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Graco 332144C User's Manual

1. OO pressure is higher so use Qo N Qc the RES side valve to bal ance pressures ep 4 2 If pressure imbalance continues see Proportioner Troubleshooting page 36 Status Code 2 Pressure Deviation from Setpoint NOTE The unit does not check for pressure deviation at setpoint less than 400 psi 2 8 MPa 28 bar Unit senses pressure deviation from setpoint and warns or shuts down depending on settings of DIP switches 3 and 4 If equipment cannot maintain enough pressure for a good mix with an impingement mix gun try using a smaller mix chamber or nozzle 332144C Troubleshooting To turn off automatic shutdown and or change pressure tolerances for status code 2 see DIP Switch Settings page 29 Deviation can occur if power is turned on if function knob AV is not set to Park Off Leave knob in Park Off mode until status indicator LED turns on Status Code 3 Pressure Transducer ISO Failure 1 Check transducer ISO electrical connection J11 at board page 45 2 Reverse ISO and RES transducer electrical connec tions at board page 45 If error moves to transducer RES Status Code 4 replace transducer ISO page 50 Status Code 4 Pressure Transducer RES failure 1 Check transducer RES electrical connection J12 at board page 45 2 Reverse ISO and RES transducer electrical connec tions at board page 45 If error moves to transducer ISO Status Code 3 replace transducer RES page
2. 16 Connect Fluid Hoses 16 Connect Gun Air Hose 16 Connect Air Supply 16 Flush Before First Use 16 Fill Wet CupS 17 Pill Fluid TANKS s erret tx 17 Purge Air and Flush Fluid From Lines 18 19 Heatup Guidelines 20 Heat Management Tips 20 SPLAVINO eR EM 21 PAUSE unitaria ee ad CS 22 Refill 15 xat 22 Pressure Relief Procedure 23 22525525044 RP CER acess 23 Maintenance 24 cT 25 Purge HOSES 355 rb Rat 26 2 TFOUDICSNOOUNG lt lt dis 27 Pump Control Status Codes 27 DIP Switch Settings 29 Heat Control Diagnostic Codes 31 Reactor Electronics 33 Healers losa daa 35 gt cari 36 a See Re ies 39 Before Beginning Repair 39 Remove Supply Tank 39 Replace Recirc Spray Valves 40 Displacement Pump 41 unida Girard dence e d 42 Motor 44 Heater o CERDO a ae e eda by 48 Pressure Transducers 50 Drive HOUSING
3. ti21490a 3 Turn Recirc Spray valves to Recirc Fluid will be dumped to supply tanks Pumps will move to the bottom of their stroke Ensure gauges drop to 0 ti21495a 332144C Pressure Relief Procedure Shutdown NOTE For longer breaks more than 10 minutes use the following procedure If you will be shutdown for more than 3 days first see Flushing page 25 1 Shut off Heater Power 3 Follow all steps of Pressure Relief Procedure page 23 4 Close gun fluid valves ISO and RES Doing this will keep the internal parts of the gun cleaner and pre vent crossover Fusion Probler 5 Refer to your separate gun manual and perform Shutdown procedure 23 Maintenance Maintenance 24 Check pump wet cups fluid level daily page 17 Throat u cup is not adjustable Do not overtighten packing nut wet cup Keep component ISO from exposure to moisture in atmosphere to prevent crystallization Wipe supply tank lid o ring inner rim and inner tank walls daily to prevent ISO crystallization Keep film of grease on o ring and inside of lid Check desiccant filter weekly Filter is blue when fresh and turns pink when saturated Remove plug X and clean fluid inlet strainer S as needed Always clean the fluid inlet strainers after flushing ti21836a Generally flush if you will shutdown for more than three days Flush more often if material is moisture sensitive and humidity is high
4. 7 Set function knob to Slow Recirc or Fast Recirc tainer 5 121489 8 When clean fluids exit both recirculation tubes 2 set function knob to Stop Park ti21490a Plug in power cords s See Table 2 page 15 9 Replace recirculation tubes in supply tanks 4 Open both pump fluid inlet valves V shown in open position 18 332144C Startup AA Heated fluid can cause equipment surfaces to become very hot To avoid severe burns Do not operate Reactor without all covers and shrouds in place Do not touch hot fluid or equipment Allow equipment to cool completely before touching it 1 Perform Setup page 15 2 2 Set function knob to Slow Recirc 24 or Fast Recirc A mM 25 See Heatup Guidelines page 20 then con tinue with steps 3 6 ti21489a 4 Settemperatures a Press Q Or change temperature scale b Press to display target temperatures C heat zone target temperature press O or y until display shows desired temperature Repeat for RES zone 332144C Startup d Press to display actual temperatures 5 Circulate through heater until temperature readouts display desired temperature See Table 6 6 Adjust heat controls as necessary for a stable spray temperature Table 6 Approximate heatup time for starting a cold machine with 5 gallons 19 liters per side 120 V 230 V 35
5. 0U 332144 Parts Fluid Inlets 247986 ISO Inlet 24T982 RES Inlet A Align Y strainer as shown AN Apply sealant to all npt threads Do not apply to JIC threads A Apply thermal lubricant to thermometer probe A Torque fitting of bent tube to 45 50 ft lbs 61 67 Nem A Align bent tube to fitting within 2 A Align thermometer dial as shown ti21851a a ee ee E 5 N GRACO 8 5 44 _ 241986 241982 A A ti21852a o ee ee ee ee gee C M 114 41 Ref Part Description Qty 401 101078 STRAINER Y 402 15D757 HOUSING thermometer Viscon HP 403 102124 THERMOMETER dial 404 241983 VALVE ball 3 4 npt mxf T handle 405 241984 FITTING adapter JIC 12 X 3 4 mxm 406 24T985 TUBE assy inlet 1 407 160327 FITTING union adapter 90 1 332144 69 Parts 241960 Fluid Manifold A Apply sealant to assembled non swiveling pipe threads A Apply sealant and PTFE tape to threads A Apply sealant to valve threads Torque to 240 260 in Ibs 27 29 Nem A Apply lubricant to mating surfaces of valve base and handle A Apply lubricant to o rings on fittings Torque to 16 20 ft lbs 22 27 Nem A Align handles as shown when open B rs 457
6. a Remove protective tape from thermocouple tip b Apply PTFE tape and thread sealant to male threads and tighten thermocouple housing H into adapter 305 c Push in thermocouple 310 so tip T contacts heater element 307 d Holding thermocouple T against heater ele ment tighten ferrule nut N 1 4 turn past tight 9 Route wires S into cart and thread into bundle as before Reconnect wires to board 10 Replace heater shroud 90 and electronics cover 55 See FIG 15 page 48 11 Turn on heaters ISO and RES simultaneously to test Temperatures should rise at same rate If one heater is low loosen ferrule nut N and tighten ther mocouple housing H to ensure thermocouple tip T contacts element 307 Apply PTFE tape and thread sealant Apply 110009 thermal heatsink compound 307 A 308 ti7924a 49 Repair Overtemperature Switch 1 See Before Beginning Repair page 39 Wait for heaters to cool Remove heater shroud 90 and electronics cover 55 See FIG 15 page 48 Disconnect one leadwire from overtemperature switch 308 Fic 16 Test across switch with ohm meter Resistance must be approximately O ohms If switch fails test remove wires and screws Dis card failed switch Apply thermal compound 110009 install new switch in same location on housing 301 and secure with screws 311 Reconnect wires NOTE If wires need replacement disconnec
7. e Heaters perform better with lower flow rates or smaller mix modules e Triggering the gun for short periods helps maintain efficient heat transfer keeping material at the desired temperature Triggering the gun for a long period may not allow enough heating time depend ing on material temperature in tanks e temperature displays fall below acceptable limits A set function knob to Slow Recirculation 2j and cir culate again to bring temperatures back up e Each 35 ft 10 7 m hose bundle adds about 5 min utes to heatup time with most materials Maximum recommended hose length is 105 ft 32 m e Fora quicker start do initial heatup circulation with the tanks 1 4 to 1 3 filled then add more material 332144C Spraying NOTE Air is supplied to spray gun with gun piston safety lock or trigger safety lock engaged and gun fluid manifold valves closed if present gt Fusion Probler al 1 Setfunction knob to Stop Park 67 Verify system status indicator LED is on ti21490a oy 7 A Yo Yo ti21491a 3 Turn function knob to Pressure Adjust e Keep turning to the right until fluid pressure gauges show desired pressure ti21492a 332144C Spraying 4 Check fluid pressure gauges to ensure proper pres sure balance If imbalanced reduce pressure of higher component by slightly turning Recirc Spray valve for that component toward Recirc until gauges show
8. MPa bar Volts Model 35 ft 10 6 m Adapter 3000 APT100 21 207 120 V 241100 25R000 Fusion Air Purge 249810 P2T100 Mo 120 V 24T100 25 000 PROBLER GCP2RA 3000 Nort APT900 21 207 230 V 24R900 25R000 Fusion Air Purge 249810 APT901 Euros 230V 24R900 258000 Fusion Air Purge 249810 P APT902 EST 230 V 248900 259000 SUA Air Purge 249810 2 900 230 V 248900 25R000 2 PROBLER P2 GCP2RA 2 901 oe 2 230V 248900 25R000 PROBLER P2 GCP2RA P2T902 or ae 230V 248900 25R000 PROBLER P2 GCP2RA 3000 North 247900 21 207 290V 248900 24T901 3000 230 V 248900 Europe 21 207 3000 Australia 247902 20 29 2480 o Models The model no series letter and serial no are located on the back of the cart For faster assistance please have that information ready before calling Customer Service Maximum Bare Working Proportioner Electrical Pressure Part Series Connection psi MPa bar Approvals 20 A cord 3000 motor 21 207 20 A cord heaters 15 A cord 3000 o motor 21 207 Intertek 9902471 15 A cord Conforms to ANSI UL heaters Std 499 Certified to CAN CSA Std C22 2 No 88 See page 15 for detailed electrical requirements 8 332144C Related Manuals Related Manuals The following manuals are for Reactor E 10hp components and accessories Some are supplied wi
9. 50 Status Code 5 Excessive Current Draw 1 Shut off unit and retry operation Brushes may be fully seated 2 Check fan operation Elevated temperature can cause excessive current draw 3 Locked rotor motor unable to turn Replace motor page 53 4 Short on control board Replace board page 44 5 Worn or hung up motor brush causing arcing of brush at commutator Replace brushes page 54 6 Disconnect motor connections from the control board Cycle power a If status code 5 is still present replace the board b If status code 5 is not active test motor See Test Motor page 53 27 Troubleshooting Status Code 6 High Motor Temperature Motor is running too hot 1 Reduce pressure duty cycle gun tip size or move Reactor to a cooler location Allow 1 hour for cool ing 2 Check fan operation Clean fan and motor housing 3 Check J9 overtemperature connector on control board Status Code 7 No Cycle Counter Switch Input Have not received input from cycle counter switch for 10 seconds after selecting Recirc mode or unit is unable to park within 15 seconds of entering park mode 1 Verify that recirc valves are open and unit is set to Recirc mode 2 Check cycle counter switch connection to board J10 see FIG 12 page 45 3 Check that magnet 224 and cycle counter switch 223 are in place under RES side motor end cover 229 Replace if necessary Status Code 8 High Cycle R
10. page 54 34 332144C Troubleshooting Heaters 2 Shut off Motor Power Before performing any troubleshooting procedures Relieve pressure page 23 1 Shut off Power 4 Allow equipment to cool Try the recommended solutions in the order given for each problem to avoid unnecessary repairs Also determine that all circuit breakers switches and con trols are properly set and wiring is correct before assum ing there is a problem PROBLEM CAUSE SOLUTION Heat turned off Primary heater s does not heat Temperature control alarm Check temperature display for diag nostic code page 31 Signal failure from thermocouple See E04 Thermocouple discon nected page 32 Failed heater element Check resistance of heater elements See Test Heater Element page 48 Control of primary heat is abnormal Dirty thermocouple connections Examine connection of thermocou high temperature overshoots or E01 ples to long green plug on heater error occurs intermittently control board Unplug and re plug thermocouple wires cleaning off any debris For 120V unplug and re plug long green connector For 230V unplug and re plug green connec tor s B Thermocouple not contacting heater Loosen ferrule nut push ther element mocouple 310 so tip T contacts heater element 307 Holding ther mocouple tip T against heater ele ment tighten ferrule nut N 1 4 turn
11. past tight See page 49 for illustra tion Failed heater element See Heaters page 35 oignal failure from thermocouple See E04 Thermocouple discon nected page 32 Thermocouple wired incorrectly See E04 Thermocouple discon nected page 32 Power up zones one at a time and verify that tempera ture for each zone rises 332144C 35 Troubleshooting Proportioner 2 Shut off Motor Power Before performing any troubleshooting procedures ae E 3 Relieve pressure page 23 1 Shut off Heater Power 4 Allow equipment to cool Try the recommended solutions in the order given for each problem to avoid unnecessary repairs Also determine that all circuit breakers switches and con trols are properly set and wiring is correct before assum ing there is a problem PROBLEM CAUSE SOLUTION Reactor does not operate No power Plug in both power cords Cycle Motor Power and Heater Power off then JE aisi to reset both breakers Motor does not operate Power turned on while function knob set to a run position Set function knob to Stop Park once status LED turns on Then select desired function Loose connection on control board Check connection at motor power connections on bottom board See FIG 12 page 45 Worn brushes Check both sides Replace brushes worn to less than 1 2 in 13 mm see page 54 Broken or misaligned brush springs Realign or r
12. within the setpoint limits Press target key prior to adjusting RES Setpoint Decrease Decreases the temperature setpoint by one degree in the units selected within the setpoint limits Press target key prior to adjusting ISO Heater On Off Key Turns heater on or off for ISO zone Also clears heater zone diagnostic codes see page 31 RES Heater On Off Key Turns heater on or off for RES zone Also clears heater zone diagnostic codes see page 31 G Actual Temperature Key Press to display actual temperature Press and hold to display electrical current Target Temperature Key Press to display target temperature Press and hold to display heater control circuit board temperature Temperature Scale Key F Press to change temperature scale to degrees Fahrenheit Temperature Scale Key C Press to change temperature scale to degrees Celsius Temperature Display Show actual temperature or target temperature of heater zones depending on selected mode Defaults to actual at startup Range is 32 170 F 0 77 C for ISO and RES UJ lI Alo TI TI U O Heater Indicators ISO Heater Activity LEDs flash when heater zones are on The duration of each flash shows the extent that the heater is turned on RES Heater Activity LEDs flash when heater zones are on The duration of each flash shows the extent that the heater is turned on O Actual Temperatures Active Actual temperatures are displayed P Target Temperatures Acti
13. 230 V Proportioner SAY AAN SN FSV 2 IN S z 2 7 AN o S TAR pS LONI iL E 2 y y gt US 5 8 Y A P 6 LN WAN A gt N O N S d a 9 LY 7 7 x y A 4 7 Y 27 WA A Ar WT d Y 2 227 30 30a ti21853b 332144C 58 Parts ti21855b 59 332144C Parts 2 20 1 ti21854a lt N PR A ERS Le L 332144C 60 Parts N Apply sealant to all non swiveling pipe threads A Orient SSR with terminals 1 and 2 towards the top A Apply sealant to threads of nut cap A Orient fan to flow down and connector plug towards the back A Apply lubricant to thread and axle of cart Ad Orient heater module with fins outwards A Apply even distribution of thermal grease on bottom of metal N Assemble sensor flush to tank surface surface of solid state relays Install clamp on ferrite near termination of transducer wires A Torque to 125 in lbs 14 Nem See FIG 24 page 73 A Torque to 150 in lbs 17 Nem Install clamp on ferrite on black and red motor power wires See FIG 24 page 73 LN Assemble nut to finger tight only 24T100 120 V Proportioner 24R900 230 V
14. 7 Instructions Parts GRACO EN 332144C Reactor E 10hp For spraying or dispensing polyurea coatings and polyurethane foam For professional use only Not approved for use in explosive atmospheres or hazardous locations 207 bar Maximum Working Pressure 3000 psi 21 MPa Important Safety Instructions Read all warnings and instructions in this manual Save these instructions e CN 22 NN abe i 7 ti21488a PROVEN QUALITY LEADING TECHNOLOGY Contents amp rs eee eee 3 Important Isocyanate ISO Information 6 Isocyanate Conditions 6 Material Self ignition 6 Keep Components ISO and RES Separate 6 Moisture Sensitivity of Isocyanates 6 Foam Resins with 245 fa Blowing Agents 6 Changing Materials 7 SVSIEMS cu ice no a det M 8 16161 nO te E AR dead 8 Related Manuals 9 OVCIVIOW osx aded xp Lad Gau i 10 Component Identification 11 Controls and Indicators 12 Heater Controls 12 System Controls 12 Controls and Indicators 13 SEMUD Locos wis EUM LE d De E EA 15 Locate Reactor 15 Electrical Requirements 15 Ground System
15. A 463 ti21838a Ref Part Description Qty Ref Part Description Qty 460 127130 FITTING straight JIC 5 x 2 451 24 961 MANIFOLD fluid 1 SAE ORB 452 102814 GAUGE pressure fluid 2 461 127128 7 45 elbow JIC 5 mxf 2 2 SWIVe posi m aan 462 127131 FITTING straight JIC 6 2 SAE ORB 453b 111699 GASKET 1 463 127129 FITTING 45 elbow JIC 6 mxf 2 454 224807 BASE valve 2 SWIVEL 455 187625 HANDLE valve drain 2 4644 189285 LABEL warning hot surface 1 456 111600 PIN grooved A Replacement Danger and Warning labels tags and 457 16V434 FITTING 90 elbow JIC 6 2 cards are avallable at no cost SAE ORB 458 119789 FITTING elbow street 45 2 459 162453 FITTING 1 4 x 1 4 npt 2 70 332144C 25R000 Insulated Hose Bundle with Recirculation Lines Ref Part Description Qty 501 24R996 HOSE fluid component ISO 2 moisture guard 1 4 in 6 mm ID no 5 JIC fittings mxf 35 ft 10 7 m 502 249997 HOSE fluid component RES 1 4 2 in 6 mm ID no 6 JIC fittings mxf 35 ft 10 7 m Outlet Manifold ti21846a N Apply lubricant to o rings A Orient housing with exhaust hole pointing down Ref Part Description Qty 551 241976 MANIFOLD fluid pump outlet 1 552 247520 HOUSING rupture disc 1 553 111457 PACKING o ring 1 554 24K999 TRANSDUCER pressure control 1 332144C Ref 903 504 505 16991 Part Description 15G342 HOSE air 1 4 in 6 mm ID 1 4 npsm
16. Generator Size 120 V 230 V Heater Power 120 V 230 V Sound Pressure 7500 W minimum 3000 W during recirculation 2000 W during pressure spray mode 4000 W during recirculation 2760 W during pressure spray mode In fast recirculation mode 71 3 dB A Measure at 2500 psi 17 MPa 172 85 6 dB A bar 1 3 8 lpm Sound Power In fast recirculation mode 79 9 dB A Measure at 2500 psi 17 MPa 172 93 3 dB A bar 1 3 8 lpm 332144C Technical Data Fluid Outlets ISO Side 5 JIC male RES Side 6 JIC male Fluid Circulation Returns ISO side 5 JIC male RES side 6 JIC male Hose Markings ISO side RES side Wetted Parts Wetted parts on all models Aluminum stainless steel carbon steel brass carbide chrome chemically resistant o rings PTFE ultra high molecular weight polyethylene Sound power measured per ISO 9614 2 All other brand names or marks are used for identification purposes and are trademarks of their respective owners 76 332144C Notes Notes 332144C 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 o
17. Identification 332144C 10200702 Component Identification Desiccant Dryer Recirculation Tubes Air Line Inlet quick disconnect fitting Outlet Hose Connections Return Hose Connections Fluid Temperature Sensors located on heater assembly under shroud Hose Rack and Control Shield Fluid Inlet Ball Valves each side Fluid Inlet Strainers each side Power Cords not shown Fluid Temperature Gauges each side Air Filter Moisture Separator 11 Controls and Indicators Controls and Indicators See Controls and Indicators identification table page 13 Heater Controls AA AB AC AD AG AH To prevent damage to soft key buttons do not press the buttons with sharp objects such as pens plastic cards or fingernails FiG 2 Heater Controls and Indicators System Controls AW AX AT AU AL AE AF AJ AK AY STATUS 0 AV Fic 3 System Controls and Indicators 12 332144C Controls and Indicators Controls and Indicators Heater Controls AA ISO Setpoint Increase Increases the temperature setpoint by one degree in the units selected within the setpoint limits Press target key prior to adjusting ISO Setpoint Decrease Decreases the temperature setpoint by one degree in the units selected within the setpoint limits Press target key prior to adjusting RES Setpoint Increase Increases the temperature setpoint by one degree in the units selected
18. balanced pressures The pressure imbalance alarm Status Code 1 is inactive for 10 seconds after entering spray pressure mode to allow time to balance pressures In this example RES side pressure is higher so use the RES side valve to bal ance pressures ti21493a NOTE Watch gauges for 10 seconds to be sure pres sure holds on both sides and pumps are not moving 5 Open gun fluid manifold valves impingement mix guns only T 224 Fusion Probler NOTE On impingement guns never open fluid manifold valves or trigger gun if pressure are imbalanced 6 Disengage piston safety lock or trigger safety lock Tr lt Fusion Probler 7 Test spray onto cardboard or plastic sheet Verify that material fully cures in the required length of time and is the correct color Adjust pressure and temperature to get desired results Equipment is ready to spray 21 Pause Pause To bring the hose and gun back to spray temperature after a brief break use the following procedure 1 Engage piston safety lock or trigger safety lock Fusion Probler NE A 2 Setfunction knob to Slow Recirc Os 121494 3 Set Recirc Spray valves to Recirc until temperature readouts come back up t121495a 4 Ifyou stop spraying for more than 2 minutes when using an impingement mix gun close gun fluid valves Doing this will keep the internal parts of the gun cleane
19. fbe 35 ft 10 7 m buy TUBE foam insulated 1 3 8 in locally 35 mm ID 31 ft 9 5 m 156971 NIPPLE 1 4 npt for joining air line to another hose bundle Parts Qty 1 1 1 71 Parts 5 4 15 Say NIVIN z ti23356a VCH COH CH MAIN HEAT Hee O U d E 2 n gt 211 4112 613 14 T4 a ES 0 90H mr 9 x cH gt bib lt lt 59 z gt aia 0 pi lt OSI 15008 9 6 ros gy ANO E 7 2 O 23 CY CN 23 Power Harness 78 Wire Identification 332144 Parts ti23357a OTOR OTSWITCH ANK LVL SENSOR RED BOOST FEAT LED TRANSDUCER ISO TRANSDUCER RES YELLOW TANK LED RED MOTOR LED 24 332144C 73 Suggested Replacement Parts Suggested Replacement Accessories Parts Part 24K984 24K983 101078 180199 114228 239914 24L002 24K999 24L006 249855 241975 Part Description 24E727 Probler Recirc Kit Description 24U342 Lift Ring Kit DRYER desiccant SWITCH motor or heater power with circuit breaker Y STRAINER includes 180199 element ELEMENT Y strainer 20 mesh ELEMENT air filter 5 micron polypropylene VALVE recirc spray includes seat and gas ket POTENTIOMENTER control knob TRANSDUCER pressure PUMP displacement fits either side REPAIR KIT displacement pump
20. includes seals balls bearings intake seat O RING tank lid Dimensions 74 46 in 1168 mm 332144C Technical Data Technical Data JJ O O e m Maximum fluid working pressure 3000 psi 20 6 MPa 206 bar Maximum spray pressure 120 V 2200 psi 15 2 MPa 152 bar Maximum spray pressure 230 V 2500 psi 17 2 MPa 172 bar Maximum fluid temperature 170 F 77 C gt Maximum ambient temperature 48 C Maximum output 3 8 liters min Output per cycle ISO and RES 0 0038 gallons cycle 0 014 liters cycle Air inlet 1 4 in quick disconnect industrial type pin fitting Air outlet 1 4 nosm m Overpressure relief Recirc Spray valves automatically relieve excessive fluid pressure back to supply tanks Gun compressed air requirements Fusion Gun purge air and operating air 4 scfm 0 112 m min Maximum hose length 105 ft 32m Tank capacity each nominal 22 7 liters Weight empty 239 lb 108 kg Recommended Mix Chamber Sizes Fusion Air Purge 000 AW2222 00 and 01 at reduced spray pressure Probler P2 AA 00 and 01 at reduced spray pressure Electrical Requirements 120 V 120 VAC 1 phase 50 60 Hz 3840 W requires two separate dedicated 20 A circuits Full load peak amperage 16 A per circuit 230 V 230 VAC 1 phase 50 60 Hz 5520 W requires two separate dedicated 15 A circuits Full load peak amperage 12 A per circuit 5000 W minimum
21. 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 presente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires executes donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les procedures 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 For patent information see www graco com patents Original instructions This manual contains English MM 332144 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2013 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com Revised March 2014
22. material you have before pouring it in the supply tanks Pouring is easier If pails are not filled to the top Open only one supply tank at a time to avoid splash ing material from one tank into the other when filling NOTE Using a drill and mixing blade mix filled or sepa rated materials in the pail before adding to the tanks Material left in the tanks overnight may need to be remixed in the tanks 332144C Setup 1 Lift hose rack Remove tank cover and pour ISO into tank red side with desiccant filter in cover Replace cover AN 486 5 10 oot 2 A A ISO 7 4 N 1 A lt A AN Add thin coating of grease lubricant to tank o ring if lid is difficult to assemble to tank NOTE Desiccant filter is blue when fresh and turns pink when saturated Be sure shipping plugs are removed from openings on desiccant filter 2 Remove tank cover and pour resin into RES tank blue side Replace cover A 17 Setup Purge Air and Flush Fluid From 5 Turn on Motor Power System status indicator AY should turn on Lines To avoid fire and explosion 6 Flush equipment only in a well ventilated area Ensure main power is off and heater is cool before flushing Do not turn on heater until fluid lines are clear of solvent ti21495a 1 Remove both recirculation tubes P from the tanks a secure each in a dedicated waste
23. ventilation is not available a supplied air respirator is required for everyone in the work area To prevent contact with isocyanates appropriate per sonal protective equipment including chemically impermeable gloves boots aprons and goggles is also required for everyone in the work area Material Self ignition Some materials may become self igniting if applied too thick Read material manufacturer s warnings and material MSDS Keep Components ISO and RES Separate 1 Cross contamination can result in cured material in fluid lines which could cause serious injury or damage equipment To prevent cross contamination e Never interchange ISO and RES wetted parts e Never use solvent on one side if it has been con taminated from the other side Moisture Sensitivity of Isocyanates Exposure to moisture such as humidity will cause ISO to partially cure forming small hard abrasive crystals which become suspended in the fluid Eventually a film will form on the surface and the ISO will begin to gel increasing in viscosity NOTICE Partially cured ISO will reduce performance and the life of all wetted parts e Always use a sealed container with a desiccant dryer in the vent or a nitrogen atmosphere Never store ISO in an open container Keep the ISO pump wet cup or reservoir if installed filled with
24. yellow LED turns on 6 Slowly turn the adjustment screw S counterclock wise until the yellow LED barely turns off 56 7 Slowly turn the adjustment screw S counterclock wise an additional 1 2 turn NOTE The yellow LED should stay turned off 8 Fill tank with desired material and verify that sensor detects material The yellow LED will turn on when material reaches the one gallon mark If the yellow LED does not turn on after two gallons of the material then the material density may be too low and is not detected by the sensor Turn the adjustment screw clockwise in 1 8 turn increments until sensor detects the material and the yellow LED turns on NOTE If the adjustment screw is turned a total 1 2 turn then it will not detect an empty tank 9 Reinstall the shroud 89 332144C Parts System Packages 16W239 15G958 Package 101 102 npo PartNo Region APT100 24T100 25 000 249810 2 100 24 100 25R000 GCP2RA APT900 24R900 25R000 249810 16W239 North America APT901 24R900 25R000 249810 15G958 APT902 24R900 25R000 249810 15G962 Australia Asia P2T900 24R900 25R000 GCP2RA 16W239 North America P2T901 24R900 25R000 GCP2RA 15G958 P2T902 24R900 25R000 GCP2RA 15G962 Australia Asia Probler packages use recirc accessory kit 24 727 Not included 332144C Parts 57 Parts E 10hp Proportioners 241100 120 V Proportioner 24R900
25. 0 psi 2 1 MPa 21 500 psi 3 5 MPa 35 Causes deviation if pressure setpoint is greater than bar bar 25 if lt 800 psi 5 6 40 if lt 800 psi 5 6 MPa 56 56 bar DIP Switch 5 DEVIATION SHUTDOWN Causes shutdown or displays a status code for low fluid level in tanks DIP Switch 6 DISABLE ENABLE Enables or disables boost heat DIP Switch 7 Not used Default DIP Switch Settings DIP Switch 1 and 2 Settings 300 psi 2 1 MPa 21 bar 300 psi 2 1 500 psi 3 5 MPa 21 bar MPa 35 bar 500 psi 3 5 800 psi 5 6 MPa 35 bar MPa 56 bar a a a 500 psi 3 30 332144 Troubleshooting Heat Control Diagnostic Codes e Failed heater element where thermocouple is installed Heat control diagnostic codes appear on the tempera e Loose wire ture display E01 Checks These alarms turn off heat Codes E03 and E04 can be cleared by pressing O 1 Toclear other codes 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 2 Shut off Heater Power NOTE Before checking the thermocouple note which zone ISO or RES has high fluid temperature 1 Check that connector B is firmly plugged into heater control module See Temperature Control Mo
26. 4 Install new heater element 307 holding mixer 309 so it does not block thermocouple port P 5 Reinstall thermocouple page 49 ti21845a 6 Reconnect heater element leadwires to heater wire FiG 15 connector 7 Replace heater shroud 90 and electronics cover 55 Line Voltage The primary heaters output their rated wattage at either 120 Vac or 230 Vac depending on system Low line voltage will reduce power available and the heaters will not perform at full capability 48 332144C Thermocouple 1 See Before Beginning Repair page 39 2 Wait for heaters to cool 3 Remove heater shroud 90 and electronics cover 55 See FIG 15 page 48 4 Loosen and remove temperature control module bracket mounting fasteners 56 Move control mod ule up and out of the way to access thermocouple 5 Disconnect thermocouple wires from B on tempera ture control module See Temperature Control Modules Connections page 47 6 Clip cable ties as necessary Note path as wires must be replaced in the same way 7 See FIG 16 Loosen ferrule nut N Remove ther mocouple 310 from heater housing 301 then remove thermocouple housing H Do not remove the thermocouple adapter 305 unless necessary lf adapter must be removed ensure that mixer 309 is out of the way when replacing the adapter lI 309 FIG 16 Thermocouple 332144C 301 305 Repair 8 Replace thermocouple FIG 16
27. Adjust position of tank fluid level sensor 57 so that the sensor contacts the surface of the tank 1 Loosen sensor jam nuts and press sensor 57 against the tank 2 Spin on inner jam nut until flush then tighten inner jam nut one more turn Retighten outer jam nut 8 8 2 D Q 5 TT v 1 ti21849a 5 N Replace 1 Loosen jam nuts and remove level sensor assembly 57 2 Remove supply tank see page 39 3 Cut zip ties securing the sensor cable to the cart 4 Remove the display control cover 26 ti21923a 5 Disconnect level sensor connector from J6 on con trol board See FIG 12 page 45 332144C Repair 6 Route new tank level sensor cable through grommet on bottom of cart and through the grommet on bot tom of control panel Connect new level sensor 57 to J6 7 Install the display control cover 26 8 Zip tie tank level sensor cable with other low voltage cables 9 Reinstall supply tank See page 39 10 Adjust position of level sensor assembly 57 See Adjust 11 Set sensitivity See Reset Sensitivity page 56 12 Check operation of both sensors a Hold one hand inside both tanks for 5 seconds near inner wall where the tank level sensor is located b The tank level indicator LED on the control panel will stop flashing when it sens
28. FUSE 5A 5 x 20 mm 127239 CONNECTOR 5 pin 127240 CONNECTOR 10 pin 751 120748 CONNECTOR 2 pin 6 127237 CONNECTOR 6 pin 7 116171 BUSHING strain relief 16W761 BUSHING strain relief 247994 24985 ORF 247596 150 241997 2x 247598 3 247999 4 240008 CORD 20 120 V 240000 CORD 16A 230 V 113505 NUT keps hex hd 125835 CLIP ferrite bead 24U001 COVER proportioner lower 24U002 COVER proportioner upper 115492 SCREW mach slot hex wash hd 24U003 GUARD splash hose rack 24U004 RACK hose 120008 PLUG tube 120150 ISOLATOR pad rubber 119999 BOLT shoulder 110533 WASHER flat nylon 1 4 15G280 LABEL safety warning multiple 189930 LABEL electric shock 104 217374 LUBRICANT ISO pump A Replacement Danger and Warning labels tags and cards are available at no cost Not shown 1 241993 E E 00 5 8 00 N EEN 20121111 EME ESE E 211121 2212 eer ELA pee 22 11 18 A ee See FIG 23 on page 72 Not available for purchase 64 332144C Parts 241954 120 V and 230 V Bare Proportioner 201 208 steel 209 A A A 210 bronze 211 bronze 213 A Apply lubricant to all gear teeth motor pinion and motor endbell on both sides of motor A App
29. Proportioner 24T100 24R900 1 2 BRACKET 4 BRACKET gusset cart 5 BRACKET motor mount 110996 NUT hex flange head 101765 GROMMET 119975 GRIP vinyl gray 1 25 in 154636 WASHER flat 10 SPRING compression 11 WASHER flat nylon 2 news we 8 RING retaining ext a 24964 PROPORTIONER ses page 65 3 3 18 T9749 SCREW mach hexwasherha 420 16 FAN cooling 120 VAC FAN cooling 230 V 2 24U009 HEATER assy 120V 1000W see page 67 241955 HEATER assy see page 67 167002 INSULATOR heat 2 108296 SCREW mach hex wash hd 10 N N gt gt 241960 MANIFOLD outlet recirc see page 70 241962 DISPLAY control see page 68 117623 NUT cap 3 8 16 24U005 DIODE light emitting 120 V 241970 DIODE light emitting 230 V 24R648 COVER display 1 332144C 61 N MIN PO O N O OO N Parts Quantity X 00 24R900 Description BENE V EM V 27 241973 TAK Tr SCREW Ep PERRO Hene SCREW Bak 30 241875 UiDrincludes o ring 803 201020 mmm ORNG 24K976 MUFFLER 1 4 NPT WASHER plain CABLE sst lanyard 14 in DRYER desiccant mini in line E MM I ol RS 100176 BUSHING hex hex LEES 24K977 FILTER regulator air with 3 8 npt auto drain includ
30. RD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and explosion Use equipment only in well ventilated area Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present Ground all equipment in the work area See Grounding instructions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail Do not use pail liners unless they are antistatic or conductive Stop operation immediately if static sparking occurs or you feel a shock Do not use equipment until you identify and correct the problem Keep a working fire extinguisher in the work area THERMAL EXPANSION HAZARD Fluids subjected to heat in confined spaces including hoses can create a rapid rise in pressure due to the thermal expansion Over pressurization can result in equipment rupture and serious injury e Open valve to relieve the fluid expansion during heating e Replace hoses proactively at regular intervals based on your operating conditions PRESSURIZED ALUMINUM PARTS HAZARD Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture Failure to follo
31. ROBLEM CAUSE SOLUTION ISO side rich lack of RES side RES side rich lack of ISO side Tank level sensor does not sense empty tank indicator LED on control panel never blinks Tank level sensor does not sense full tank indicator LED on control panel always blinking 38 ISO side gauge is low RES side restriction downstream of gauge Check gun check valve screen mix module or mix manifold restrictor RES side gauge is low RES side material supply problem Check RES side inlet strainer and pump intake valve ISO side gauge is low ISO side material supply problem Check ISO side inlet strainer and pump intake valve RES side gauge is low ISO side restriction downstream of gauge Check gun check valve screen mix module or mix manifold restrictor Material build up Flush and clean inside of tanks Clean outside of sensor and recessed area on tank LED wires disconnected inside con LED wires trol panel Tank level sensor sensitivity is too Reset tank fluid level sensor sensitiv high ity page 56 Tank level sensor is too far away Check position of both tank level sen from tank sors See Tank Fluid Level Sen sors page 55 Sensor wires disconnected Reconnect sensor wires in display panel Tank level sensor sensitivity is too Reset tank fluid level sensor sensitiv low ity page 56 332144C Repair Before Beginning Repair Repairing this equipment requires acc
32. S side drive housing cover 229 includes the cycle counter switch 223 mounted in the cover When reassembling be sure to install cover with switch on RES side 0 6 in 15 2 mm from inside edge 1 0 in 25 4 mm from inside bottom edge 17028 208 209 steel bronze 211 bronze ti21847a 219 X NE A Crankshaft must be in line with crankshaft at other end of motor so pumps move up and down in unison FIG 18 Drive Housing 52 332144C Repair Electric Motor To prevent dropping the motor two people may be Test Motor required to lift If motor is not locked up by pumps it can be tested using a 9 V battery 10 Remove screws 15 holding motor 201 to bracket Lift motor off unit 1 Open recirculating valves 11 If replacing motor remove shroud mounting bolts 2 Disconnect motor connections from control board 207 and brackets 233 and set aside see FIG 12 page 45 Touch jumpers from battery to motor connections Motor should turn slowly and Installation smoothly 1 If replacing motor install fan assemblies 16 and shroud mounting brackets 233 on new motor Removal 201 NOTE See wiring schematic page 45 2 Place motor 201 and fans 16 on unit Thread motor switch harness through grommets in cart and into the back of the display See FIG 24 on page 73 3 Fasten motor 201 with screws 15 underneath 1 See Befor
33. Temperature The motor control board is too hot Shutdown and move Reactor to a cooler location Allow 1 hour for cooling Status Code 15 19 Motor Controller Faults Cycle power If error is still present replace board See page 44 332144C DIP Switch Settings To avoid electric shock always unplug both power cords before servicing Reactor and wait one minute 1 Turn power off and unplug power cords from wall outlets 2 Remove screws and display cover 26 ti21923a 3 Locate the DIP switch on the control board Fic 6 DIP Switch 4 Set DIP switches to the desired positions See DIP Switch Settings and Functions page 30 5 Replace display cover 26 and plug in unit 6 Cycle power switch to activate changes to DIP switch 332144C Troubleshooting 29 Troubleshooting DIP Switch Settings and Functions DIP Switch Settings and Functions DIP Switch 1 DEVIATION DEVIATION AND If selected displays a status code or displays a status code SHUTDOWN and causes shutdown if the pressure imbalance exceeds selection made in DIP Switch 2 DIP Switch 2 Select pressure imbalance limits that if exceeded will cause See Dip Switch 1 and 2 Settings table page a deviation and a shutdown if enabled 30 DIP Switch 3 DEVIATION SHUTDOWN If selected causes shutdown or displays a status code due to deviation of pressure from setpoint exceeds selection made in DIP Switch 4 DIP Switch 4 30
34. UT 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
35. appropriate lubricant The lubricant creates a barrier between the ISO and the atmosphere Use only moisture proof hoses compatible with ISO Never use reclaimed solvents which may contain moisture Always keep solvent containers closed when not in use Always lubricate threaded parts with an appropri ate lubricant when reassembling NOTE The amount of film formation and rate of crystal lization varies depending on the blend of ISO the humidity and the temperature 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 332144C Important Isocyanate ISO Information Changing Materials NOTICE Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime When changing materials flush the equipment multiple times to ensure it is thoroughly clean Always clean the fluid inlet strainers after flushing Check with your material manufacturer for chemi cal compatibility When changing between epoxies and urethanes or polyureas disassemble and clean all fluid com ponents and change hoses Epoxies often have amines on the RES hardener side Polyureas often have amines on the RES resin side 332144C 7 Systems Systems Working Pressure Unheated psi Proportioner Hose Cord
36. as shown Remove tape from probe tip prior to inserting Insert probe until tip bottoms on heater element Tip must touch heating element Insert ferrule and tighten ferrule nut to sensor probe Orient sensor as shown and torque 1 4 turn past tight Ref 308 Part 15B137 Description Qty SWITCH overtemperature 309 310 311 312 316 16U940 117484 124132 241959 240014 MIXER heater SENSOR SCREW mach 46 32 O RING HEATER fire rod 230 V 241955 only HEATER fire rod 120 V 24U009 only Not available for purchase NEXNN NO 67 Parts 241962 Display Ref 351 352 353 354 355 356 357 358 359 360 361 363 364 68 Part 24T963 241964 247966 247967 24K983 241001 241002 156053 300005 117523 127157 127158 241968 Description PLATE display front ENCLOSURE control DISPLAY heat two zone CONTROL board assy SWITCH rocker w breaker 240v 20a KNOB control w ball plunger POTENTIOMETR adjustment pressure PLATE detent display FILTER board NUT cap 10 SCREW mach captive 8 NUT captive 8 DIODE light emitting red Qty A coo Ref 365 366 367 368 373 Part 241971 113505 101765 127019 ti21841a Description DIODE light emitting yellow CLAMP cable NUT keps hex hd GROMMET CONNECTOR jumper e stop Not available for purchase Qty
37. ate System is spraying more than 1 gpm System will shut down if spraying more than 1 1 gpm 1 Reduce pressure and or gun tip size Status Code 9 Low Tank Level The tank level sensors sense ISO and RES material density inside the tank and warns or shuts down depending on settings of DIP switch 5 See DIP Switch Settings page 29 1 Add material to supply tank if necessary 2 Check that the tank level sensor is in contact with the surface of the tank Replace if necessary See Tank Fluid Level Sensors page 55 28 3 Check J6 connections on control board See Table 8 page 45 Level Sensor LED Sensor is powered Sensor is not powered Sensor detects material Yellow off Sensor does not detect material Status Code 11 Locked Motor Rotor Verify that pumps are not seized and move freely The motor is unable to turn Replace motor page 53 Shut off unit and contact distributor before resuming operation Status Code 12 Motor Controller Overvoltage Too much voltage connected to control board See Technical Data page 75 for power requirements Cycle power and check status indicator to see if error is still active Status Code 13 Motor Controller Undervoltage Not enough voltage connected to control board See Technical Data page 75 for power requirements Cycle power and check status indicator to see if error is still active Status Code 14 Motor Controller High
38. ball valve and quick disconnect coupler to the gun air hose then connect the coupler to the gun air fitting Connect Main Air Supply Connect the main air supply to the quick disconnect fit ting on the unit Air supply hose must be at least 5 16 in 8 mm ID up to 50 ft 15 m or 3 8 in 10 mm ID up to 100 ft 30 m NOTE Air Filter Moisture Separator Z is equipped with an automatic moisture drain Flush Before First Use The Reactor is tested with a plasticizer oil at the factory Flush out the oil with a compatible solvent before spray ing See Flushing page 25 332144C Fill Wet Cups Keep the felt washers in the pump wet cups saturated with Graco ISO pump oil Part No 217374 The lubricant creates a barrier between the ISO and the atmosphere Pump rod and connecting rod move during operation Moving parts can cause serious injury such as pinching or amputation Keep hands and fingers away from wet cup during operation Shut off Motor Power lt VJ before filling wet cup Fill wet cups through slots in plate or loosen screws and swing plate aside NOTICE To prevent cross contamination of fluids and equip ment parts never interchange isocyanate and resin parts or containers Have at least two 5 gal 19 liter pails to transfer fluid from drums to supply tanks Label one pail ISO and the other RES using the red and blue labels pro vided Always double check which
39. crankshaft 210 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 bear ings 209 211 213 gear reducer 214 crankshaft 210 and inside drive housing 215 Grease is supplied with replacement parts kits NOTE RES side crankshaft 210 includes the cycle counter magnet 224 When reassembling be sure to install crankshaft with magnet on RES side If replacing crankshaft remove magnet 224 Reinstall magnet in center of offset shaft on new crankshaft Posi tion shaft in Park position 2 Install bronze bearings 211 213 in drive housing 215 as shown 3 Install bronze bearings 209 211 and steel washer 208 on crankshaft 210 Install bronze bearing 213 and steel washer 212 on gear reducer 214 332144C Repair 4 Install gear reducer 214 and crankshaft 210 into motor end bell MB NOTE Crankshaft 210 must be in line with crankshaft at other end of motor Pumps will move up and down together NOTE If connecting rod 216 or pump 219 were removed reassemble rod in housing and install pump page Displacement Pump page 41 5 Push drive housing 215 onto motor 201 Install screws 220 6 Install drive housing covers 229 and screws 207 Pumps must be in phase both at same position in stroke 51 Repair Replace Cycle Counter Switch NOTE RE
40. d ules Connections page 47 2 Clean and re plug connections 4 Turn on Motor Power and Heater power to clear 3 Check connections between the temperature con trol module and overtemperature switch and between the temperature control module and ther Code Code Name Alarm Corrective Zone Action page mocouples Ensure all wires are securely connected to connector B on heater control module See Table High fluid temperature Individual 7 page 32 High zone current Individual 04 Thermocouple con Individual nected E01 High Fluid Temperature e Thermocouple ISO or RES 310 senses a fluid tem perature above 260 F 71 C e Overtemperature switch ISO or RES 308 senses fluid temperature above 230 F 110 C and opens At 190 F 87 C the switch closes again e Thermocouple ISO or RES 310 fails is damaged is not touching the heater element 307 or has a poor connection to the temperature control board e Overtemperature switch 308 fails in the open posi tion e The temperature control board fails to turn off any heat zone e Zone power wires or thermocouples are switched from one zone to another 332144C 31 Troubleshooting 4 Remove connector B from heater control module and check continuity of thermocouples by measur ing resistance across pins on the plug end 5 Verify fluid temperature using an external tempera ture sensing device Table 7 Connector B Resis
41. e Beginning Repair page 39 Do not tighten yet 2 Relieve pressure page 23 4 Plug motor temp switch harness to connector J9 and grounding cable from grounding screw 3 Remove four screws 91 shroud 89 and mount ing brackets 233 See Fic 18 5 Plug in motor power connector 4 Remove fans 16 and disconnect cable 80 See 6 Secure all cables to cart frame with zip ties FIG 20 7 Install display control cover 26 5 Remove drive housing pump assemblies page 51 8 Install supply tank 6 Remove display control cover 26 Disconnect motor cables as follows 9 Install drive housing pump assemblies page 51 Reconnect inlet assemblies to pumps a Unplug motor power connector before ferrite 88 10 Torque screws 15 to 150 in Ibs 17 11 Return to service b Unplug motor temp switch harness from con nector J9 and remove grounding cable from grounding screw 7 Remove RES supply tank See Remove Supply Tank page 39 8 Cut zip ties 9 Thread motor power switch harness and over temp switch out bottom of control module and cable chan nel to free motor 332144C 53 Repair Motor Brushes 9 See instruction sheet 406582 included with Brush Repair Kit 287735 NOTE Replace brushes worn to less than 1 2 in 13 mm Brushes wear differently on each side of motor check both sides Brush Repair Kit 287735 is available kit includes instruction sheet 406582 NOTE Motor commuta
42. ensor B Connections B 2 4 5 3 B2 1 5 Thermocouple ISO R red B2 2 6_ Thermocouple ISO Y yellow B2 4 8 Thermocouple RES red B2 5 9 RES Y yellow B2 3 Bi 94710 Unsed 1 POWER RELAY HEATER T C HEATER T C ISO RES OVER Eo RES R Y X R DATA DISPLAY TEMP R R FIG 14 Temperature Control Module Connections COMMUNICATION PROGRAM 332144C 47 Repair Heater 4 Disconnect heater element wires from heater wire connector Test with onmmeter Replace heater ele ment if the resistance reading does not fall within Test Heater Element the range SEX Heater NA Heater Wattage Per Element Voltage Zone Wattage 1 See Before Beginning Repair page 39 E 2 Wait for heater to cool 120 1500 24 32 1000 12 16 3 Remove heater shroud 90 and electronics cover 230 2000 620 73 94 55 1380 32 43 Remove Heater Element 1 To remove heater element first remove thermocou ple 310 to avoid damage see step 7 page 49 2 Remove heater element 307 from housing 301 Be careful not to spill any fluid left in housing 3 Inspect element NOTE It should be relatively smooth and shiny If there is a crusted burnt ash like material adhered to element or sheath shows pitting marks replace element p e 2 2
43. ent only for its intended purpose Call your distributor for information Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not kink or over bend hoses or use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations MOVING PARTS HAZARD Moving parts can pinch cut or amputate fingers and other body parts e Keep clear of moving parts e Do not operate equipment with protective guards or covers removed e Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure and disconnect all power sources BURN HAZARD Equipment surfaces and fluid that s heated can become very hot during operation To avoid severe burns e Do not touch hot fluid or equipment Important Isocyanate ISO Information Important Isocyanate ISO Information Isocyanates ISO are catalysts used in two component materials Isocyanate Conditions y nm uae Spraying or dispensing materials containing isocya nates creates potentially harmful mists vapors and atomized particulates Head 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 ventila tion in the work area If sufficient
44. eplace page 54 Brushes or springs binding in brush Clean brush holder and align brush holder leads for free movement Shorted armature Replace motor page 53 Check motor commutator for burn Remove motor Have motor shop spots black pitting or other damage resurface commutator or replace motor page 53 Failed control board Replace board See page 44 Pump output low Plugged fluid inlet strainer Clear see page 24 Leaking or plugged piston valve or Check valves See pump manual intake valve in displacement pump 36 332144C Troubleshooting PROBLEM CAUSE SOLUTION One side doesn t come up to pres Low fluid in tank Refill sure in spray mode Dirty or damaged Recirc Spray valve Clean or repair page 40 Plugged fluid inlet strainer Clear see page 24 Pump intake valve plugged or stuck Clean pump intake valve See page open 41 Material is too viscous to pump Warm material before adding to tanks Pressure is higher on one side when Pump intake valve partially plugged Clean pump intake valve See page setting pressure with function knob 41 Air in hose Fluid is compressible Purge air from hose Unequal size hoses or unequal hose Use matching hoses or balance construction pressures before spraying Pressures are not balanced when Unequal viscosities Change temperature setting to bal running but pressure is generated ance viscosities and holds on both strokes Change restrictor a
45. er 55 Failed circuit board Display is failing Replace Loose display cables on control Check cable connections to each dis board play FIG 23 on page 72 Failed control board displays get Remove access panel Check if power from control board board LED is lighted If not replace board page 44 Inadequate power to control board Check that power supply meets requirements Loose power cable Check cable connections FIG 23 on page 72 Heater power switch circuit breaker Display is powered from heater tripped power circuit breaker Cycle heater IE power off then c to reset breaker Erratic display display turns on and Low voltage Ensure input voltage is within specifi off page Technical Data page Poor display connection cable connections FIG 23 on page 72 Replace damaged cable Display cable damaged or corroded Clean connections replace cable if is damaged 332144C 33 Troubleshooting PROBLEM CAUSE SOLUTION Display does not respond properly to Poor display connection Check cable connections FIG 23 button pushes page 72 Replace damaged cable Display cable damaged or corroded Clean connections FIG 23 page 72 Replace damaged cable Ribbon cable on display circuit board Connect cable FIG 23 page 72 disconnected or broken or replace Broken display button Replace page 42 Fan not working Check fan wire Defective fan Replace
46. es FETE omit a wih wa HERES 1 64a A 21020005 NN ADAPTER N N ADAPTER FITTING bulkhead FITTING line air 1 4 18 npt ADAPTER 9 16 18 JIC x 1 4 NPT FITTING swivel 1 4 npt x 6 JIC 44 lt lt MANIFOLD assembly outet see page 7t 2 2 FITTING 6 JIC 1 4PM TUBE pump outlet ISO 47 TUBE heater outlet ISO i8 241979 HOSE coupled recite SOT 9 247080 TUBE 08501020 50 241981 HOSE coupled rect FEST 62 332144C Quantity 241100 m Description EM V 51 114225 TRIM edge protection protection renee FTG pp E MIND 53 247982 MANIFOLD inlet RES ee page 89 54 247985 MANIFOLD inet 1SO see page 89 1 1 _ mmo as 56 115942 NUT hexane RAR 57 241888 SENSOR tank level 58 241890 PANEL heater contorno f 201020 S 247858 MODULE heater 2 2 60 zaros PANEL conor mount 24T308 MODULE heater control 120 V 24T307 MODULE heater control 230V RELAY SSR 120 V RELAY SSR 230 V EE EN 65 ROCK camp end 24U007 CONNECTOR contactor 120 V 24T992 CONNECTOR contactor 230 V 68 12617 COVERen 69 126818 BLOCK mid 3 wire 126810 RELAY cradle 332144C Parts 63 Parts 24T100 24R900 120 V 230 V 1 1 Description RELAY 12V 2 255043 HOLDER fuse terminal block 5 x 20mm 3 255023
47. es both of your hands c The tank level indicator LED will flash if either tank sensor indicates that it is low Alternately remove each hand away from inner wall for 5 seconds The tank level indicator LED on the control panel will flash Table 12 Sensor LED Identification Sensor is powered Sensor is not powered Yellow on Sensor detects material immediate 5 second display Yellow off Sensor does not detect material ti21963a Fic 21 Sensor LEDs 55 Repair Reset Sensitivity The tank fluid level sensor sensitivity may need to be adjusted when e Anew tank has a different insulation density than the previous tank e Material build up is on the inside or outside of the tank Adjust sensitivity rather than thoroughly clean ing the tank e Level sensor sensitivity comes out of alignment through misuse or harsh environment e Material density is less than normally pumped mate rials 1 Ensure tank is completely empty 2 Remove shroud 89 to expose the sensors 3 Ensure sensor 57 and tank are properly installed See Adjust page 55 4 Locate the adjustment screw S above the green and yellow LEDs NOTE The adjustment screw on some tank level sen sors is covered by white tape Remove the white tape to access the adjustment screw A ti21963a 22 Adjustment Screw 5 Use a small flathead screwdriver and slowly turn the adjustment screw S clockwise until the
48. esas iaa 51 Replace Cycle Counter Switch 52 Electric 53 Motor Brushes 54 A a aah 54 Tank Fluid Level Sensors 55 OO 57 System Packages 57 E 10hp Proportioners 59 Suggested Replacement Parts 74 Accessories 74 a 74 Technical Dala 5255 54 45 75 NOLES 22 Ao rdv P ecc S 77 Graco Standard Warranty 78 332144C 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 or on warning labels refer back to these Warnings Product specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable 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 e Read MSDSs to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines ELECTRIC SHOCK HAZARD T
49. ess to parts which may cause electric shock or other serious injury if work is not performed properly Have a qualified electrician connect power and ground to main power switch terminals see page 15 Be sure to shut off all power to the equipment before repairing 1 Flush if possible see page 25 If not possible clean all parts with solvent immediately after removal to prevent isocyanate from crystallizing due to mois ture in the atmosphere 2 Set function knob to Stop Park 67 Ga 4 2 5 6 5 Sy 7 ti21490a 5 Relieve pressure page 23 6 Disconnect heater and motor power cords 332144C Repair Remove Supply Tank 1 See Before Beginning Repair page 39 2 Relieve pressure page 23 3 Flush page 25 4 Place waste container under y strainer 5 Close fluid valve V ti21893a 6 Remove filter drain hex nut N and drain material 7 Remove recirculation tubes P and place in waste containers 39 Repair 8 Disconnect swivel elbow at pump fluid inlet 9 Remove six screws 28 holding tank 27 to cart frame 28 ti21837a 10 Loosen nut and slide tank level sensor S away from the tank 11 Pivot top of tank to side and remove the tank with fluid inlet fittings off the cart 12 Reinstall in reverse order Torque screws 28 to 125 in lbs 14 Nem 40 Replace Recirc Spray Valves 1 See Before Beginning Repair page 39 2 Rel
50. f 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 B
51. ft 10 7 m Hose Temperature 1 bundle 125 F 52 C 15 minutes 170 F 77 C 40 minutes NOTE Heatup times are based on 70 F 21 C starting material temperature and 70 F 21 C ambient tempera ture Fluid Spray Target NOTE Different fluids will absorb heat at different rates When refilling a warm machine heatup times will be less 19 Startup Heatup Guidelines The fluids must be circulated from the pumps through the heater hoses and back to the tanks to ensure warm fluids are supplied to the gun Slow Recirculation 8 e Slow Recirc results in a higher temperature transfer in the heater so hoses and gun heat up quicker e Good for touchup or low flow spraying up to moder ate temperature Fast Recirculation 5 Fast Recirc keeps heaters on full time to bring fluid tanks up to temperature The higher your flow rate the more heat needed in the tanks before spraying e For230 V systems Use Fast Recirc until pump inlet fluid temperature gauges Y are within 45 F 25 C of target outlet temperature e For 120 V systems Use Fast Recirc until pump inlet fluid temperature gauges Y are within 30 F 17 C of target temperature e Volume in tanks Use only what you need For example 2 5 gal 10 in each tank will heat up almost twice as fast as 5 gal 20 1 e Mixes fluid within tanks to avoid heating only the fluid at the top of the tank e Use for flushing 20 Heat Management Tips
52. h a storage fluid such as Bayer Mesamoll plasticizer or at minimum clean motor 6 Set function knob to Fast Recirc 25 Pump mate rial from supply tanks until no more comes out 1 Engage piston safety lock or trigger safety lock gum Close fluid valves ISO and RES Leave air on A 4 9 4 gt ti31496a lt Fusion Probler 7 Set function knob to Stop Park 67 121490 8 Wipe out any remaining material from the supply tanks Fill each supply tank with 1 2 gal 3 8 7 6 I of solvent recommended by your material manufac turer 332144C 25 Flushing A 9 Set function knob to Fast Recirc 25 Pump solvent through system to waste containers YA 4 2 ti31496a 10 When nearly clear solvent comes from recirculation tubes set function knob to Stop Park Return recirculation tubes to supply tanks ti21490a 11 Set function knob to Fast 25 Circulate sol vent through system for 10 20 minutes to ensure thorough cleaning ti31496a NOTE To flush gun refer to gun instruction manual Purge Hoses Disconnect hoses from gun and secure back into the tanks for thorough cleaning with solvent e Turn Recirc Spray valve ISO to Spray e Open gun into waste ISO container oA a e Set function knob to Slow Recirc Ds until hose is flushed e Set function knob to Stop Park e Repeat for RES
53. haft See Before Beginning Repair page 39 2 Remove screws 21 and back cover 26 5 Remove nut N part of 357 and detent plate 358 1 See Before Beginning Repair page 39 6 Install new potentiometer 357 in reverse order 2 Remove screws 21 and display cover 26 Position potentiometer so slot S is horizontal Position knob 356 so pointer P faces up Install knob on shaft so slot S engages alignment pin in knob Push knob onto shaft against detent spring before tightening setscrews 356a 7 Reconnect potentiometer wires to J5 ti21923a 3 Puton static conductive wrist strap 4 Disconnect main display cable 81 from upper right corner of temperature display 353 See FIG 10 5 Remove jumper 373 from back of display 353 Set aside and install jumper on new display 6 Disconnect ribbon cable s R from back of display see FIG 10 ti21840a 8 Disassemble display 353 see detail in FIG 10 9 Reassemble in reverse order see FIG 10 Apply medium strength thread sealant where shown 42 332144C Repair N LO C 360 ti21841a 351 Fic 10 Control Panel 43 332144C Repair Motor Control Power Bootup Check NOTE Power must be on to check See FIG 11 or loca tion Function is e Motor ready LED on e Motor not ready LED off e Status code motor not running LED blinks status code e Multiple status c
54. his equipment must be grounded Improper grounding setup or usage of the system can cause elec tric shock e Turn off and disconnect power cord before servicing equipment Connect only to grounded electrical outlets Use only 3 wire extension cords Ensure ground prongs are intact on power and extension cords 4 PERSONAL PROTECTIVE EQUIPMENT w gt Wear appropriate protective equipment when in the work area to help prevent serious injury including eye injury hearing loss inhalation of toxic fumes and burns This protective equipment includes but is not limited to e Protective eyewear and hearing protection Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer SKIN INJECTION HAZARD High pressure fluid from gun hose leaks or ruptured components will pierce skin This may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment e Engage trigger lock when not spraying Do not point gun at anyone or at any part of the body Do not put your hand over the spray tip Do not stop or deflect leaks with your hand body glove or rag Follow the Pressure Relief Procedure when you stop spraying and before cleaning checking or servicing equipment Tighten all fluid connections before operating the equipment Check hoses and couplings daily Replace worn or damaged parts immediately 332144C 3 Warnings FIRE AND EXPLOSION HAZA
55. hrust BEARING thrust GEAR reducer first stage HOUSING drive KIT repair connecting rod PIN straight NUT jam pump PUMP displacement SCREW mach hex washer hd KIT cover includes switch COVER pump rod SWITCH reed with cable MAGNET disc 0 38 dia 0 100 thick not shown TAPE foam 1 2 wide KIT cover BRACKET shroud tab Included 300001 Crankshaft Kit 210 1 Included 244242 Gear Reducer Kit 214 Included 287055 Drive Housing Kit 215 Included in 287053 Connecting Rod Kit 216 66 Qty O gt N 332144C 24U009 120 V Heater 241955 230 V Heater Parts 310 A 307 AN A 305 306 A 55 NT 1 T ey B D e SS 309 3124 316 A 301 A Torque to 120 ft lbs 163 Nem N Torque to 23 ft lbs 31 Nem A Apply 110009 thermal heat sink compound AY Apply sealant and tape to all non swiveling and threads without o rings Ref Part Description Qty 301 BLOCK heater 1 302 15H302 FITTING reducer 1 3 16 SAE x 1 2 4 npt 303 16V432 FITTING adapter 6 JIC x npt 4 mxm 304 15H304 FITTING plug 9 16 SAE 2 305 15H306 ADATPER thermocouple 9 16 2 1 8 306 120336 O RING packing 2 307 24T958 HEATER fire rod 230 V 24T955 2 only 24U012 HEATER fire rod 120 V 24U009 2 332144C only A Apply lubricant to o rings before assembling in heater housing A Tighten NPT fitting from sensor to heater housing
56. ieve pressure page 23 3 See FIG 7 Disassemble Recirc Spray valves Clean and inspect all parts for damage 4 Ensure that the seat 453a and gasket 453b are positioned inside each valve cartridge 453 5 Apply PTFE pipe sealant to all tapered pipe threads before reassembling 6 Reassemble in reverse order following all notes in FIG 7 ti21838a A Torque to 250 28 Nem A Use blue threadlocker on valve cartridge threads into manifold A Part of item 453 FIG 7 Recirc Spray Valves 332144C Displacement Pump NOTE Use dropcloth or rags to protect Reactor and surrounding area from spills OwA 1 See Before Beginning Repair page 39 2 Relieve pressure page 23 3 Close both fluid valves V ti21893a NOTE Use dropcloth or rags to protect Reactor and surrounding area from spills 4 Open filter drain hex nut on y strainer Remove Intake Valve Only NOTE If pump is not generating any pressure the intake ball check may be stuck closed with dried mate rial If the pump is not generating pressure on the down stroke intake ball check may be stuck open Either of these conditions can be serviced with the pump in place 5 Disconnect fluid inlet C and swing it aside 6 Remove intake valve by hitting ears E firmly right to left with a non sparking hammer Unscrew from pump See displacement pump manual for repair and parts Remove Entire Pump As
57. in the storage area or if material may separate or settle out over time If using an impingement mix gun close gun fluid valves when not spraying Doing this will keep the internal parts of the gun cleaner and prevent cross over Clean gun mix chamber ports and check valve screens regularly See gun manual e Fusion Probler If using an Fusion Air Purge impingement mix gun always grease the gun after use until purge air car ries grease mist out the front of the gun Use Part No 117773 Grease See gun manual 332144C Flushing Flushing 3 Shut off Heater Power Allow system to cool To avoid fire and explosion Flush equipment only in a well ventilated area Ensure main power is off and heater is cool before flushing 4 Remove recirculation tubes P from supply tanks and place in original containers or waste containers Do not turn on heater until fluid lines are clear of 9 solvent e 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 e Flush out old fluid with new fluid or flush out old fluid with a compatible solvent before introducing new fluid e Use the lowest possible pressure when flushing e Always leave some type of fluid in system Do not use water ti21495a e For long term storage flush out the solvent wit
58. ire for the electric current Reactor grounded through power cord Generator if used follow your local code Start and stop generator with power cord s disconnected Spray gun grounded through the supplied fluid hoses connected to a properly grounded Reactor Do not oper ate without at least one grounded fluid hose Object being sprayed follow your local code 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 card board which interrupts grounding continuity 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 Connect Fluid Hoses 1 Connect fluid supply hoses to outlet hose connec tions R FIG 5 Red hoses for ISO blue for RES Fittings are sized to prevent connection errors Con nect other end of hoses to ISO and RES inputs of gun NOTE Probler guns use recirc accessory kit 24E727 16 2 Connect recirculation hoses from gun recirculation ports to connections S FIG 5 Connect Gun Air Hose 1 Connect gun air hose to the gun air input and to the air filter outlet Z If you are using more than one hose bundle join the air hoses with the nipple pro vided with the hose bundle 2 Onunits with Fusion guns connect the supplied
59. is displayed 1 Check for tripped circuit breaker on Reactor or at power source of 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 46 If error disappears replace faulty module 4 f E03 occurs for all zones the contactor may not be closing Verify wiring from heater control to contac tor coil E04 Thermocouple disconnected 1 Check temperature sensor connections to green connectors B on temperature control module See Temperature Control Modules Connections page 47 2 Unplug and re plug sensor wires 332144C Troubleshooting Reactor Electronics 2 Shut off Motor Power 7 7 3 Relieve pressure page 23 Before performing any troubleshooting procedures 4 Allow equipment to cool 1 Shut off Heater Power 5 Try the recommended solutions in the order given 0 7 for each problem to avoid unnecessary repairs Also determine that all circuit breakers switches and controls are properly set and wiring is correct before assuming there is a problem PROBLEM CAUSE SOLUTION Temperature display does not Display disconnected Check cable connections page 45 illuminate Display cable damaged or corroded Clean connections replace cable if is damaged Blown fuse Replace fuse 73 in fuse holder on DIN rail located under elec tronics cov
60. ly lubricant to rectangular cavity on connecting link A Apply lubricant to threads of pump cylinder before assembly into housing Align top of cylinder flush within 0 06 to inside bottom of pump mounting hole Torque fasteners to 140 160 105 15 18 Nem A Assemble nut to finger tight only 332144C 207 233 ti21847a 0 6 in 15 2 mm from inside edge 1 0 in 25 4 mm from inside bottom edge 17028 4 A Torque fasteners to 30 35 in lbs Applies only when fasteners are assembled in plastic housings 215 LN Switch mounts to cover opposite brush end of motor only A Housing must be installed on motor with crankshafts aligned with each other A Assemble magnet to center of offset crankshaft on switch cover side of motor and adjust for park location AN Affix switch to motor cover with double sided tape Cut to 2 in 50 8 mm Mount cover on side opposite brush end of motor 65 Parts Ref 201 2071 208 209 210 211 2121 2137 2141 2151 2160 217 218 219 220 2211 2224 223 224 227 229 233 Part 241758 115492 116074 107434 300001 180131 116073 116079 244242 287055 287053 196762 195150 241 006 117493 300002 158589 117770 24K982 115711 300003 16W162 Description MOTOR electric SCREW mach slot hex wash hd WASHER thrust BEARING thrust KIT crankshaft BEARING thrust WASHER t
61. odes are separated by a longer LED off duration Control Board LEDs If LEDs on bottom board are on and the top board LEDs are off the following may have occurred e pressure transducer shorted out e Ashort occurred between the power and ground pin of the potentiometer Description Red on Hardware or software eae reen on Power on Red on Hardware or software failure 6 Green on Power on D16 under C52 D4 bottom side of board 44 Replace Control Board A ij NOTE Check motor before replacing board See Test Motor page 53 1 See Before Beginning Repair page 39 2 Remove access cover 26 on back of cart to expose control board 354 ti21923a 3 Disconnect all cables and connectors from board 354 See Table 8 page 45 4 Remove six nuts 363 and remove board from con trol board 354 See FiG 10 page 43 5 Install new board in reverse order 332144C Repair Table 8 Control Board Connectors see FIG 12 TopBoard Connectors Board Connectors Bottom Board Connectors n a Not Used Female Quick Power Connect Terminals n a Not Used Plug Housing with Motor Power Male Blades Error LED Tank Level LED T Function Knob 1 Brown ISO Sensor V 2 Blue ISO Sensor V Black ISO Sensor Signal Brown RES Sensor V 5 Blue RES Sensor V 6 Black RES Sensor Signal Boost Power Relay Motor Overtempera
62. ontrols monitor fluid pressures drive the motor and alerts the operator if errors occur See Motor Pump Status Codes page 14 for further infor mation 10 The Reactor E 10hp has two recirculation speeds slow and fast and an adjustable pressure output Slow Recirculation 8 e Slow circulation results in a higher temperature transfer in the heater so hoses and gun heat up quicker e Good for touchup or low flow spraying up to moder ate temperature e Not used to circulate full tanks up to temperature e Use with 245 fa blowing agent foams to minimize heat returned to tank and reduce frothing 200 A Fast Recirculation 2 e Use to support higher flow rates or higher tempera tures by preheating the tanks e Agitates fluid within tanks to avoid heating only the fluid at the top of the tank e Use for flushing Pressure Adjust Automatically maintains selected pressure output for dispensing or spraying 332144C Component Identification Key for Fic 1 Supply Tank ISO Supply Tank RES Pump ISO Pump RES Heater under shroud Fluid Pressure Gauges Recirc Spray and Overpressure Relief Valves Tank Level Sensors bottom of tanks Control Panel see FIG 2 page 12 Electric Motor and Drive Housings Insulated Hose Bundle includes circulation return hoses Fusion Air Purge Spray Gun FPATOTmMOOU gt lt lt lt EC SS N eN Ns FiG 1 Component
63. r and prevent crossover Fusion Probler 22 Refill Tanks Material can be added to the tanks at any time See Fill Fluid Tanks page 17 NOTE If you are operating at high temperatures or flow rates follow Pause instructions to bring tanks up to tem perature NOTICE To prevent cross contamination of fluids and equip ment parts never interchange ISO and RES parts or containers Have at least two 5 gal 19 liter pails to transfer fluid from drums to supply tanks Label one pail ISO and the other RES using the red and blue labels pro vided Always double check which material you have before pouring it in the supply tanks Pouring is easier if pails are not filled to the top Open only one supply tank at a time to avoid splash ing material from one tank into the other when filling 332144C Pressure Relief Procedure Follow the Pressure Relief Procedure whenever TN you see this symbol A MO This equipment pressurized until pressure manually relieved To help prevent serious injury from pressurized fluid such as skin injection splashing fluid and moving parts follow the Pressure Relief Procedure when you stop spraying and before cleaning checking or servicing the equipment 1 Engage piston safety lock or trigger safety lock Probler Fusion OA 2 Setfunction knob to Stop Park 1 3 4 D y 5 6
64. riate adapter to the unit s power cord before connecting to your power source Setup To avoid electric shock always unplug both cords before servicing Reactor and wait one minute Heater Power 17061 AN Motor Power AM Ensure no other high amp loads are connected while running Reactor A To verify separate circuits plug in Reactor or a worklight and cycle breakers on and off Fic 4 Use Two Separate Circuits Table 4 Electrical Requirements Required Power Power Cord Source Connectors Supplied Local Adapters 230 V 1 phase 50 60 Two separate dedi Hz two 15 4 5 catedcircuits rated at power cords minimum of 15 A each 120V 50 60 Hz two 15 ft 4 5 m power cords Two separate dedi cated circuits rated at minimum of 20 A each Two IEC 3 20 C20 Plugs NEMA 6 15P 90 Euro CEE74 Oe YP 39 AS3112 Australia Asia North America Europe Two NEMA 5 20P Plugs Table 5 Extension Cord Requirements Required Wire Size Uptosoft ism Upto100ft 30m models models 12 o O 10 NOTE Cords must be 3 conductor grounded rated for your environment 332144C 15 Setup Ground System The equipment must be grounded to reduce the risk of static sparking and electric shock Electric or static sparking can cause fumes to ignite or explode Improper grounding can cause electric shock Grounding provides an escape w
65. sembly 7 Disconnect fluid inlet C and outlet D lines Also disconnect steel outlet tube 46 from heater inlet 332144C 10 11 Repair Remove pump rod cover 222 Push clip up in back and push pin 217 out Loosen locknut 218 by hit ting firmly right to left with a non sparking hammer Unscrew pump See manual 311076 for pump repair and parts Install pump in reverse order of disassembly follow ing all notes in FIG 8 Clean strainer 51 Recon nect fluid inlet C and outlet D lines Tighten fluid outlet fitting D then tighten locknut 218 by hitting firmly with a non sparking hammer Set function knob to Slow Recirc 25 Purge air and prime See Purge Air and Flush Fluid From Lines page 18 3 M y 2 217 DA 222 p AQ NY y 121839 N ae 51 218 AA AM Flat side faces up Tighten by hitting firmly with non sparking hammer A Lubricate threads with ISO oil or grease 7025 FIG 8 Displacement Pump 41 Repair Control Panel Replace Function Knob Potentiometer NOTICE 3 Disconnect potentiometer wires from J5 on motor Before handling board put on a static conductive control board 354 See FIG 12 page 45 wrist strap to protect against static discharge which can damage board Follow instructions provided with 4 See Fic 9 Remove two setscrews 356a and pull wrist strap function knob 356 off potentiometer 357 s
66. side 26 ali gt 12 Set function knob to Stop Park 13 Solvent flushing is a two step process Go back to step 4 drain solvent and flush again with fresh sol vent 14 Leave unit filled with solvent plasticizer clean motor oil or refill supply tanks with new material and reprime NOTE Never leave the unit dry unless it has been dis assembled and cleaned If fluid residue dries in the pumps the ball checks may stick the next time you use the unit 332144C Troubleshooting Pump Control Status Codes Determine the status code by counting the number of times the system status indicator blinks The status indi cator will blink 1 19 times to indicate a status code Multiple active status codes are separated by a longer duration pause Status Code 1 Pressure Imbalance NOTE The unit does not check for pressure imbalance at setpoints less than 300 psi 2 1 MPa 21 bar NOTE The unit does not check for pressure imbalance for 10 sec after entering pressure mode Unit senses pressure imbalance between components ISO and RES and warns or shuts down depending on settings of DIP switches 1 and 2 To turn off automatic shutdown and or tighten pressure tolerances for status code 1 see DIP Switch Settings page 29 1 Reduce pressure of higher component by slightly turning Recirc Spray valve for that component toward Recirc until gauges show balanced pres sures In this example RES side
67. t from heater control module See FIG 24 on page 73 Pressure Transducers 1 See Before Beginning Repair page 39 2 50 Remove back cover 26 ti21923a Disconnect transducer cables from J11 and J12 connectors Reverse ISO and RES transducer con nections and check if status codes follows the bad transducer Replace transducer if the transducer fails test Remove supply tank page 39 Follow transducer cable on cart frame and cut zip ties Disconnect transducer from pump out let manifold Install o ring 553 on new transducer 554 Apply lubricant to o ring 553 Install transducer 554 in manifold Mark end of cable with tape red ISO blue RES Route cable back through cart frame to the con trol board See FIG 12 page 45 Install supply tank ti21846a Fic 17 Transducer 332144C Drive Housing Removal 1 See Before Beginning Repair page 39 2 Remove screws 207 and end covers 229 see 18 NOTE Examine connecting rod 216 If rod needs replacing first remove the pump 219 page 41 NOTICE To prevent equipment damage do not drop gear reducer 214 and crankshaft 210 when removing drive housing 215 These parts may stay engaged in motor end bell MB or may pull away with drive hous ing 3 Disconnect pump inlet and outlet lines Remove screws 220 and pull drive housing 215 off motor 201 Connecting rod 216 will disengage from
68. t mix point to bal ance back pressure Restriction on one side Clean mix module or restrictor at mix manifold Clean gun check valve screens Fluid leak in pump packing nut area Worn throat seals Replace See pump manual Pressure doesn t hold when stalled Leaking Recirc Spray valve Repair page 40 against gun in spray mode Leaking piston valve or intake valve Repair See pump manual in displacement pump Leaking gun shutoff Repair See gun manual Pressure is higher on RES side dur This is normal RES is typically No action required ing startup of recirculation especially higher viscosity than ISO until the in High Recirc mode material is heated during recircula tion One gauge shows half as many Loss of pressure on downstoke Intake valve is leaking or not closing pulses as the other when pumps are Clean or replace valve see page 40 cycling Loss of pressure on upstoke Piston valve is leaking or not closing Clean or replace valve or packings see page 40 Status indicator not lit Function knob is not set to Park Off Turn function knob to Park Off when power is applied Check that cable is connected at J3 Loose indicator cable on top motor control board See page 45 Failed control board Replace board See page 44 Shorted pressure transducer or See Control Board LEDs page 44 potentiometer input for troubleshooting 332144C 37 Troubleshooting P
69. tance Measurements 120V 230V TN eading Bi 12 81 1 2 Overtemperature Switch nearly 0 ohms B2 1 Bt 5 Thermocouple ISO red B2 2 81 6 Thermocouple ISO Y yellow B2 4 81 8 __ Thermocouple RES R red B2 5 81 9 _ Thermocouple RES Y yellow Unused 3 4 7 10 If temperature 5 too high sensor reading is 260 F 127 C or above 6 Check if thermocouples are damaged or not con tacting the heater element see FIG 16 page 49 7 Check if temperature control module turns off when equipment reaches temperature setpoint a Set temperature setpoints far below displayed temperature b Turn zone on If temperature rises steadily power board is failing c Verify by exchanging with another power mod ule See Replace Temperature Control Mod ules page 46 d Ifthe exchanged module does not fix the prob lem the power module is not the cause 8 Verify continuity of heater elements with an onmme ter see page 48 E02 High zone current When there is a high current error the LED on that zone s module will turn red while the error is displayed 1 See Before Beginning Repair page 39 2 Exchange zone module with another one Turn zone on and check for error If error disappears replace faulty module 32 4 6 ohms 4 6 ohms N A E03 No zone current When ano current error occurs the LED on the specific zone s module turns red when the error
70. th your package depending on its configuration Manuals are also available at www graco com Displacement Pump Description 311076 Instruction Parts Manual English Fusion Air Purge Spray Gun Description 309550 Instruction Parts Manual English Probler P2 Spray Gun PartNo Description Instruction Parts Manual English Probler P2 Recirculation Kit PartNo Description Instruction Parts Manual English Lift Ring Kit PartNo Description 332977 Instruction Parts Manual English 332144C 9 Overview Overview The Reactor E 10hp is a portable electric powered 1 1 mix ratio proportioner for use with e Polyurea e Polyurea hybrid coatings e Polyurethane foam Material may be applied with impingement mix spray guns The Reactor E 10hp is gravity fed from 6 gal 22 7 liter supply tanks mounted on the unit Severe duty positive displacement reciprocating piston pumps meter fluid flow to the gun for mixing and apply ing When set to recirculation mode Reactor E 10hp will circulate fluids back to the supply tanks The Reactor E 10hp uses primary heating rods and boost heating rods for each fluid and an insulated hose bundle with circulation return hoses This allows the hoses and gun to be preheated to the desired tempera ture before spraying The boost heating rods are used during circulation mode to reduce heatup time Digital displays show the temperatures of the two fluids Electronic c
71. to 19 ul times to indicate status code pause then repeat or will control module blink other active error codes See TABLE 1 for a brief description of status codes Tank Level Sensor LED Pressure Adjusts fluid pressure to Adjust gun in spray mode Table 1 Motor Pump Status Codes The tank level sensor E AX is triggered when chem ical is not present in either tank Table 3 Tank Level Indicator AX Chemical Status Of 5 Excessive current draw 6 High motor temperature No cycle counter switch input High cycle rate deviation more than 1 0 GPM ii High cycle rate shutdown more than 1 1 GPM 9 Low tank level Motor controller high temperature 5 19 Motor controller fault NOTE The default is to shut down if a status code indi cation occurs 1 gallon of lt 1 gallon Flashing 14 332144C Setup Locate Reactor 1 Locate Reactor on a level surface 2 Do not expose Reactor to rain Electrical Requirements Improper wiring may cause electric shock or other serious injury if work is not performed properly All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations 1 Connect Reactor to the correct power source for your model See Table 4 Power cords must be con nected to two separate dedicated circuits See FIG 4 2 Some models include cord adapters for use outside North America Connect the approp
72. tor should be smooth If not resurface commutator or replace motor AMA ti21916a 1 See Before Beginning Repair page 39 Fic 19 Motor Brushes 2 Relieve pressure page 23 Fans 3 Remove four screws 91 and motor shroud 89 See FIG 18 1 Disconnect fan cable 80 from fan 16 With Motor Power on test cable connector for line voltage 120 4 Remove fans 16 and disconnect cable 80 See V or 230 V FIG 20 2 If voltage is 120 V 230 V fan is defective 5 Loosen pump inlet and outlet connections Remove screws holding fan to shield 17 Install new fan in reverse order 6 Remove the display control cover 26 Disconnect motor cables as follows 3 If voltage is not 120 V or 230 V check fan cable connection at terminal blocks 1 and 2 see FIG 23 a Unplug motor power connector on page 72 b Unplug motor temp switch harness from con nector J9 Disconnect grounding cable from grounding screw 7 Toreplace the front motor brush a Remove the two bolts and access cover plate See FIG 19 b Remove old brushes and install new ones sup plied in kit 8 Toreplace the rear motor brush a Remove motor mounting bolts Slide the motor forward and lean on the cart frame ti21848a a Remove the two bolts and access cover plate See FIG 19 b Remove old brushes and install new ones sup plied in kit 54 332144C Tank Fluid Level Sensors Adjust
73. ture Cycle Switch ISO Pressure Transducer RES Pressure Transducer Top Bottom Fic 12 Wiring Connections 332144C 45 Repair Replace Temperature Control Modules 4 Disconnect all cables and connectors from tempera ture control module 59 NOTICE Before handling assembly put on a static conductive wrist strap to protect against discharge which can damage assembly Follow instructions provided with wrist strap 1 See Before Beginning Repair page 39 2 Remove heater shroud 89 and electronics cover 55 ti21844a FIG 13 5 Remove hex nut 56 and replace defective module 6 Install new module in reverse order Connect all cables and connectors S as a Numan xy HEN CAM ti21845a 3 Puton static conductive wrist strap 46 332144C Repair Temperature Control Modules Connections Table 9 Heater Control Module Connections Table 9 Heater Control Module Connections Description Table 10 Temperature Power Module Connections Sensor B See Table 11 H POWER RELAY Circuit board power input and contactor control output COMMUNICATION Communication to power COMMUNICATION Communication to control D boards board PROGRAM E Software programming POWER J Power to heater BOOT F Software bootloader Table 11 S
74. ve Target temperatures are displayed Fahrenheit Units Active ndicates that temperatures are displayed in F Celsius Units Active ndicates that temperatures are displayed in C stem Controls Heater Power Enables heater control The switch includes a 20 A circuit breaker Enables motor The switch includes a 20 A circuit breaker Motor Pump Control Function Knob Selects operation mode pressure setpoint See Motor Pump Control Function Knob page 14 JJ 0 2 lt o lt lt C 4 o ystem Indicators Boost Heat Indicator Indicates boost heat is active X Tank Level Indicator See Tank Level Sensor LED page 14 Y System Status Indicator Flashes an error code if alarm or deviation is active See Motor Pump Status Codes page 14 gt bk 332144C 1 C3 Controls and Indicators Motor Pump Control Function Knob Heater Control Diagnostic Codes Use knob AV to select desired function Heater control diagnostic codes appear on the tempera ture display These alarms turn off heat Setting Function Table 2 Heater Control Diagnostic Codes 01 High fluid temperature Stops motor and automati Stop Park cally parks pumps Slow Recirc Slow recirculation speed Fast Recirc Fast recirculation speed High controller temperature Individual No communications with zone Individual pod Motor Pump Status Codes 09 Display is missing Individual If error occurs status indicator AY will blink 1
75. w this warning can result in death serious injury or prop erty damage e Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents e Many other fluids may contain chemicals that can react with aluminum Contact your material sup plier for compatibility 4 332144C Patar PSI Li 7 7 332144 Warnings EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury e Do not operate the unit when fatigued or under the influence of drugs or alcohol e 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 manu facturer s replacement parts only Do not alter or modify equipment Alterations or modifications may void agency approvals and create safety hazards Make sure all equipment is rated and approved for the environment in which you are using it Use equipm

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