer 6 hd M6 x 1 BRACKET heater 1 SCREW mach hex flange M6 13 x1 NUT cap 3 8 16 4 SCREW mach panhd M5x 2 0 8 BUSHING strain relief 1 3A1570A 17 123970 18 123971 19 123972 20 205447 21 160921 22 160922 23 160923 24 160924 25 112125 26 117666 27 150795 28 107128 29 114110 30 162449 31 158491 32 262660 33 114269 34 160918 85 246995 36 234366 37 262695 38 16 152 44 247791 45 261669 49 167002 50 162433 51 16 434 52 261821 53 54 206994 55 206995 56 186494 57 58A 150280 59A 189930 60A 189285 61A 15H108 62 158380 63 160952 64 65 m 66x 67 24B563 681 24B659 3A1570A SWITCH disconnect 40a KNOB disconnect operator SWITCH fourth pole COUPLING hose TUBE fluid A heater inlet TUBE fluid A heater outlet TUBE fluid B heater inlet TUBE fluid B heater outlet PLUG tube TERMINAL ground FILTER air 40 micron TEE service ELBOW male swivel NIPPLE reducing NIPPLE VALVE ball 1 2 npt x 1 2 npt GROMMET rubber COVER heater BOTTLE assembly complete KIT fluid inlet pair see page 46 KIT wheel see page 51 BRACKET lube reservoir HARNESS wire hose KIT fluid temp sensor coupler INSULATOR heat HARNESS wire display ext HARNESS over temp a side b side CONNECTOR wire 6awg FLUID oxide inhibitor FLUID TSL 8 oz bottle FLUID TSL 1 qt CLIP spring HOSE PTFE 5 ft
31. 8a SEAT 208b GASKET 209 119998 ADAPTER 5 16 JIC x 1 4 npt 210 116702 FITTING union 1 4 npt x 3 8 JIC 212 187625 HANDLE valve drain 213A189285 LABEL caution 214 224807 BASE valve lt N NN N N N N N N N N N N N Replacement Danger and Warning labels tags and cards are available at no cost 46 3A1570A 6 kw Dual Zone Heater 24J788 353 N A Torque to 120 ft Ibs 163 Nem A Torque to 23 ft lbs 31 Nem A Torque to 40 ft lbs 54 Nem A Apply 110009 thermal heatsink compound A Apply sealant and PTFE tape to all non swiveling and threads without o rings A Apply lubricant to o rings A Orient rupture disc housing 369 with exhaust hole pointing towards the bottom of the heater Ref 351 352 353 354 355 356 357 358 3A1570A Part 124132 15H305 121309 15H304 15H306 120336 16A112 Description HEATER dual zone O RING FITTING plug hollow hex 1 3 16 sae FITTING adapter sae orb x jic FITTING plug 9 16 sae ADAPTER thermocouple 9 16 x 1 8 O RING packing HEATER immersion 1500w 230v A361 359 360 361 362 369 15B137 15B135 117484 247520 Parts 352 N358 ti17998a SWITCH over temperature MIXER immersion heater SENSOR SCREW mach pnh KIT rupture disc 47 Parts A 25 Air Motor Pump Assembly 262573 A Apply PTFE tape and sealant to non swiveling pipe threads
32. E02 High zone current 11 203 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 iers das T ee cee ec EC 13 Be nea eee 14 Flushing Aoi ev 14 Troubleshooting 15 Problems utet xe Ere h 15 the 15 Pumps and Pressures 15 Electronics 17 Heater a 19 Hose Heat System 20 2 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
33. Repair Parts gt g GRACO TSR Uit 25 3A1570A PLURAL COMPONENT PROPORTIONER EN 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 ti16811a C PROVEN QUALITY LEADING TECHNOLOGY Contents Proportioner Models 3 Systems tse Ste LE AN ERU 3 Related Manuals 3 Warnings leg ia Saag Saas ci ee e 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
34. e Part psi MPa bar Proportioner 50 ft 15 10 ft 3 Model Part P22614 2000 14 138 262614 246678 246050 Probler P2 GCP2R1 AP2614 2000 14 138 262614 246678 246050 Fusion AP 246101 CS2614 2000 14 138 262614 246678 246050 Fusion CS CS01RD P22572 2000 14 138 262572 246678 246050 Probler P2 GCP2R1 AP2572 2000 14 138 262572 246678 246050 Fusion AP 246101 CS2572 2000 14 138 262572 246678 246050 Fusion CS CS01RD Related Manuals Manuals are available at www graco com Manual Description Component manuals in English 309852 Circulation and Return Tube Kit Instruc tions Parts 309572 Heated Hose Instructions Parts Manual Description 309550 3A1569 Reactor A 25 Proportioner Operation 312666 m Spray Gun 309577 Proportioning Pump Repair Parts Fusion CS Spray Gun Instructions Parts 309815 Feed Pump Kit Instructions Parts 313213 Probler P2 Spray Gun Instructions Parts 309827 Feed Pump Air Supply Kit Instruc 313541 DataTrak Kits Installation Parts tions Parts 312796 NXT Air Motor Instructions Parts 3A1570A 3 Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion 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
35. e Connections 3A1570A Test SCR Circuit 1 Testthe SCR circuit in the on position a Make sure everything is connected including the hose b Turn main power ON c Adjust the hose heat setpoint above the ambi ent hose temperature d Turn on heat zone by pressing o e Hold down Q to view electrical current Hose current should ramp up to 45 If there is no hose current see E03 No zone current page 11 If hose current exceeds 45 see E02 High zone current page 11 If hose current stays several amps below 45 hose is too long or voltage is too low 2 Testthe SCR circuit in the off position a Make sure everything is connected including the hose b Turn main power ON c Adjust the hose heat setpoint below the ambi ent hose temperature d Turn on heat zone by pressing o Using a voltmeter carefully measure the voltage at the hose connector You should not get a voltage reading If you do the SCR on the temperature control module is bad Replace the temperature control assembly 3A1570A Repair Replacing Temperature Control Assembly Modules P A Before handling assembly put on static conductive wrist strap to protect against static discharge which can damage assembly Follow instructions provided with wrist strap 1 Turn main power off Disconnect power supply 2 Relieve pressure page 13 3 Refer to electrical diagrams See Reactor A 25 Wir
36. ed pump Pump does not reverse direction Obstruction of air motor or pumps Check and clear obstruction Unequal fluid pressure between UP DOWN stroke Feed pumps boost pressure on up stroke Reduce feed pump pressures Air motor doesn t move with air pres sure applied Damaged air valve Replace or service air valve See Air Motor manual Damaged pilot valve Park valve left open or leaking Replace valve See Air Motor man ual Pump movement speed is erratic Worn air motor seals Replace seals See Air Motor man ual Worn pump seals Replace seals see Pump manual Electronics Problem Cause Display does not illuminate Solution Plug in power cord NO power Turn disconnect ON Low voltage Ensure input voltage is within specifi cations page 36 Loose wire Check connections page 36 Display disconnected Check cable connections page 36 Temperature display does not illuminate Display disconnected Check cable connections page 36 Display cable damaged or corroded Clean connections replace cable if is damaged 3A1570A 17 Troubleshooting Problem Cause Solution Erratic display display turns on and off Low voltage Ensure input voltage is within specifi cations page 36 Poor display connection Check cable connections page 36 Replace damaged cable
37. eplace Fuse 1 Remove the screw metal strap and plastic holder 2 Pullthe fuse away from the board 3 Replace with a new fuse Solenoid Cable Connection Sensor Cable Connection Battery ti11994a Fic 18 DataTrak Battery and Fuse Location 3A1570A Accessories Feed Pump Kits Pumps hoses and mounting hardware to supply fluids to Reactor Includes 246483 Air Supply Kit See 309815 246483 Air Supply Kit Hoses and fittings to supply air to feed pumps agitator and gun air hose Included in feed pump kits See 309827 246978 Circulation Kit Return hoses and fittings to make circulation system Includes two 246477 Return Tube Kits See 309852 246477 Return Tube Kit Desiccant dryer return tube and fittings for one drum Two included in 246978 Circulation Kit See 309852 TSL Throat Seal Liquid 206995 1 qt 1 liter bottle 206996 1 gal 3 8 liter container 24A592 DataTrak with Cycle Count Only Kit Data Track and reed switch for Air Motor See man ual 313541 Heated Hoses 50 ft 15 2 m and 25 ft 7 6 m lengths 1 4 in 6 mm 3 8 in 10 mm or 1 2 in 13 mm diameter 2000 psi 14 MPa 140 bar or 3500 psi 24 MPa 241 bar See 309572 Heated Whip Hoses 10 ft 3 m whip hose 1 4 in 6 mm or 3 8 in 10 mm diameter 2000 psi 14 MPa 140 bar or 3500 psi 24 MPa 241 bar See 309572 Fusion Spray Gun Air Purge Gun available in round or flat pattern
38. equipment requires special attention to avoid equipment damage and downtime When changing materials flush the equipment mul tiple 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 compo nents and change hoses Epoxies often have amines on the B hardener side Polyureas often have amines on the B resin side 3A1570A DataTrak Diagnostic Codes 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 Important Two Component Material Information To acknowledge the diagnosis and return to the normal operating screen press e 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 d E 3 Low Battery Battery voltage too low to stop Low battery Replace battery E 3 runaway see page 38 E 6 Blown Fuse Fuse is blown Replace fuse Faulty solenoid or solenoid E 38 wiring Extreme temperatures Fuse P JN above 140 F 60 C Temperature Control Diagnostic Codes Temperature control diagnostic codes appear on tem
39. 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 equipme
40. g 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 Procedure e uo 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 m RET ti2409a 3A1570A Before Beginning Repair 5 Close gun fluid inlet valves A and B ti2421a 1771 Shutdown 1 Turn main heater power OFF i 2 Follow Park 3 Check and fill wet cups AK Z AK e ti16974a SS 7 2 STN 4 Follow gun shutdown procedure See gun manual 13 Park Park Park the pumps at the end of the day to cycle compo nent A pump to home position submerging displace ment rod 1 Open the park valve 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 14 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 ne
41. hose zone test FTS by plugging directly into machine ti17788a 5 To verify heater control module is not causing the problem use a wire to short circuit the two pins cor responding 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 If an error occurred for the hose zone temporarily use the current control mode Refer to Reactor Operation manual 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 bot tom of electrical cabinet 4 Clean heatsink fins behind heater control modules 5 Ambient temperature may be too high Allow Reac tor to cool by moving to a cooler location E06 Communication cable unplugged 1 Unplug and re plug cable that connects heater con trol module to heater module 2 Replace communication cable if problem persists 12 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
42. iG 15 11 Replace board 102a or membrane switch 102b as necessary 12 Reassemble in reverse order see 15 Apply medium strength thread sealant where shown Be sure display cable ground wire G is secured between cable bushing and cover 105 with screws 107 3A1570A Repair ti18026a Detail of Membrane Switches and Temperature Display Board 102a Temperature Display 102b A 1020 A ti18003a Fic 15 Display Module 3A1570A 37 Repair Replace DataTrak Battery or Fuse uw The battery and fuse must be replaced in a non hazardous location Use only the following approved replacement batter ies Use of an unapproved battery will void Graco s warranty and FM and Ex approvals e Ulttralife lithium U9VL e Duracell alkaline MN1604 Energizer alkaline 522 e Varta alkaline 4922 Use only a Graco approved replacement fuse Order Part 24C580 Replace Battery 1 Unscrew cable from the back of the reed switch assembly See 16 2 Remove the cable from the two cable clips 11992 Fic 16 Disconnect DataTrak 3 Remove DataTrak module from bracket See 17 Take module and attached cable to a non haz ardous location 38 4 Remove two screws on back of module to access battery 5 Disconnect the used battery and replace with an approved battery See 18 R
43. imals away from work area Comply with all applicable safety regulations 9 EQUIPMENT MISUSE HAZARD e Misuse can cause death or serious injury 4 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 x MOVING PARTS HAZARD Moving parts can pinch cut or amputate fingers and other body parts Keep clear of moving parts a 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
44. less necessary If adapter must be removed ensure that mixer 360 is out of the way when replacing the adapter 360 Fic 8 Thermocouple 8 Replace thermocouple 8 a Remove protective tape from thermocouple tip D b Apply PTFE tape and thread sealant to male threads and tighten thermocouple housing H into adapter 356 c Pushin thermocouple 361 so tip T contacts heater element 358 d Holding thermocouple T against heater ele ment tighten ferrule nut N 1 4 turn past tight 9 Route wires S into cabinet and thread into bundle as before Reconnect wires to board 10 Replace heater shroud 11 Turn on heaters A and B simultaneously to test Temperatures should rise at same rate If one heater is low loosen ferrule nut N and tighten ther mocouple housing H to ensure thermocouple tip T contacts element 358 A Apply PTFE tape and thread sealant A Apply 110009 thermal heatsink compound 301 ti7924a 30 3A1570A Overtemperature Switch AR d Read Warnings on page 4 Wait for heater to cool before repairing 1 Turn main power OFF supply Disconnect power 2 Relieve pressure page 13 3 Wait for heaters to cool 4 Remove heater shroud 5 Disconnect one leadwire from overtemperature switch 359 8 Test across switch with ohmme ter Resistance must be approximately O ohms 6 If switch fails test remove
45. nch Torque to 32 38 ft lbs 43 51 Nem See FIG 1 Install tie rods 309 in the bottom of the air motor 308 See FiG 3 Install tie rods through plate 301 Ensure screws 814 fit in the bracket slots 311 Install screws 314 See Fia 2 Tighten nut 313 to 32 38 ft Ibs 43 51 Nem Evenly torque four tie rod nuts 310 in small incre ments to 27 32 ft lbs 37 43Nem See FIG 2 3A1570A Recirculation Over Pressure Relief Block Valves can be serviced with the block on the machine see page 46 for parts view For thorough cleaning remove the block assembly as follows 1 Disconnect two fluid tubes connected to back of recirculation block 3 2 Loosen and remove two screws 10 in back of recir culation block ti17995a Fic 4 3 See Fluid Manifold page 46 Clean and inspect all parts for damage Ensure that the seat 8a and gasket 8b are positioned inside each valve car tridge 8 4 Apply PTFE pipe sealant to all tapered pipe threads before reassembling 5 Reassemble in reverse order following all notes on page 46 3A1570A Repair Air Inlet Filter Water Separator Auto Drain Air Filter Element Removal 1 Close air inlet valve 302 on filter 301 2 Hold in metal spring clip and twist black cover coun terclockwise to remove ti17996a Fic 5 3 Unscrew clear drain cover by hand 4 Unscrew black filter element retainer to remove ele ment
46. nect hose cable F Test with ohmmeter between pins of cable connector fitting ISO Pins Result 1102 approximately 10 ohms 1to3 infinity 3 to FTS groundscrew 0 ohms 1 to FTS component A infinity 4 If FTS fails any test replace FTS 5 Disconnect air hoses C L and electrical connec tors D 6 Disconnect FTS from whip hose W and fluid hoses A B 7 Remove ground wire K from ground screw on underside of FTS 8 Remove FTS probe H from component A ISO side of hose Installation The Fluid Temperature Sensor FTS is supplied Install FTS between main hose and whip hose See Heated Hose manual 309572 for instructions Fic 10 Fluid Temperature Sensor and Heated Hoses ti9581c 32 3A1570A Repair Transformer Primary Check 3 To verify transformer voltage turn on hose zone Measure voltage from 178CB 2 to HPOD 1 see Reactor A 25 Wiring Schematic page 51 1 Turn main power OFF Model Secondary Voltage 2 Locate the two smaller 10 AWG wires coming out 310 ft 90 Vac of transformer Trace these wires back to contactor and circuit breaker 911 Use an ohmmeter to test 210 ft 62 Vac for continuity between two wires there should be continuity For 230 Vac line voltage Transformer Secondary Check Replace Transformer 1 Turn main power OFF P MN 2 Locate the two larger 6 AWG wires coming out of
47. non swiveling pipe threads 1 x A Attach ground wire from harness 116 between connector on harness 106 and display cover 105 A Attach harness 106 to J13 on board 102 A Attach harness 119 to J1 on board 102 ti18002a m 112 16F810 NUT regulator steel 1 Ref Part Description Qty 114114 FITTING elbow male swivel 4 101 169912 PLATE display 1 114 114362 VALVE ball air 1 102 24G883 DISPLAY temperature includes 1 115 110637 SCREW mach pan head 2 102a 102c 116 331342 SCREW screw 10 24 x1 2 in 4 102a 24G882 BOARD circuit ph pn hd 102b 246478 SWITCH membrane 117 114469 FITTING elbow m swivel 1 102 112324 SCREW 118 116643 VALVE relief air 90 psi 620 5 1 103 117523 cap 10 kPa 104 166958 GASKET display cover 119 16J431 HARNESS jumper heater dis 1 105 16G913 COVER display play 106 16J432 HARNESS wire display 121 160525 LABEL control 1 107 SCREW pan head phillips 108 116257 GAUGE pressure 109 100451 COUPLING 1 8 npt 110 114151 FITTING elbow male swivel 111 157536 REGULATOR air 3 8 npt N OAH 44 3A1570A Temperature Control 151 152 154 154 Ref Part Description 153 155 Module Module To Hose a Heater Module To B Heater To A Heater Qty 151 16G925 PANEL pod mounting 152 247827 MODULE heater control 153 247828 MODULE heater 154 1
48. nt 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 p
49. pump only a Install two pipe plugs 324 b Reconnect two tubing lines N from ISO Pump Lube reservoir Flush and refill reservoir with TSL 206995 Refill Resin B pump wet cup with TSL 206995 23 Repair Remove Air Motor 1 Press in tube fitting ferrules and pull out tubing 65 to disconnect air line 2 Disconnect DataTrak communication cable if installed 3 Place wrench on adapter 315 and a another wrench on lock nut 313 Remove lock nut 313 lol JU q a 1 bl 315 Q 5 313 wa 4 ti17992a FiG 1 4 Remove four nuts 310 from tie rods 309 309 301 310 ti17993a 308 Lay air motor on a clean flat work space Place a wrench on the tie rod flats 309 and hold one of other tie rods with your hand to keep the air motor 308 in place Remove the tie rods from the air motor ti17994a Fic 3 5 24 Loosen two screws 314 behind air motor bracket Carefully lift air motor and tie rods away from the proportioner frame and plate 301 7 Use a wrench to hold the piston rod in place and remove the adapter 315 with another wrench See FiG 1 See air motor manual for repair instructions Install Air Motor 1 Apply medium blue thread lock on adapter 315 Use a wrench to hold the piston rod in place and install the adapter 315 with another wre
50. rm but hoses downstream are cold 3A1570A Shorted connection or failed hose heating element With hose heat on and temperature setpoint above displayed hose zone temperature verify voltage between connectors at each section of hose Voltage should drop incrementally for each section of hose further from Reactor Use safety precautions when hose heat is turned on 21 Repair Repair W Unless otherwise noted all repair procedures must be completed with incoming power switched OFF and locked out at the source Any electrical repair or troubleshooting required beyond the scope of this manual must be performed by a qualified electrician Shut off air inlet ball valve and shut off all air supply pressure Disconnect Pump Air motor shaft yoke pump rod and connecting rod move during operation Moving parts can cause serious injury such as pinching or amputation Keep hands and fingers away from connecting rod during operation NOTE See manual 309577 for pump repair instructions 1 Turn main heater power OFF 2 Follow Flushing page 14 3 Follow Pressure Relief Procedure page 13 4 Follow Park instructions page 14 5 Shutoff both feed pumps and close both inlet supply valves F F ti17988a 22 6 Shut off inlet air ball valve G 7 Remove screws 13 15 and pump covers 63 ti17989a 8 Disconnec
51. roducts 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 r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice Original instructions This manual contains English MM 3A1750 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2011 Graco Inc All Graco manufacturing locations are registered to ISO 9001 ww
52. se temperature Hose temperature setpoint too low Check Increase if necessary to maintain heat Flow too high Use smaller mix chamber Decrease pressure Low current FTS not installed Install FTS see operation manual Hose heat zone not turned on long enough Allow hose to heat up or preheat fluid Loose hose electrical connections Check connections Repair as neces sary 18 3A1570A Heater Troubleshooting PROBLEM CAUSE SOLUTION Primary heater s does not heat Heat turned off Press or B zone keys Temperature control alarm Check temperature display for diag nostic code page 9 Signal failure from thermocouple See E04 Fluid Temperature Sen sor FTS or thermocouple discon nected page 11 Control of primary heat is abnormal high temperature overshoots or E01 error occurs intermittently Dirty thermocouple connections Examine connection of thermocou ples to long green plug on heater control board Unplug and re plug thermocouple wires cleaning off any debris Unplug and re plug long green connector Thermocouple not contacting heater element Loosen ferrule nut N push in ther mocouple 361 so tip T contacts heater element 358 Holding ther mocouple tip T against heater ele ment tighten ferrule nut N 1 4 turn past tight See page 30 for illustra tion Failed heater elemen
53. t See Primary Heater page 28 Signal failure from thermocouple See E04 Fluid Temperature Sen sor FTS or thermocouple discon nected page 11 Thermocouple wired incorrectly See E04 Fluid Temperature Sen sor FTS or thermocouple discon nected page 11 Power up zones one at a time and verify that tempera ture for each zone rises 3A1570A 19 Troubleshooting Hose Heat System PROBLEM CAUSE SOLUTION Hose heats but heats slower than usual or it does not reach tempera ture Ambient temperature is too cold Use auxiliary hose heat system FTS failed or not installed correctly Check FTS page 11 Low supply voltage Verify line voltage Low line voltage significantly reduces power available to hose heat system affecting longer hose lengths Hose does not maintain temperature while spraying A and B setpoints too low Increase A and B setpoints Hose is designed to maintain temperature not to increase it Ambient temperature is too cold Increase A and B setpoints to increase fluid temperature and keep it steady Flow too high Use smaller mix chamber Decrease pressure Hose was not fully preheated Wait for hose to heat to correct tem perature before spraying Low supply voltage Verify line voltage Low line voltage significantly reduces power available to hose heat system affecting longer hose lengths
54. t A side 21 and B side 23 steel outlet tubes from adapters 312 21 318 324 317 ti17990a 9 Remove adapter 312 from fluid outlet M 10 For A Side pump disconnect barb fitting 318 elbow fitting 317 and two pipe plugs 324 NOTE It is not necessary to cut tubes connected to barb fittings 3A1570A 11 Push retaining wire clip 307 up Push retaining pin 306 out 307 303 ti17991a 12 Loosen lock nut 302 by hitting firmly with a non sparking hammer 13 Unscrew pump out of pump mounting plate 301 14 See pump manual for repair procedures and replacement parts Connect Pump 1 Ensure locknut 302 is screwed on pump with flat side up Grease pump mounting threads in plate and pump cylinders 303 304 with lithium grease Screw pump into pump mounting plate 301 until top of pump thread is above mounting plate 1 2 to 1 1 2 threads above flush NOTE Pump rod connecting links 302 should be posi tioned so that pins 306 are in line with each other 2 Align pump rod hole with link hole Push retaining pin 306 in Pull retaining wire clip 307 down to cover pin ends 3 Tighten locknut 302 by hitting firmly with a non sparking hammer 4 Install adapter 312 in fluid outlet Connect A side 21 and B side 23 steel outlet tubes 3A1570A 5 6 Repair For Iso A
55. t 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 gt a n 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 POD MPa bar PSI 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
56. ter element leadwires to heater wire connector 12 Replace heater shroud 28 Line Voltage The primary heaters output their rated wattage at 230 Vac Low line voltage will reduce power available and the heaters will not perform at full capability 3A1570A Repair On p 9 0 352 351 Torque to 120 ft lbs 163 Nem A Torque to 23 ft lbs 31 Nem Torque to 40 ft lbs 54 Nem N358 ti17998a Apply 110009 thermal heatsink compound A Apply sealant and PTFE tape to all non swiveling and threads without o rings A Apply lubricant to o rings Orient rupture disc housing 369 with exhaust hole pointing towards the bottom of the heater Fic 7 6 kW Dual Zone Heater 3A1570A 29 Repair Thermocouple Read Warnings on page 4 Wait for heater to cool before repairing 1 Turn main power OFF Disconnect power supply 2 Relieve pressure page 13 3 Wait for heaters to cool 4 Remove heater shroud 5 Disconnect thermocouple wires from B on tempera ture control module See Table 2 page 26 and FIG 6 page 26 6 Feed thermocouple wires out of cabinet Note path as wires must be replaced in the same way 7 See 8 Loosen ferrule nut N Remove thermo couple 361 from heater housing 351 then remove thermocouple housing H Do not remove the thermocouple adapter 356 un
57. ve the screen A from the strainer manifold Thoroughly flush the screen with compatible solvent and shake it dry Inspect the screen No more than 25 of the mesh should be restricted If more than 2596 of the mesh is blocked replace the screen Inspect the gasket B and replace as required 4 Ensure the pipe plug D is screwed into the strainer plug C Install the strainer plug with the screen A and gasket B in place and tighten Do not over tighten Let the gasket make the seal 5 Open the fluid inlet valve ensure that there are no leaks and wipe the equipment clean Proceed with operation Ti10974a Fic 14 Fluid Inlet Strainer 36 Temperature Display aA Before handling board put on static conductive wrist strap to protect against static discharge which can damage assembly Follow instructions provided with wrist strap 1 Turn main power OFF Disconnect power supply 2 Relieve pressure page 13 3 Referto Reactor A 25 Wiring Schematic page 51 4 Puton static conductive wrist strap 5b Disconnect main display cable 106 at lower left corner of display module see FIG 15 6 Remove screws 116 and cover 105 see FiG 15 7 Disconnect cable connector from back of tempera ture display 102 See 15 8 Disconnect ribbon cable s R from back of display see FIG 15 9 Remove nuts 103 and plate 101 10 Disassemble display see detail in F
58. voir LR out of the bracket RB and remove the container from the cap Hold ing the cap over a suitable container remove the check valve and allow the lubricant to drain Reat tach the check valve to the inlet hose ST See FIG 13 3 Drain the reservoir and flush it with clean lubricant 4 When the reservoir is flushed clean fill with fresh lubricant 5 Thread the reservoir onto the cap assembly and place it in the bracket 6 The lubrication system is ready for operation No priming is required 3A1570A 35 Repair Fluid Inlet Strainer Screen Mes The inlet strainers filter out particles that can plug the pump inlet check valves Inspect the screens daily as part of the startup routine and clean as required Isocyanate can crystallize from moisture contamination or from freezing If the chemicals used are clean and proper storage transfer and operating procedures are followed there should be minimal contamination of the A side screen NOTE Clean the A side screen only during daily startup This minimizes moisture contamination by immediately flushing out any isocyanate residue at the start of dispensing operations 1 Close the fluid inlet valve at the pump inlet and shut off the appropriate feed pump This prevents mate rial from being pumped while cleaning the screen 2 Place a container under the strainer base to catch drain off when removing the strainer plug C 3 Remo
59. w fluid or flush out old fluid with a compatible solvent such as toluene naptha or mineral spirits before introducing new fluid e Use lowest possible pressure when flushing To flush feed hoses pumps and the heater sepa rately from the heated hoses set PRESSURE RELIEF SPRAY valves SA SB to PRESSURE RELIEF CIRCULATION Flush through bleed lines N 2 a N 7 ti8441a Toflush 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 Eu 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 3A1570A Troubleshooting Troubleshooting ENSE 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 each problem to avoid unnecessary repairs Also determine that all circuit breakers switches and con trols are properly set and wiring is correct before assum ing there is a problem PROBLEM CAUSE SOLUTION Heat zones do not operate No power Connect power cord Turn Main Disconnect Switch ON
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61. wires and screws Dis card failed switch Apply thermal compound 1100089 install new switch in same location on housing 351 and secure with screws 311 Reconnect wires NOTE If wires need replacement disconnect tempera ture control module See Table 2 page 26 and FiG 6 page 26 Heated Hose Refer to the heated hose manual for hose replacement parts Check Hose Connectors 1 Turn main power OFF Disconnect power supply 2 Relieve pressure page 13 NOTE Whip hose must be connected 3 Disconnect hose connector D at Reactor FIG 9 4 Using an ohmmeter check between the two termi nals of the connector D There should be continu ity 3A1570A Repair 5 If hose fails test retest at each length of hose including whip hose until failure is isolated Check FTS Cables 1 Turn main power OFF supply Disconnect power 2 Relieve pressure page 13 3 Disconnect FTS cable F at Reactor FIG 9 ti17788a Fic 9 Heated Hose 4 Test with ohmmeter between pins of cable connec tor Pins Result 1102 approximately 35 ohms per 50 ft 15 2 m of hose plus approximately 10 ohms for FTS 1to3 infinity 5 If cable fails test retest at FTS page 32 31 Repair Fluid Temperature Sensor FTS Test Removal 1 Turn main power OFF Disconnect power supply 2 Relieve pressure page 13 3 Remove tape and protective covering from FTS Discon
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