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Graco 312063S User's Manual

1. Check which zone is displaying the E01 error 1 Check that connector Bis firmly plugged into tem perature control module see FIG 8 page 35 2 Clean and re plug connections 3 Check connections between the temperature con trol module and overtemperature switches A and B 308 and between temperature control module and thermocouples A and B 310 or FTS 21 depend ing on which zone is displaying E01 See TABLE 6 page 35 Ensure that all wires are securely con nected to connector B 3120635 4 Remove connector B from temperature control mod ule and check continuity of overtemperature switches A and B thermocouples A and B or FTS by measuring resistance across the pins on the plug end see TABLE 1 Before doing the following checks note which zone A B FTS or all has high fluid temperature Table 1 Sensor Connector Continuity Checks Pins Description Reading 4 6 ohms approximately 35 ohms per 50 ft 15 2 m of hose plus approximately 10 ohms for FTS i 10 amp 12 5 Verify fluid temperature using an external tempera ture sensing device e If temperature is too high sensor reading is 229 F 109 C or above 6 Check if thermocouples A and B are damaged or not contacting the heater element page 38 7 To test that temperature control module turns off when equipment reaches temperature setpoint a Set temperature setpoints far below displayed temperat
2. ti3172a FIG 13 Display Module 3120635 43 Repair Inlet Fluid Strainer Screen NA The inlet strainer at each proportioning pump filters out solid matter that can plug the inlet check valves Inspect the screens daily as part of the startup routine and clean as required Isocyanate can crystallize from moisture contamination or from freezing If the chemicals used are clean and proper storage transfer and operating procedures are followed there should be minimal contamination of the A side screen Clean the A side screen only during daily startup This minimizes moisture contamination by immedi ately flushing out any isocyanate residue at the start of dispensing operations 1 Close the material supply valve at the pump inlet to prevent material from being pumped while the strainer plug 59j is removed 2 Place a container under the strainer base to catch drain off when removing the strainer plug 3 Remove the screen 59g from the strainer mani fold Thoroughly flush the screen with gun cleaner and shake it dry Inspect the screen for blockage No more than 2596 of the mesh should be restricted If more than 25 is blocked replace the screen Inspect the strainer gasket 59h and replace as required 4 Ensure the pipe plug 59k is securely screwed into the strainer plug 59j Install the strainer plug with the screen 59g and gasket 59h in place and tighten Do n
3. 64 Primary Heaters A and B 18 MeL 65 Hose Heat System 19 Temperature Control 66 Hydraulic Drive System 21 Fluid Manifold 67 Proportioning System 23 Circuit Breaker Modules 68 Blue EE 72 Technical Data 252 2E IER ERE ERE 73 Graco Standard Warranty 74 Graco Information 74 2 3120635 Models H 25 SERIES Full Load Peak Amps Part Series Per Phase 255400 F F 69 H 40 SERIES Full Load Part Peak Amps Series Per Phase Primary Heater Watts System WattsT 000 22 10 000 2 10 15 960 son 22 23 260 15 300 22 23 260 15 300 22 5300 Ja 10 10 10 10 Primary System Heater WattsT Approximate Output per Cycle A B gal liter 063 0 24 0 063 0 24 0 063 0 24 0 063 0 24 0 063 0 24 063 0 24 Approximate Output per Cycle A B gal liter Hydraulic Pressure Ratio Models Maximum Fluid Working Pressure psi MPa bar 2000 13 8 138 Hydraulic Pressure Ratio Maximum Fluid Working Pressure psi MPa bar 5 20 2000 13 8 138 400V 3 253407 E 95 Sam 0 063 0 24 H 50 SERIES Primary System Heater WattsT Approximate Output per Cycle A B gal liter Hydraulic Pressure Ratio Maximum Fluid Working Pressur
4. 110k FIG 16 Change Hydraulic Fluid and Filter 4 Remove drain plug 110k 45 Repair 5 Place a rag around base of oil filter 135 to prevent b Screw filter on snug then an additional 1 4 turn oil from spilling Unscrew filter 1 4 3 4 turn to break air lock in filter Wait five minutes to allow oil in filter 8 Refill reservoir with approved hydraulic fluid See to drain back into reservoir Unscrew filter and Table 9 remove 9 Proceed with normal operation 6 Reinstall drain plug 110k Upon starting motor hydraulic pump may make a screeching noise until primed If this noise contin a Coat filter seal with fresh oil ues for more than 30 seconds switch off motor control See Hydraulic Drive System page 21 7 Replace filter 135 Table 9 Approved Anti Wear AW Hydraulic Oils BP Oil International Energol HLP HM ISO Grade 46 Carl Bechem GmbH Staroil HVI 46 Moi 0 Mobil DTE 25 ISO Grade 46 Shell Tellus ISO Grade 46 Note Do not mix mineral based and synthetic hydraulic oils Completely drain oil from reservoir and pump prior to converting between oils If the approved oils are not available in your area use an alternative hydraulic oil meeting the following require ments Oll TYPE im asm arte me de dCi m ole e Anti Wear AW Hydraulic Viscosity cSt at 100 C 6 5 9 0 VISCOSITY INA 2e het hard t ete cte nee 95 or higher Pour Point ASTM D 97
5. 6 If switch fails test remove wires and screws Dis card failed switch Apply thermal compound 1100089 install new switch in same location on housing 301 and secure with screws 31 1 Heconnect wires If wires need replacement disconnect from tem perature control board See TABLE 6 page 35 and FiG 8 page 35 Heated Hose Refer to the heated hose manual 309572 for hose replacement parts Check Hose Connectors 1 Turn main power OFF Disconnect power supply 2 Relieve pressure page 27 yu hose must be connected 3 Disconnect hose connector D at Reactor FIG 10 3120635 Repair 4 Using an ohmmeter check between the two termi nals of the connector D There should be continu ity 5 If hose fails test retest at each length of hose including whip hose until failure is isolated Check FTS Cables 1 Turn main power OFF Disconnect power supply 2 Relieve pressure page 27 3 Disconnect FTS cable F at Reactor FIG 10 ti9878a Fic 10 Heated Hose 4 Test with ohmmeter between pins of cable connec tor approximately 35 ohms per 50 ft 15 2 m of hose plus approximately 10 ohms for FTS 5 If cable fails test retest at FTS page 40 39 Repair Fluid Temperature Sensor FTS 4 f FTS fails any test replace FTS Test Removal 5 Disconnect air hoses C L and electrical connec tors D 6 Disconnect FTS from whip hose W and fluid
6. e Overtemperature switch A or B 308 senses a fluid temperature above 230 F 110 C and opens At 190 F 87 C the switch closes again e Thermocouple A or B 310 fails is damaged is not touching the heater element 307 or has a poor connection to the temperature control board e Overtemperature switch A or B 308 fails in the open position 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 e Failed heater element where thermocouple is installed e Loose wire e On8 kW heater models only Jumper wire on J1 connector between module 3 and display 4 is loose or incorrectly wired Code Code Name Alarm Corrective Zone Action page High fluid temperature Individual LC 8 C High zone current Individual 9 03 No zone current with E hose heater on 04 FTSnotconnected not connected CR Board overtemperature Individual 10 2 00 cable CITA CNN DIS from module Loss of communication A 18 For hose zone only if FTS is disconnected at startup display will show hose current OA Checks Ab Troubleshooting this equipment requires access to parts that may cause electric shock or other serious injury if work is not performed properly Have a quali fied electrician perform all electrical troubleshooting Be sure to shut off all power to the equipment before repairing
7. page 51 TUBE outlet 15R651 15R651 15R651 15R644 15R644 15R644 15R644 15R644 15R644 component B page 51 6 MODULE breaker C A C A C A page 68 COVER heater 247502 247502 247502 247502 247502 247502 ire BRACKET heater 247831 247831 247831 247843 247848 247843 247848 247843 24784 page 48 CONNECTOR 120871 120871 120871 120871 120871 120871 120871 120871 12087 2 pin motor power SWITCH added 123968 123968 123968 pole 400V only 03 CONDUIT assy 247814 247814 247814 247814 247814 247814 247814 247814 247814 motor power Qty NO er 14 15 16 17 z uv O C1 2 esch D H 56 3120635 Parts H 40 and H XP3 Models 253400 253401 253402 253403 253404 253405 253407 253408 H 40 H 40 H 40 H XP3 H XP3 H XP3 H 40 H 40 12 0 kW 15 3 kW 15 3 kW 12 0 kW 20 0 KW 20 0 KW 20 4 kW 20 4 kW 230V 230V 400V 230V 1 230V 400V 230V 400V Description 1 phase 3 phase 3 phase phase 3 phase 3 phase 3 phase 3 phase HEATER 247834 247813 247813 247834 247833 247833 247833 247833 pages 61 63 MOTOR page 247810 247785 247785 247810 247785 247785 247785 247785 52 CL tt p opo heater wire heater page 48 2 COVER 247846 247846 247846 247846 247846 247846 247846 247846 heater a B EN B EN EE SWITCH added pole CONDUIT 247814 247790 247790 247814 247790 247790 247790 247790
8. 110 3120635 53 Parts Parts Used on All Models Ref 2 10 11 13 14 15 16 17 18 36 37 38 39 40 42 54 Part 245974 247823 247832 246976 115834 247787 15B380 15B383 261669 103181 15B360 255047 116149 117666 C19843 123969 123967 117723 C20487 167002 117623 113796 115942 15K817 Qty Description d HEATER see page 56 for part 2 numbers MOTOR see page 56 for part num 1 bers DISPLAY page 65 1 CONTROL temperature see page 1 66 for part numbers BOARD circuit motor control see 1 page 56 for part numbers MANIFOLD fluid page 67 1 TRANSFORMER see page 56 for 1 part numbers COVER motor 1 COVER main cabinet 1 PUMP proportioning see page 56 1 for part numbers FAN cooling 1 TUBE inlet component A see 1 page 56 for part numbers TUBE outlet component A see 1 page 56 for part numbers TUBE inlet component B see 1 page 56 for part numbers TUBE outlet component B see 1 page 56 for part numbers CABLE harness heaterovertemp 1 includes 12 pin connector CABLE hose control see manual 1 312064 CABLE display KIT fluid temp sensor coupler WASHER lock ext GASKET fan STRAIN RELIEF M40 thread MODULE see page 56 for part numbers SPACER 4 TERMINAL ground 1 SCREW CAP socket hd 1 SWITCH disconnect 1 KNOB operator disconnect 1 SCREW mach slotted hd 4 NIPPLE hex 2 COVER heater wire see page 56 2 for part nu
9. SCREW machine pan hd M5 x 0 8 16 mm CABLE display SCREW machine M2 5 x 6 ti3172a Qty A NO esch 65 Parts Temperature Control Ref 601 602 603 604 605 606 66 606 Part 247772 247827 247828 115942 247801 247825 603 Description PANEL module mounting HOUSING control module HOUSING heater module NUT hex CABLE communication KIT cover connector with screws Qty sch RK DA 605 ToB Heater Module To A Heater Module To Hose Heater Module TI9843a 3120635 Parts Fluid Manifold N Torque to 355 395 in Ib 40 1 44 6 Nem A Apply sealant 113500 to threads A Valve must be closed with handle position as shown on drawing Apply PTFE tape or thread sealant to tapered threads E 705 TI9839b Qty Bab Par Bescrimion Qty Ref Part Description P 714 121312 ELBOW 90 degrees 2 701 247837 MANIFOLD fluid 715 100840 ELBOW street 1 4 npsm x 1 4 npt 2 702T 247824 VALVE drain cartridge 716 111457 O RING PTFE 2 eet ee ee 717A 189285 LABEL caution 1 702bt 247779 SEAL seat valve j 2 71 15082 PRIN i 703 102814 GAUGE pressure fluid e 150829 9 G compression 704 162453 FITTING 1 4 npsm x 1 4 npt 705 246123 TRANSDUCER pressure control 706 247788 HANDLE red 707 247789 HANDLE blue 708f 112309 NUT hex jam 712 117556 NIPPLE 8 JIC x 1 2 npt 713 117557 NIPPLE 10 JIC x 1 2 npt A Heplaceme
10. lt 813 819 818 812 822 3120635 69 Parts E 400V 3 Phase Circuit Breaker Modules For wiring and cable connections refer to electrical diagrams manual 312064 supplied See page 71 for parts 817 810 821 820 805 806 8 EIEICIEIEIEIETA OOO 801 an d NC IEEE CE LY 318 819 70 3120635 Circuit Breaker Modules Parts List Breaker Modules B C D 230V 3 phase 400V 3 phase 230V 1 phase 230V 3 phase Description 400V 3 phase Qty 801 IRAIL mounting 255028 255028 255028 255028 802 CLAMP block end 255045 255045 255045 255045 803 HOLDER fuse terminal block 255043 255043 255043 255043 804 FUSE 255023 255023 255023 255023 255023 ERMINAL block 255042 255042 255042 255042 807 BRIDGE plug in jumper 255044 255044 255044 255044 808 BLOCK terminal ground 255046 255046 255046 255046 809 BREAKER 1 pole 50A 255026 255026 255026 255026 810 CONTACTOR relay 65A 255022 255022 ONTACTOR relay 65A 255022 11 BREAKER 2 phase 40A DENM 255022 247768 247768 255050 1247768 Po 120579 255049 DRE 255025 pr 117679 a EE 255024 247802 247803 247806 247808 255027 255027 120895 120895 255031 255031 mE 255030 247791 247791 247768 247768 255050 12 IBREAKER 2 phase 25A REAKER 2 phase 40A 1247768 120579 REAKER 2 phase 50A 255049 13 BREAKER 2 phase 20A REAKER 3 pole 20A 255025 REAKER 2 phase 30A 117679 14 CONNE
11. 244 Part 100206 15H524 155541 121312 295225 112793 295852 177156 295829 295826 295397 295229 255037 255038 15H184 15H253 296607 Not shown Parts available in Kit 261863 Description BUSHING ACCUMULATOR pressure 1 4 npt FITTING union swivel 90 degrees ELBOW 3 4 SAE ORB x 1 2 in JIC PLUG pipe flush O RING NUT ADAPTER lube cylinder O RING CYLINDER lube PLUG 3 8 mpt x 0 343 in ELBOW 90 degree 1 4 npt m x 3 8 in 9 5 mm OD tube ELBOW 3 4 npt m x 1 2 in 13 mm OD tube FITTING grease 1 4 28 ELBOW 3 4 npt f CONNECTOR WIRE bidirectional cable assy HOSE gauge hydraulic 3000 psi shown on page 51 TOOL clevis pin extractor Qty sch sch sch sch ND LRO Ll sch Mi 3120635 Parts 10 2 KW and 6 0 KW Heaters Two Per Machine Parts 247833 and 247834 ae 8 304 309 r 247833 312063 ANS Use ELA J Z A Apply 110009 thermal heatsink compound 307 cA Or GEN 315 Qty Ref Part Description Qty 1 Ref Part Description oe o See M detresse 1 311 100518 SCREW machine pan hd 2 303 121309 ADAPTER 3 4 SAE ORB x e EE E EE 1 2 in JIC 314 295607 PLUG not shown 1 304 15H304 PLUG 3 315 124132 O RING 4 305 15H306 ADAPTER thermocouple 1 306 120336 O RING fluoroelastomer 1 307 HEATER immersion 4 16A110 2550W 10 4 kW heater only 16A112 1500 W 6 0 kW heater only 308 15B137 SWITCH overtemperature 309
12. Continue with step e If the higher gauge and display do not match that transducer is not communicating with the motor control board Check wire con nections and replace transducer page 34 e Turn pumps off Reduce pressure of higher component by slightly turning PRESSURE RELIEF SPRAY valve for that component toward PRESSURE RELIEF CIRCULATION A Oy while watching the display and the analog gauges As soon as the higher analog pressure drops below the lower analog pressure the dis play should change to the new higher reading Continue reducing the original higher pressure an additional 200 psi 1 4 MPa 14 bar digital display should stop dropping f Repeat for the other side to check the other transducer Turn valve slightly to reduce pressure of higher AN ti9877a 3120635 4 Motor Control Diagnostic Codes To test if the failure is with the transducer or the Socket on the motor control board a Heverse connections at J3 and J8 on the motor control board b Runthe unit until pressure is 1000 1500 psi 7 10 5 MPa 70 105 bar c Ifthe problem stays on the same side as before replace the motor control board If the problem appears to move to the other side replace the transducer If the gauge readings are not very close Secure bleed lines in grounded waste containers or route back to respective component A or B supply drum Reduce pressure of higher component by slightly turning PR
13. PLUG strainer Fluid Inlet Kit 2 Series A PLUG strainer Fluid Inlet Kit 2 Series B PLUG pipe 3 8 npt Fluid Inlet Kit 2 Series A PLUG pipe 1 4 npt Fluid Inlet Kit 2 Series B UNION swivel 3 4 npt m x 1 2 1 npt f A side only HOUSING thermometer GUARD gauge SCREW cap hex hd HESERVOIR lube hose assy SPACER COVER front WIRE mechanical switch cable see page 59 CO ch c nm nm 3120635 Ref 66x 107 110 110b 110c 110d 110f 110j 110k 110m 112 113 114 115 116 117 118 Part 117284 206995 115836 186494 205447 054826 15H207 189285 114269 247851 247852 111802 112958 15T895 247784 247853 15G816 120302 112125 15H189 119253 247826 247778 247771 247777 247770 116919 255032 255021 247822 247819 247830 255019 247855 247821 247820 247829 255020 255035 247856 3120635 Description CONNECTOR 2 PIN motor power see page 56 for part num bers GRILL fan guard SWITCH added pole see page 56 for part numbers THROAT SEAL LIQUID 1 quart GUARD finger CLIP spring COUPLING hose TUBE PTFE 1 4 in 6 mm ID 8 ft 2 4 m BRACKET tensioner LABEL caution GROMMET rubber FITTING reducer 5 x 8 JIC FITTING reducer 6 x 10 JIC SCREW cap hex hd 1 2 13 x 3 4 in 19 mm NUT hex flanged 3 8 16 HOSE supply TUBE return ADJUSTER belt tensioner COVER plate wire way CAST
14. Verify with EC Le if nec essary page 42 Defective fan Replace page 42 3120635 17 Troubleshooting Primary Heaters A and B 2 Turn main power OFF A AN N ed 3 Allow equipment to cool Try the recommended solutions in the order given for Before performing any troubleshooting procedures each problem to avoid unnecessary repairs Also determine that all circuit breakers switches and con 1 Relieve pressure page 27 trols are properly set and wiring is correct before assum ing there is a problem PROBLEM CAUSE SOLUTION Heat turned off Press A or zone 1 keys Temperature control alarm Check temperature display for diag nostic code page 8 Signal failure from thermocouple See E04 Fluid Temperature Sen sor FTS or thermocouple discon nected page 10 Primary heater s does not heat 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 Unplug and re plug long green connector Thermocouple not contacting heater Loosen ferrule nut N push in ther element mocouple 310 so tip T contacts heater element 307 Holding themo couple tip T against heater element tighten ferrule nut N 1 4 turn past tight See page 38 for illustrat
15. 15 F 26 C or lower Formulated for anti wear anti foaming oxidation stability corrosion protection and water separation 46 312063S Repair 3120635 47 Parts Parts See page 52 See page 49 See page 52 See page 51 See page 51 52 See pages 61 63 ti9831a 3120635 48 Parts Detail of Cabinet Area 8 0 kW Heater Bracket Ref 36 Shown D See page 50 54A TI9834a 3120635 49 Left Side of Cabinet 5 Right Side of Cabinet 312063S Parts Detail Fluid Manifold Area 15 7 see page 67 TI9838a Detail Proportioner Area 111 Ref See page 60 59 see page 53 TI9833a 51 3120635 Parts Detail Electric Motor Area 111 Ref ti7709a Detail Hydraulic Reservoir Area 119 120 22 111 Ref 150 111 1 Ref 92 60 TI9832b 52 3120635 Parts 59a 59b B Side 59k di W St TI9841 a 59f en 59ke NOTE Fluid Inlet Kit 59 has two versions Series A and Series B Fluid Inlet Kit Series A uses a flat gasket 59h and can be identified by a white seal The gasket material has been upgraded for improved sealing and is now a light gray color Fluid Inlet Kit Series B shown above uses an o ring seal 59h with a different manifold 59d and strainer plug 59j The seal is not visible when fully assembled Ref 110 Hydraulic Reservoir 39 A ti9840a 8 110k
16. 15B135 MIXER immersion heater 4 3120635 61 Parts 8 0 KW Dual Zone Heater One Per Machine Part 247815 AN Apply 110009 thermal heatsink compound B Ref 301 302 303 304 305 306 307 308 62 303 Part 15H302 121319 15H304 15H306 120336 16A111 15B137 301 Description HOUSING heater FITTING reducer ADAPTER 1 2 npt m x 1 2 in JIC PLUG ADAPTER thermocouple O RING fluoroelastomer HEATER immersion 2000 W SWITCH over temperature Qty 1 4 4 2 2 2 4 1 Ref 309 310 311 312 313 303 302 r 247815 312063 Part Description 15B135 MIXER immersion heater 117484 SENSOR 100518 SCHEW machine pan hd 15M177 INSULATION not shown 124132 O RING Qty e N NN SFA 3120635 7 65 KW Single Zone Heater Two Per Machine Part 247813 313 Ref 301 303 304 305 306 307 308 309 Part 121309 15H304 15H306 120336 15B138 15B137 15B135 3120635 Description HOUSING heater ADAPTER 3 4 SAE ORB x 1 2 in JIC PLUG ADAPTER thermocouple O RING fluoroelastomer HEATER immersion 2550 W SWITCH overtemperature MIXER immersion heater 301 r 247813 312063 N Apply 110009 thermal heatsink compound Qty 1 2 D D sch W Ref 310 311 313 314 315 Part 117484 100518 15H305 295607 124132 Description SENSOR SCREW machine pan hd PLUG hollow PLUG not shown O RING Parts
17. 30 35 2550 18 21 Total Heater Wattage 6 000 7 650 8 000 2000 23 26 10 200 2550 18 21 6 To remove heater element first remove thermocou ple 310 to avoid damage see step 7 page 38 7 Remove heater element 307 from housing 301 Be careful not to spill any fluid left in housing 8 Inspect element It should be relatively smooth and shiny If there is a crusted burnt ash like material adhered to element or sheath shows pitting marks replace element 9 Install new heater element 307 holding mixer 309 so it does not block thermocouple port P 10 Reinstall thermocouple page 38 11 Reconnect heater element leadwires to heater wire connector 12 Replace heater shroud 3120635 Repair Line Voltage The primary heaters output their rated wattage at 230 Vac Low line voltage will reduce power available and the heaters will not perform at full capability 37 Repair 8 Thermocouple 1 Turn main power OFF Disconnect power supply 2 Relieve pressure page 27 A 7 3 Wait for heaters to cool 4 Remove heater shroud n 5 Disconnect thermocouple wires from B on tempera ture control module See TABLE 6 page 35 and FIG 8 page 35 1 6 Feed thermocouple wires out of cabinet Note path 11 as wires must be replaced in the same way 7 See FIG 9 Loosen ferrule nut N Remove thermo couple 310 from heater housing 301 then remove thermocouple h
18. Erratic hose temperature FTS not installed correctly FTS should be installed close to end of hose in same environment as gun Ver ify FTS installation page 40 Missing or damaged insulation around Make sure the hose bundle has ade FTS causing the hose heat to be ON _ quate insulation evenly covering the constantly entire length and connection joints FTS failed or is not contacting Check FTS page 40 correctly FTS not installed correctly FTS should be installed close to end of Hose does not heat hose in same environment as gun Ver ify FTS installation page 40 Temperature control alarm Check temperature display or diagnos tic code page 40 Hoses near Reactor are warm but Shorted connection or failed hose heat With hose heat on and temperature hoses downstream are cold ing element setpoint above displayed hose zone temperature verify voltage between connectors at each section of hose Voltage should drop incrementally for each section of hose further from Reac tor Use safety precautions when hose heat is turned on 20 3120635 Troubleshooting Hydraulic Drive System 2 Turn main power OFF B A AN N ed 3 Allow equipment to cool Problems Before performing any troubleshooting procedures 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 ar
19. H 50 1 phase 1700 psi 11 7 MPa 11 7 bar Model H 50 3 phase 2000 psi 13 8 MPa 138 bar Models H XP2 and H XP3 3500 psi 24 1 MPa 241 bar Fluid Oil Pressure Ratio Models H 25 and H 40 1 91 1 Model H 50 1 64 1 Models H XP2 and H XP3 2 79 1 Fluid Inlets Component A ISO 1 2 npt f 250 psi 1 75 MPa 17 5 bar maximum Component B RES 3 4 npt f 250 psi 1 75 MPa 17 5 bar maximum Fluid Outlets Component A ISO 8 1 2 in JIC with 5 5 16 in JIC adapter Component B RES 10 5 8 in JIC with 6 3 8 in JIC adapter Fluid Circulation Ports 1 4 npsm m with plastic tubing 250 psi 1 75 MPa 17 5 bar maximum Maximum Fluid Temperature 190 F 88 C Maximum Output 10 weight oil at Model H 25 22 Ib min 10 kg min 60 Hz ambient temperature Model H XP2 1 5 gpm 5 7 liter min 60 Hz Model H 50 52 Ib min 24 kg min 60 Hz Model H 40 45 Ib min 20 kg min 60 Hz Model H XP3 2 8 gpm 10 6 liter min 60 Hz Output per Cycle A and B Models H 25 and H 40 0 063 gal 0 23 liter Model H 50 0 073 gal 0 28 liter Models H XP2 and H XP3 0 042 gal 0 16 liter 400V 3 phase units 338 457 Vac 50 60 Hz A and B heaters total no hose Hecommended hydraulic fluid Citgo A W Hydraulic Oil ISO Grade 46 Sound power per ISO 9614 2 90 2 dB A Sound pressure 1 m from equip 82 6 dB A ment Weight Units with 8 0 kW Heaters 535 Ib 243 kg Units with 12 0 kW Heaters 597 Ib 271 kg
20. Units with 15 3 kW Heaters H 25 H XP2 models 562 Ib 255 kg Units with 15 3 kW Heaters H 40 H XP3 H 50 models 597 Ib 271 kg Units with 20 4 kW Heaters 597 Ib 271 kg Wetted Parts Aluminum stainless steel zinc plated carbon steel brass carbide chrome fluoroelastomer PTFE ultra high molecular weight polyethylene chemically resistant o rings All other brand names or marks are used for identification purposes and are trademarks of their respective owners Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompat
21. assy motor 312063S 57 esch PUMP proportioning 14 TUBE inlet 15 16 17 26 1 moto po a am a 123968 123968 123968 400V only motor power 100 LABEL 247780 247780 247780 247781 247781 247781 247780 247780 esch power zi N N N 5 c sch c NI lt H 50 Models 253725 253726 253727 256505 256506 H 50 H 50 H 50 H 50 H 50 12 0 KW 15 3 KW 15 3 KW 20 4 KW 20 4 KW Description 230V 1 phase 230V 3 phase 400V 3 phase 230V 3 phase 400V 3 phase HEATER pages 247834 247813 247813 247833 247833 61 63 MOTOR page 52 247810 247785 247785 247785 247785 BOARD motor 247835 247835 247835 247835 247835 control page 50 TRANSFORMER 247786 247786 247786 247786 247786 page 50 PUMP Model 140 Model 140 Model 140 Model 140 Model 140 proportioning page 59 TUBE inlet 15R646 15R646 15R646 15R646 15R646 component A page 51 TUBE outlet 15R645 15R645 15R645 15R645 15R645 component A page 51 TUBE inlet 15R650 15R650 15R650 15R650 15R650 component B page 51 TUBE outlet 15R644 15R644 15R644 15R644 15R644 component B page 51 MODULE C breaker page 68 COVER heater 247502 247502 247502 247502 247502 wire 6 BRACKET heater 247843 247843 247843 247843 247843 page 48 2 COVER heater 247846 247846 247846 247846 247846 CONNECTOR 120871 2 pin motor power SWITCH added 123968 123968 pole 400V only 00 LABEL 256509 25
22. fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed e Read MSDS s 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 e Always wear impervious gloves when spraying or cleaning equipment PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you from serious injury including eye injury inhalation of toxic fumes burns and hearing loss This equipment includes but is not limited to e Protective eyewear e Clothing and respirator as recommended by the fluid and solvent manufacturer e Gloves e Hearing protection SKIN INJECTION HAZARD High pressure fluid from gun hose leaks or ruptured components will pierce skin This may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment 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 Do not spray without tip guard and trigger guard installed Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment Tighten all fluid connections before operating the eq
23. on your operating conditions PRESSURIZED ALUMINUM PARTS HAZARD Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment Such use can cause serious chemical reaction and equipment rupture and result in death serious injury and property damage EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury This equipment is for professional use only Do not leave the work are while the equipment is energized or under pressure Turn off all equipment and follow the Pressure Relief Procedure in this manual when the equipment is not in use Do not operate the unit when fatigued or under the influence of drugs or alcohol Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings For complete information about your material request MSDS forms from distributor or retailer Check equipment daily Repair or replace worn or damaged parts immediately with genuine manufacturer s replacement parts only Do not alter or modify equipment Use equipment only for its intended purpose Call your distributor for information Route hoses and cables away from traffic areas sharp edges moving parts and hot
24. see page 32 b Remove motor electric junction box cover c Make a note of or label the wire connections Refer to the Reactor Electrical Diagram manual 312064 and the diagram inside the motor junc tion box cover The motor must operate coun terclockwise when looking at the output shaft CAUTION Motor is heavy Two people may be required to lift 5 Remove screws holding motor to bracket Lift motor off unit 3120635 31 Repair Motor Control Board Motor control board has one red LED D11 Power must be on to check See FIG 5 for location Func tion Is Startup 1 blink for 60 Hz 2 blinks for 50 Hz Motor running LED on Motor not running LED off Diagnostic code motor not running LED blinks diagnostic code pauses then repeats for example E21 21 blinks pause 21 blinks CAUTION Before handling board put on a static conductive wrist strap to protect against static discharge which can damage board Follow instructions provided with wrist strap 1 Turn main power OFF ep Disconnect power supply aN 2 Relieve pressure page 27 3 Refer to electrical diagrams Motor control board is on right side inside cabinet 4 Puton static conductive wrist strap 5 Disconnect all cables and connectors from board 6 Remove nuts 40 and take entire motor control assembly to workbench 7 Remove screws and take board off heatsink 8 Set DIP switch SW2 on new bo
25. 18 Instruction Parts Manual English languages and corresponding part numbers Circulation Valve Kit Part Language a 312063 English 312070 Instruction Parts Manual English 312428 Data Reporting Kit 312429 Description aa 309867 Instruction Parts Manual English Rupture Disk Assembly Kit Description 309969 312071 Seal Kits Instruction Parts Manual English Reactor Hydraulic Proportioner 312062 Reactor Hydraulic Proportioner Oper ation Manual English Reactor Electrical Diagrams 312064 Reactor Hydraulic Proportioner Elec trical Diagrams English Proportioning Pump Part Description 312068 Proportioning Pump Repair Parts Manual English 3120635 5 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 symbol refers to procedure specific risk Refer back to these warnings Additional product specific warnings may be found throughout the body of this manual where applicable A ELECTRIC SHOCK HAZARD AN Improper grounding setup or usage of the system can cause electric shock Turn off and disconnect power cord before servicing equipment HI Use only grounded electrical outlets e Use only 3 wire extension cords Ensure ground prongs are intact on sprayer and extension cords Do not expose to rain Store indoors TOXIC FLUID OR FUMES HAZARD Toxic
26. 26 See Pumps Do Not Reverse Direc tion page 26 See Pumps Do Not Reverse Direc tion page 26 Feed pump pressure is too low Adjust pressure to maintain 100 psi 0 7 MPa 7 bar minimum Fluid is too thick Consult your mate rial supplier for recommended fluid temperature to maintain a viscosity of 250 to 1500 centipoise See Pumps Do Not Reverse Direc tion page 26 Replace directional valve Open clear use hose with larger ID See pump manual 312068 Check feed pump pressure and adjust to 100 psi 0 7 MPa 7 bar minimum Fluid leak at pump rod seal Worn throat seals Replace See pump manual 312068 No pressure on one side Fluid leaking from pump outlet rup ture disk 216 Inadequate feed pump pressure Check if heater 2 and PRESSURE RELIEF SPRAY valve SA or SB are plugged Clear Replace rupture disk 216 with a new one do not replace with a pipe plug Check feed pump pressure and adjust to 100 psi 0 7 MPa 7 bar minimum 24 3120635 Troubleshooting A ISO Inlet Supply Valve A ISO Over pressure Rupture Disk A ISO Proportioning Pump B Resin Over pressure Rupture Disk B Resin Proportioning Directional Valve Pump Activator Plate Reversing Switch Rocker v gt Arm B Resin Inlet Supply Valve ti9874a Fic 1 Proportioning System Table 2 Directional Valve Indicator Status Left Pump Directional Right Pump Direct
27. 5 H XP2 models only ELBOW male GUN grease GREASE lubricant HOSE coupled HOSE coupled DIPSTICK with breather cap FILTER oil 18 23 psi bypass FITTING H 40 H 50 H XP3 models only H 25 H XP2 models only SCREW cap socket head FITTING npt part of hydraulic pump assembly H 25 H XP2 models only SCREW part of hydraulic pump assembly H 25 H XP2 models only SCREW cap hex hd NUT hex flange hd 5 16 18 NUT lock hex COVER access NUT strain relief M40 thread CONNECTOR heater SCREW set 1 4 x 1 2 13 mm CONNECTOR wire 6 AWG pair WASHER thrust Parts ch sesch ee sesch sesch sesch D PO NN NN A Replacement Danger and Warning labels tags and cards are available at no cost Not shown x Required for all A D series models Included in Knob Repair Kit 258920 purchase separately Fluid Inlet Kit 59 has two versions Series A and Series B Fluid Inlet Kit Series A uses a flat gasket 59h and can be identified by a white seal The gas ket material has been upgraded for improved sealing and is now a light gray color Fluid Inlet Kit Series B shown on page 53 uses an o ring seal 59h with a different manifold 59d and strainer plug 59j The seal is not visible when fully assembled Included in Strainer Manifold Kit 247503 Series A manifold is not available Order replace ment kit 247503 55 Parts Parts that Vary by Model Use the fol
28. 6509 256509 256509 256509 03 CONDUIT assy 247814 247790 247790 247790 247790 motor power JI O1 CO CO NO ech CO NO N O O1 sch O O1 S ot N N no c r c mS NI lt Parts Sub Assemblies Proportioner Assembly 213 214 34 Cow 201 see 219 N N page 64 N gt D LM VS C l g Se e fen is manual S NM 312068 233 TI9837b A Torque to 10 15 ft lb 13 6 20 3 Nem 3120635 59 Parts Proportioner Assembly Ref 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 60 Part 295027 295824 106258 298040 113467 120299 C19986 247817 247818 157021 100214 108751 159842 248187 M70430 261864 296653 261862 158683 Description CYLINDER hydraulic w spacers see page 64 for parts PUMP see manual 312068 SCREW socket hd 5 16 24 x 3 in 76 mm O RING MANIFOLD hydraulic SCREW socket hd VALVE directional hydraulic SCREW socket hd BRACKET mounting SWITCH reversing WASHER lock SCREW pan hd 8 32 x 3 8 WASHER lock SCREW socket hd ADAPTER HOUSING rupture disc kit see manual 309969 SCREW socket hd 1 4 28 x 0 19 CLEVIS hex PIN clevis KIT activator and bushing ELBOW 90 degree Qty D ND BB ANN HAH HD N NN P Ref 222 223 224 226 227 228 229 230 231 232 233 234 235 239 240 241 242 243
29. CTOR power lug ONNECTOR power lug 117805 O0 i C1 AR power buss 3 phase AR power buss 1 phase AR power buss 3 phase 3x3 247802 247803 CO 16 CABLE harness lower 247805 247807 CO 17 CABLE harness upper 255027 255027 18 CONNECTOR 2 pin large A EN EM 5 120895 120895 19 OI Q O O Z Z E 2 m ITI O O O O E D 255031 255031 20 J 21 255030 822 CABLE harness hose wire 247191 Q O Z Z m O O J N TD o 3 D 247791 8 kW H 25 models only 1 15 3 kW H 25 H XP2 H 40 H 50 models only 12kW H 40 H 50 models only 3120635 71 Dimensions Dimensions Dimension in mm A height 55 0 1397 B width 39 6 1006 C depth 18 5 470 D front mounting holes 29 34 745 E rear mounting holes 33 6 853 Front of Machine D 72 Dimension in mm F side mounting holes 16 25 413 G mounting post inner diameter 0 44 11 H front mounting post height 2 0 51 J rear mounting post height 3 6 92 Side View ti7742a ti9830a Detail of mounting post height to correctly size mounting bolts ti7743a 3120635 Technical Data Technical Data Category Data O Maximum Fluid Working Pressure Models H 25 and H 40 2000 psi 13 8 MPa 138 bar Model
30. ER PLUG tube LABEL see page 56 for part num bers BOOT wire feed through CONDUIT assembly motor power see page 56 for part numbers SUPPRESSOR ferrite 151 ohm RESERVOIR hydraulic includes 110b 110m see page 53 HOUSING inlet GASKET inlet TUBE inlet TUBE return FILTER inlet PLUG FITTING straight BRACKET motor mount BRACKET mounting pump H 40 H 50 H XP3 models only H 25 H XP2 models only PUMP hydraulic H 40 H 50 H XP3 models only H 25 H XP2 models only BRACKET reservoir hydraulic BRACKET support pumpmount COOLER hydraulic ELBOW 1 1 16 npt m x 1 2 in 13 mm tube H 40 H 50 H XP3 models only H 25 H XP2 models only PULLEY fan H 40 H 50 H XP3 models only Qty N O1 NO NNa lt N A sch sch I ch sesch b b Ll Ll NS Ref 119 120 122 125 126 127 129 130 131 132 133 134 135 137 139 140 141 142 143 144 146 147 148 150 151 153 Part 247857 15H512 15H204 117560 247793 255029 121320 121321 255036 117792 117773 15G782 15G784 116915 247792 116793 110792 107156 115764 112161 112586 110996 C19862 247836 255048 255039 261821 104373 Description H 25 H XP2 models only LABEL control KNOB pressure SCREW set socket hd HOSE inlet coupled GAUGE pressure fluid panel mount ELBOW H 40 H 50 H XP3 models only H 2
31. ESSURE RELIEF SPRAY valve for that component toward PRESSURE A RELIEF CIRCULATION Oy until gauges show balanced pressures Turn valve slightly to reduce pressure of higher N ti9877a Turn PRESSURE RELIEF SPRAY valve only enough to balance pressure If you turn it com pletely all pressure will bleed off If you cannot get the pressures to balance a Check for damaged pump seals or check valves b Check if you ve run out of material c Check for a plugged fluid path by using the feed pump to push fluid through the gun manifold If you are able to balance pressures try running the unit 13 Motor Control Diagnostic Codes 4 Ifa fast E24 error occurs again and the gauges readings are not very close a Check and clean the gun inlet screens b Check and clean the gun mix chamber impinge ment ports and center port See gun manual Some mix chambers have counter bored impinge ment ports requiring two drill sizes to clean com pletely Slow E24 Errors Slow E24 errors occur gradually The pressures are bal anced when you begin spraying but slowly become imbalanced until an E24 occurs Causes of Slow E24 Errors one side of the gun is partially plugged the A or B proportioner pump has failed the A or B feed pump has failed the A or B feed pump pressure is set too high the A or B proportioner pump inlet screen is plugged the hose is not heating properly e kinked supply ho
32. IG 15 3120635 3 Drain the reservoir and rinse with clean lubricant 4 When the reservoir is clean fill with fresh lubricant 5 Thread the reservoir onto the cap assembly and place it into the bracket 6 Push the larger diameter supply tube ST approxi mately 1 3 of the way into the reservoir 7 Push the smaller diameter return tube RT into the reservoir until it reaches the bottom Important The return tube RT must reach the bottom of the reservoir to ensure that isocyanate crystals will settle to the bottom and not be siphoned into the supply tube ST and returned to the pump 8 The lubrication system is ready for operation No priming is required ti9911a ti9887a axi Seed Fic 15 Pump Lubrication System 3120635 Repair Change Hydraulic Fluid and Filter A A N G l M d See Table 8 for recommended frequency of oil changes Change break in oil in a new unit after first 250 hours of operation or within 3 months whichever comes first Table 8 Frequency of Oil Changes Ambient Recommended EE re lotog0F to 90 F 1000 4000 hours or 12 months or 12 months 17 to 32 C whichever comes first 90 F and above 500 hours or 6 months which 32 C and above ever comes first 1 Relieve pressure page 27 2 Allow hydraulic fluid to cool 3 Place a pan under reservoir drain plug 110k to catch oil ti9888a
33. If the display shows E30 continuously there is a loose connection causing the display and board to repeatedly lose and regain communication E31 Pumpline reversing switch failure high cycle rate Failure of a pumpline switch or switch mechanism may result in a high cycle rate causing an E31 to occur Replace the switch or switch mechanism See Pumps Do Not Reverse Direction page 26 E31 may also occur if the system is modified to produce a higher flow rate 3120635 E99 Loss of communication If communication is lost between the motor control dis play and the motor control board or the temperature control display and the temperature control module the affected display will show E99 1 Check all wiring between the display and the motor control board and the temperature control module Pay close attention to the wire crimping at J13 on the motor control board page 33 and C on the temperature control module page 35 Unplug and re plug connectors Incoming voltage should be 230 Vac Check the temperature control module voltage at terminal block 805 on the circuit breaker module see page 68 Check the motor control board voltage at motor pumps circuit breaker 813 see page 30 Check if temperature control module or motor control board is causing error Swap display connection on temperature control module C with display connection on motor control board J13 If error no longer occurs the board or modu
34. MPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du presente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call to id
35. O ond 63 Parts Hydraulic Cylinder 413 Ref 401 402 403 404 405 406 407 408 64 415 Part 295029 295030 295031 296642 295640 295641 295642 296643 Rod Bushing Detail Description PLATE retainer CYLINDER BUSHING rod PISTON O RING U CUP RING backup RING wear Qty 2 1 2 1 2 2 2 1 405 402 P di NC 405 K l 413 Ba See Rod Bushing d Detail Ref 409 410 411 412 413 414 415 416 Part 158776 295644 295645 296644 295032 261861 295034 295035 Description O RING RING backup WIPER rod SEAL shaft SPACER proportioning pump SPACER reverse switch ROD tie BLOCK port ti7727a Qty D PIA NN D D ND ON 3120635 Display Ref 501 501a 501b 501c 502 502a 502b 502c 503 507 506 Part 24G884 24G882 246479 112324 24G883 24G882 246479 112324 15B293 3120635 508 Description DISPLAY pressure includes 501a 501c BOARD circuit SWITCH membrane SCREW DISPLAY temperature includes 502a 502c BOARD circuit SWITCH membrane SCREW GASKET sch D a D sch Ref 504 505 506 507 508 510 511 512 501 Part 15B292 15B291 246287 117499 117523 111393 15B386 195853 Parts ti2574a 501c 501a Description COVER PLATE HARNESS wire red stop button HANDLE NUT cap 10 24
36. Repair Parts PREACTER 7 GRACO 31206395 EN Hydraulic Heated Plural Component Proportioner For spraying polyurethane foam and polyurea coatings For professional use only Not for use in explosive atmospheres Important Safety Instructions e Read all warnings and instructions in this manual Save these instructions See page 3 for model information including maximum working pressure and approvals For patent information see WWW graco com patents Model H 40 Shown TI9830a NTER TE LE ll LISTE 9902471 Conforms to ANSI UL PROVEN QUALITY LEADING TECHNOLOGY Std 499 Certified to CAN CSA Std C22 2 No 88 Contents MOGBIS 31431 iii A ea edente d od 3 HOD eau othe eu eer ee ous 27 Supplied Manuals 5 Pressure Relief Procedure 27 Related Manuals 5 PIUSHING se aot d op dc RE i EAT OR edid 28 Ward bereede 6 Proportioning Pumps 28 Temperature Control Diagnostic Codes 8 Circuit Breaker Module 30 E01 High fluid temperature 8 ElectriC MOtOf sesi oma mem macto xv a 31 E02 High zone current 9 Motor Control Board 32 E03 No zone current 9 Transducers 4 esit do Eae bra Ro ee 34 E04 Fluid Temperature Sensor FTS or Ele GI TIO Fan uncus ute ate nih ele di dt RUP acp md 34 thermocouple discon
37. ard See TABLE 4 for factory settings See FIG 5 for location on board Ne To prevent overpressurization DIP switch 2 must be set to ON for Model H 25 32 Table 4 DIP Switch SW2 Settings Sm ona ren Motor soft start ON factory default Switch 1 Motor soft start OFF Not applicable to 3 phase motors OFF for pressure imbalance warning Switch 2 ON for pressure imbalance alarm factory default Switch 3 Standby ON Standby n Set PN ee Switch 4 ON for Models H 25 E for ees and H 40 H XP2 and H XP3 system dependent system depen dent 9 Install new board in reverse order Apply thermal heatsink compound to mating surfaces of board and heatsink Kg Part 110009 Thermal Compound Table 5 Motor Control Board Connectors Connector Pin Description J18 J5 2 Pumpline reversing switch COM 3 Pumpline reversing switch NC 4 Pumpline reversing switch NO 3120635 Repair Motor Control DIP Switch SW2 Settings Models H 25 H 40 H 50 ON J3 A Y BA J8 B 1234 ti3178c 3 J9 Models H XP2 amp H XP3 ge J12 123 4 SW2 ti3178c 4 J13 AN Apply 110009 thermal heatsink ug J7 compound to mating surfaces J1 J14 JA ti7724a Fic 5 Motor Control Board 3120635 33 Repair Transducers 1 Turn main power OFF ep Disconnect power supply Ki 2 Relieve pressure page 27 3 Refer to electrical diagrams Motor control bo
38. ard is on right side inside cabinet 4 Disconnect transducer cables at board see FIG 5 page 33 Reverse A and B connections and check if 706 A Side 701 Fic 6 Transducers Electric Fan 1 Turn main power OFF Disconnect power supply aN 2 Relieve pressure page 27 3 Check fuses F at left of breaker module FIG 7 Replace if blown If good continue with step 4 4 Refer to electrical diagrams Disconnect fan wires from fuses F 34 diagnostic code follows see E21 No component A transducer page 12 5 If transducer fails test thread cable through top of cabinet Note path as cable must be replaced in same way 6 Install o ring 720 on new transducer 706 FIG 6 7 Install transducer in manifold Mark end of cable with tape red transducer A blue transducer B 8 Route cable into cabinet and thread into bundle as before 9 Connect transducer cable at board see FIG 5 page 33 706 B Side 720 ti9885a 5 Remove fan 6 Install fan in reverse order LS ic Se HL i 000 alata IT n ix x FiG 7 Fan Fuses ti9884a 1 3120635 Repair Temperature Control Module Table 6 Temperature Control Module Connections DATA A Data reporting PIN Y 12 HOSE T C P FTS purple 11 10 HOSE T C S FTS silver unshielded bare wire p HEATER T C B Y e he
39. d 2 Engage gun piston safety lock ti2409a ti2554a ti2421a 4 Shut off feed pumps and agitator if used 3120635 27 Repair Flushing AN Flush equipment only in a well ventilated area Do not spray flammable fluids Do not turn on heaters while flushing with flammable solvents 28 Flush out old fluid with new fluid or flush out old fluid with a compatible solvent before introducing new fluid Use the lowest possible pressure when flushing All fluid components are compatible with common solvents Use only moisture free solvents To flush feed hoses pumps and heaters separately from heated hoses set PRESSURE RELIEF SPRAY valves SA SB to PRESSURE A RELIEF CIRCULATION Oy Flush through bleed lines N ti9880a To flush entire system circulate through gun fluid manifold with manifold removed from gun To prevent moisture from reacting with isocyanate always leave the system dry or filled with a mois ture free plasticizer or oil Do not use water Proportioning Pumps Din Ne manual 312068 for pump repair instructions 1 Shut off D 3 and heat zones 2 Flush page 28 3 If pumps are not parked press D Trigger gun until pumps stop Turn main power OFF Disconnect power supply 5 Shut off both feed pumps Close both fluid inlet ball valves B ti9883a 6 Tur
40. ducer 1 Check transducer connection at J3 on motor con trol board page 33 and clean contacts 2 Reverse A and B transducer connections If error moves to transducer B E22 replace transducer A page 34 If error does not move replace motor con trol board page 32 E22 No component B transducer 1 Check transducer B connection at J8 on motor con trol board page 33 and clean contacts 2 Reverse A and B transducer connections If error moves to transducer A E21 replace transducer B page 34 If error does not move replace motor con trol board page 32 E23 High fluid pressure 1 Relieve pressure Verify low pressure with analog gauges Turn main power OFF then ON 11 If error persists do checks below 2 If pressure imbalance is set to Warning instead of Alarm see page 32 an E23 will occur See E24 Pressure imbalance for causes and checks 12 E24 Pressure imbalance Upon initial start up this diagnostic code will not cause an alarm for 2 minutes If the pressure difference between components A and B exceeds 500 psi 3 5 MPa 35 bar an E24 will occur This default value is adjustable see the operation manual E24 can be an alarm or a warning as desired Set DIP switch on motor control board ON for alarm OFF for warning See page 32 Fast E24 Errors Fast E24 errors occur e within 10 seconds of turning the pumps on or e assoon as you trigger the gun Causes of Fast E24 Erro
41. e psi MPa bar Full Load Part Peak Amps Series Per Phase x253725 E 100 230V 1 253726 E 30V 3 1 64 1 E 71 Tam 1 __253727 E A 400V 3 EI 95 0 073 0 28 64 1 0 073 0 28 ___256506 E 52 am 31 700 20400 71 1 256505 E 95 230V 3 52 3120635 3 Models H XP2 SERIES Approximate Maximum Fluid Full Load Primary Max Flow Output per Hydraulic Working Peak Amps Heater Cycle A B Pressure Pressure Part Series Per Phase Watts gpm Ipm gal liter Ratio psi MPa bar 255408 F 100 230V 1 23 2260 15 300 1 5 5 7 0 042 0 16 2 79 1 3500 24 1 241 255404 F 59 230V 3 23 260 15 300 1 5 5 7 0 042 0 16 2 79 1 3500 24 1 241 1 5 5 7 0 042 0 16 79 00 9 255405 F 35 400V 3 23260 15 300 1 5 5 7 0 042 0 16 2 79 1 3500 24 1 241 H XP3 SERIES Approximate Maximum Fluid Full Load Primary Max Flow Output per Hydraulic Working Part Peak Amps Heater Cycle A B Pressure Pressure Series Per Phase Watts gpm Ipm gal liter Ratio psi MPa bar 253403 E 230V 1 123 100 12 000 2 8 10 6 0 042 0 16 2 79 1 3500 24 1 241 253404 E 230V 3 131 700 20 400 2 8 10 6 0 042 0 16 2 79 1 3500 24 1 241 253405 E 400V 3 131 700 20 400 2 8 10 6 0 042 0 16 2 79 1 3500 24 1 241 Full load amps with all devices operating at maximum capabilities Fuse requirements at various flow rates and mix chamber
42. e closing Verify wiring from heater control to contac tor coil a Hose zone test hose continuity page 39 b Perform Transformer Primary Check and Transformer Secondary Check starting on page 41 When a no current error occurs the LED on the specific zone s module turns red when the error is displayed Temperature Control Diagnostic Codes E04 Fluid Temperature Sensor FTS or thermocouple disconnected 1 10 Check temperature sensor connections to long green connector B on temperature control module page 35 Unplug and re plug sensor wires Test fluid temperature sensor continuity with ohm meter page 8 If an error occurred for the hose zone check FTS connections at each section of hose If an error occurred for the hose zone test FTS by plugging directly into machine ti9878a To verify heater control module is not causing the problem use a wire to short circuit the two pins cor responding to the FTS red and yellow for A or B zone red and purple for hose The display will show the control heater module temperature If an error occurred for the hose zone temporarily use the current control mode Refer to Reactor Operation manual 312062 E05 Circuit board overheated Each module has an on board temperature sensor Heat is turned off if module temperature exceeds 185 F 85 C within the heater module 1 Check that fan above electrical cabinet is operating 2 Check that electrica
43. e and keep it steady Flow too high Use smaller mix chamber Decrease Hose does not maintain temperature pressure while spraying Hose was not fully preheated Wait for hose to heat to correct tem perature before spraying Low supply voltage Verify line voltage Low line voltage sig nificantly reduces power available to hose heat system affecting longer hose lengths A and or B heaters are overheating Check primary heaters for either a ther material mocouple problem or a failed element attached to thermocouple page 10 Faulty thermocouple connections Verify that all FTS connections are snug and that pins of connectors are Hose temperature exceeds setpoint clean Examine connection of thermo couples to long green plug on heater control board Unplug and re plug ther mocouple wires cleaning off any debris Unplug and re plug long green connector on heater control board Missing or damaged insulation around Make sure the hose bundle has ade FTS causing the hose heat to be ON _ quate insulation evenly covering the constantly entire length and connection joints 3120635 19 Troubleshooting PROBLEM CAUSE SOLUTION Faulty thermocouple connections Verify that all FTS connections are snug and that pins of connectors are clean Examine connection of thermo couples to long green plug on heater control board Unplug and re plug ther mocouple wires cleaning off any debris Unplug and re plug long green connector
44. e properly set and wiring is correct before assum ing there is a problem 1 Relieve pressure page 27 PROBLEM CAUSE SOLUTION Electric motor will not start or stops motor will not start or stops Loose connections connections Check connections at motor control connections at motor control during operation board Circuit breaker tripped Reset breaker 813 see Circuit Breaker vidis page 30 Check 230 Vac at output of breaker Damaged motor control board Replace board See Motor Control Board page 32 3120635 21 Troubleshooting PROBLEM CAUSE Hydraulic pump does not develop pressure Low or zero pressure with screeching noise 22 Pump is not primed or lost its prime Screeching noise is characteristic of cavitation and is normal at initial startup for a maximum of 30 sec onds Hydraulic fluid is too hot Electric motor operating in wrong direction for 3 Phase system Drive belt loose or broken SOLUTION Check electric motor rotation Both motor and hydraulic pump must rotate counterclockwise when viewed from shaft end If rotation is incorrect reverse leads L1 and L2 See Con nect Electrical Cord in Operation manual 312062 Check dipstick to ensure that hydrau lic reservoir is properly filled see Operation manual Check that inlet fitting is fully tight to ensure no air is leaking into the pump inlet To prime pump run unit at lowest pressure setting and slowly incr
45. e wrist strap 2 Relieve pressure page 27 5 Remove screws 509 510 and cover 504 FIG 3 Refer to electrical diagrams 13 4 Puton static conductive wrist strap 6 Disconnect button cable connectors 506 from back of temperature display 501 and pressure display 5 Disconnect main display cable 20 at lower left cor 502 ner of display module see FIG 13 6 Remove screws 509 510 and cover 504 see 7 Remove red stop button 506 FiG 13 8 Reassemble in reverse order Be sure display cable ground wire G is secured between cable bushing 4 with 12 If replacing both displays label temperature display SEENEN cables TEMP and pressure display cables PUMP before disconnecting 7 Disconnect cable connectors 506 and 511 from back of temperature display 501 or pressure dis play 502 see FIG 13 8 Disconnect ribbon cable s R from back of display see FIG 13 9 Remove nuts 508 and plate 505 10 Disassemble display see detail in FIG 13 11 Replace board 501a or 502a or membrane switch 501b or 502b as necessary 12 Reassemble in reverse order see FIG 13 Apply medium strength thread sealant where shown Be sure display cable ground wire G is secured 42 3120638 Repair A Apply medium strength thread sealant 507 506 ti2574a Detail of Membrane Switches and Display Boards Temperature Display 502c Pressure Display 502a 502b
46. ease pressure In some cases it may be necessary to remove motor cover and drive belt to allow for manual counterclockwise rotation of hydraulic pump Turn fan pulley by hand Verify oil flow by removing oil filter to see flow into filter manifold Reinstall oil filter Do NOT operate unit without a properly installed oil fil ter If noise continues longer than 30 sec onds press motor key to shut off the motor Check that the inlet fit tings are tight and that the pump has not lost its prime Ensure that the reservoir is properly serviced Improve ventilation to allow more efficient heat dissipation Motor must operate counter clock wise from pully end Check drive belt condition Replace if broken 3120635 Troubleshooting Proportioning System 2 Turn main power OFF A AN N ed 3 Allow equipment to cool Problems Before performing any troubleshooting procedures 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 Proportioning pump does not hold Pump piston or intake valve leaking 1 Observe gauges to determine pressure when stalled which pump is losing pressure 1 Relieve pressure page 27 Determine in which direction the pump has stalled by obs
47. entify 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 312063 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2007 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com Revised February 2015
48. erving which directional valve indicator light is on See Table 2 page 25 to isolate the problem Repair the valve see pump man ual 312068 Material imbalance See Pres Restriction at the gun Clean the gun see your separate sure Material Imbalance page 25 gun manual Inadequate flow from pump cavita Increase fluid supply to proportioning tion pump e Use 2 1 supply pump e Use minimum 3 4 in 19 mm ID supply hose as short as practical Fluid is too thick Consult your mate rial supplier for the recommended fluid temperature to maintain a vis cosity of 250 to 1500 centipoise Clean inlet strainer screen page 44 Worn pump inlet valve ball seat or gasket Replace see pump manual 312068 Pressure relief circulation valve leak Remove return line and determine if ing back to supply flow is present while in SPRAY T mode 3120635 23 Troubleshooting PROBLEM Pumps do not reverse direction or pumps do not move Erratic pump movement Pump output low CAUSE Bent or loose activator plate rocker arm or reversing switch Loose piston packing bolt Faulty directional valve Pump cavitation Loose activator plate rocker arm or reversing switch Faulty directional valve Obstructed fluid hose or gun fluid hose ID too small Worn piston valve or intake valve in displacement pump Inadequate feed pump pressure SOLUTION See Pumps Do Not Reverse Direc tion page
49. hoses 1 Turn main power OFF Disconnect power A B supply 7 Remove ground wire K from ground screw on 2 Relieve pressure page 27 underside of FTS 3 Remove tape and protective covering from FTS 8 Remove FTS probe H from component A ISO 21 FIG 10 Disconnect hose cable F Test with side of hose ohmmeter between pins of cable connector Installation The Fluid Temperature Sensor FTS is supplied Install Pins Result FTS between main hose and whip hose See Heated approximately 10 ohms Hose manual 309572 for instructions 1 to FTS component A infinity fitting ISO ti9581c FiG 11 Fluid Temperature Sensor and Heated Hoses 40 312063S Repair Transformer Primary Check 3 To verify transformer voltage turn on hose zone Measure voltage from 18CB 2 to POD HOSE P15 2 see Reactor Electrical Dia 1 Turn main power OFF grams manual 312064 2 Locate the two smaller 10 AWG wires coming out Model Secondary Voltage of transformer Trace these wires back to contactor 310 tt and circuit breaker 811 Use an ohmmeter to test for continuity between two wires there should be 410 ft 120 Vac continuity For 230 Vac line voltage Transformer Secondary Check Replace Transformer 1 Turn main power OFF a di this procedure to replace transformer 2 Locate the two larger 6 AWG wires coming out of transformer Trace these wires back to large green connector under hose co
50. iagrams manual 312064 e if motor board and wiring are not the cause replace the directional valve For diagnostic purposes it is possible to manually override the directional valve by using a small screwdriver to depress the button in the center of either directional valve end cap Depressing the button in the right end cap should cause the pump to travel to the right Depressing the left button should cause the pump to travel to the left If you have determined that the cause is none of the above check for a loose piston packing retaining bolt This causes the piston to contact the inner face of the pump inlet flange before the activator plate contacts the rocker arm Shut down the unit and dis assemble the appropriate pump for repair 3120635 Repair Repair 5 Turn PRESSURE RELIEF SPRAY valves SA SB PN AN N to PRESSURE RELIEF CIRCULATION A Repairing this equipment requires access to parts Route fluid to waste containers or supply tanks that may cause electric shock or other serious injury Ensure gauges drop to 0 if work is not performed properly Have a qualified electrician connect power and ground to main power switch terminals see operation manual Be sure to shut off all power to the equipment before repairing Pressure Relief Procedure NA 1 Relieve pressure in gun and perform gun shutdown 6 Disconnect gun air line and remove gun fluid mani procedure See gun manual fol
51. ibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL I
52. ieve pressure page 27 812B 25A 40A or 50A 3 Using an ohmmeter check for continuity across cir cuit breaker top to bottom If no continuity trip breaker reset and retest If still no continuity Depending on model replace breaker as follows a Refer to electrical diagrams and to TABLE 3 Dis connect wires and remove bad breaker b Install new breaker and reconnect wires NOTE To reference cables and con 812B nectors see the electrical diagrams and 813 the parts drawings on pages 68 69 ti9884a FIG 4 Circuit Breaker Module 30 3120635 Repair Electric Motor Installation 1 Place motor on unit Removal 2 Fasten motor with screws 3 Connect the wires using wire nuts Refer to the Disconnect power Reactor Electrical Diagram manual 312064 and the diagram inside the motor junction box cover The motor must operate counterclockwise when looking at the output shaft 1 Turn main power OFF supply AN 3 Phase Motors motor must rotate counterclock wise when viewed from shaft end If rotation is incorrect reverse power leads L1 and L2 See Reactor Operation manual 312062 Connect Elec trical Cord 2 Relieve pressure page 27 3 Remove motor shroud 4 Disconnect motor cables as follows 4 Return to service a Refer to electrical diagrams in the Reactor Elec trical Diagram manual 312064 Motor control board is on right side inside cabinet
53. ion Failed heater element See Primary Heaters page 37 Signal failure from thermocouple See E04 Fluid Temperature Sen sor FTS or thermocouple discon nected page 10 Thermocouple wired incorrectly See E04 Fluid Temperature Sen sor FTS or thermocouple discon nected page 10 Power up zones one at a time and verify that tempera ture for each zone rises 18 3120635 Troubleshooting Hose Heat System 2 Turn main power OFF A AN N ed 3 Allow equipment to cool Problems Before performing any troubleshooting procedures 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 Ambient temperature is too cold Use auxiliary hose heat system FTS failed or not installed correctly Check FTS page 10 Low supply voltage Verify line voltage Low line voltage sig nificantly reduces power available to hose heat system affecting longer hose lengths 1 Relieve pressure page 27 Hose heats but heats slower than usual or it does not reach temperature A and B setpoints too low Increase A and B setpoints Hose is designed to maintain temperature not to increase it Ambient temperature is too cold Increase A and B setpoints to increase fluid temperatur
54. ional Indicator Lighted Indicator Lighted B side pump piston valve B side pump inlet valve A side pump inlet valve A side pump piston valve Pressure Material Imbalance To determine which component is out of balance check the color of some sprayed material Two component materials are usually a mix of light and dark fluids so the under proportioned component can often be readily determined When you have determined which component is under proportioned spray off target focusing on the pressure gauge for that component For example if component B is under proportioned focus on the B side pressure gauge If the B gauge reads considerably higher than the A gauge the prob lem is at the gun If the B gauge reads considerably lower than the A gauge the problem is at the pump 3120635 25 Troubleshooting Pumps Do Not Reverse Direction 1 26 For the proportioning pumps to reverse direction the activator plate 219 must contact the rocker arm to activate the reversing switch 210 Check for a bent or loose activator plate rocker arm or revers ing switch See FIG 1 on page 25 and the parts drawing on page 59 Check the function of the directional valve Direction indication lights should switch on and off based on the reversing switch 210 position LEDs D19 and D20 near J5 reversing switch connector on motor board should alternately illuminate based on the reversing switch position There are two pos
55. l cabinet door is properly installed 3 Check for obstructions blocking cooling holes in bot tom of electrical cabinet 4 Clean heatsink fins behind heater control modules 5 Ambient temperature may be too high Allow Reac tor to cool by moving to a cooler location E06 Communication cable unplugged 1 Unplug and re plug cable that connects heater con trol module to heater module 2 Replace communication cable if problem persists 3120635 Motor Control Diagnostic Codes Motor Control Diagnostic Codes Motor control diagnostic codes E21 through E27 appear Warnings on pressure display There are two types of motor control codes alarms and Reactor will continue to run Press O to clear A warnings Alarms take priority over warnings warning will not recur for a predetermined amount of time varies for different warnings or until main power then ON 11 Code Name Alarm A or Corrective Warning W Action Alarms is turned OFF Alarms turn off Reactor Turn main power OFF then ON to clear No transducer compo transducer compo nent A er can also be cleared except for code 23 by 22 No transducer compo nent B pressing o High fluid pressure Pressure imbalance High motor temperature Momentary loss of com munication Pumpline reversing switch failure high cycle rate Loss of communication 3120635 11 Motor Control Diagnostic Codes E21 No component A trans
56. le was at fault Switch connections back to ensure connec tor was not poorly connected 3120635 Motor Control Diagnostic Codes 15 Troubleshooting Troubleshooting Reactor Electronics 2 Turn main power OFF l A Ab N T 3 Allow equipment to cool Try the recommended solutions in the order given for Before performing any troubleshooting procedures each problem to avoid unnecessary repairs Also determine that all circuit breakers switches and con 1 Relieve pressure page 27 trols are properly set and wiring is correct before assum ing there is a problem PROBLEM CAUSE SOLUTION Plug in power cord No power Both sides of display do not Turn disconnect ON illuminate Low voltage Ensure input voltage is within specifi cations page 42 Loose wire Loose wire Check connections page 42 Display disconnected Check cable connections page 42 Display disconnected Display disconnected Check cable connections page 42 Display cable damaged or corroded Clean connections replace cable if is damaged Defective circuit board Swap display connection to motor control board with connection to heater control board If temperature Temperature display does not illuminate display illuminates heater control board is causing problem Otherwise display cable or display is failing Display disconnected Check cable connections page 42 Dis
57. lowing tables to find parts that vary by model See Parts starting on page 48 for parts used on all models H 25 and H XP2 Models 255400 255401 255402 255403 255404 255405 255406 255407 255408 H 25 H 25 H 25 H XP2 H XP2 H XP2 H 25 H 25 H 25 8 0kW 8 0kW 8 0kW 15 3 kW 15 3 kW 15 3 kW 15 3 kW 15 3 kW 15 3 kW 230V 230V 400V 230V 230V 400V 230V 230V 400V Description 1 phase 3 phase 3 phase 1 phase 3 phase 3 phase 1 phase 3 phase 3 phase HEATER pages 24 815 247815 247815 247813 247813 247813 247813 247813 247813 61 63 Qty 1 Qty 1 Qty 1 Qty 2 Qty 2 Qty 2 Qty 2 Qty 2 Qty 2 MOTOR page 52 24 816 247816 247816 247816 247816 247816 247816 247816 247816 BOARD motor 247839 247839 247839 247839 247839 247839 247839 247839 247839 control page 50 TRANSFORMER 247812 247812 247812 247812 247812 247812 247812 247812 24781 page 50 PUMP Model Model Model Model Model Model Model Model Model proportioning 120 120 120 80 80 80 120 120 120 page 59 TUBE inlet 15R648 15R648 15R648 15R646 15R646 15R646 15R646 15R646 15R646 component A page 51 TUBE outlet 15R649 15R649 15R649 15R645 15R645 15R645 15R645 15R645 15R645 component A page 51 TUBE inlet 15R653 15R653 15R653 15R650 15R650 15R650 15R650 15R650 15R650 component B
58. mbers BRACKET heater see page 56 for part numbers INSULATOR heat 4 NUT cap 3 8 16 4 SCREW flanged hex hd 14 9 1 NO NUT hex flange head LABEL fault codes Ref Part 44 454 189930 46 247844 47 247845 48 803889 49 15B593 50x 308212 51 15B775 52 53 54A 15G280 55 113505 56 112776 57 113802 58 59 255159 59a 118459 59b 109077 59c C20487 59det 116W714 59e 102124 5Of 120300 59g 180199 59h 15H200 1C20203 59j 15H199 t 16V879 59k 104813 61555808 59m 296178 59n 15D757 59p 253481 60 111800 61 247849 62 247782 63 247850 65 15H185 Description RIVET pop 3 16 in 5 mm x 0 4 8 in 10 mm LABEL caution BRACKET reservoir lube PULLEY drive BELT SHIELD membrane switch PAD pamphlet safety COVER wire access COVER heater see page 56 for part numbers SCREW machine pan hd 8 32 x 3 8 LABEL warning NUT KEPS hex hd WASHER plain SCREW hex hd flanged STRAP tie wire 2 FLUID INLET KIT see page 53 UNION swivel 3 4 npt m x 3 4 npsm f VALVE ball 3 4 npt fbe NIPPLE 3 4 npt MANIFOLD strainer inlet Fluid 2 Inlet Kit Series A MANIFOLD strainer inlet Fluid 2 Inlet Kit Series B o oonhrtr N M N THERMOMETER dial 2 GAUGE pressure fluid 2 ELEMENT filter 20 mesh stan 2 dard GASKET strainer PTFE Fluid 2 Inlet Kit Series A GASKET strainer PTFE Fluid 2 Inlet Kit Series B
59. n both PRESSURE RELIEF SPRAY valves SA A SB to PRESSURE RELIEF CIRCULATION d Route fluid to waste containers or supply tanks Ensure gauges drop to O 3120635 Repair Use drop cloth or rags to protect Reactor and sur i j in Ib 22 6 Nem rounding area from spills A Torque to 200 in Ib 22 6 Nem 7 See FIG 2 Disconnect the B Resin side pump inlet and outlet lines Remove the pin 219 from the clevis 218 to disconnect the pump from the hydraulic cylinder 201 Remove the four screws 203 holding the pump to the spacers 413 of the cylinder Take the pump assembly to a workbench A Torque to 200 in Ib 22 6 Nem A 203 FIG 3 Proportioning Pump A Side 9 See manual 312068 for pump repair instructions cw 10 Reconnect the pump in the reverse order Torque the screws 203 to 200 in Ib 22 6 Nem ti9882a FIG 2 Proportioning Pump B Side 8 See FIG 3 Disconnect the A ISO side pump inlet and outlet lines Use the pin extractor tool 244 to remove the pin 219 which disconnects the pump from the hydraulic cylinder 201 Remove the four screws 203 holding the pump to the spacers 413 of the cylinder Take the pump assembly to a work bench 3120635 29 Repair Circuit Breaker Module Table 3 Circuit Breakers see FIG 4 1 Turn main power OFF Disconnect power supply Turn circuit breakers on to test 40A AN 812A 25A 40A or 50A 2 Rel
60. nected 10 Temperature Control Module 35 E05 Circuit board overheated 10 Primary Heaters 37 E06 Communication cable unplugged 10 Heated Hose 39 Motor Control Diagnostic Codes 11 Fluid Temperature Sensor FTS 40 PARIS AR toe Satin Bas iege abt Gere ees bo 11 Display Module 42 WOMINGS use np scade bed lod sus Va rt a a 11 Inlet Fluid Strainer Screen 44 E21 No component A transducer 12 Pump Lubrication System 44 E22 No component B transducer 12 Change Hydraulic Fluid and Filter 45 E23 High fluid pressure EE e ead dba Qoid bs 48 E24 Pressure imbalance 12 Parts Used on All Models 54 E27 High motor temperature 14 Parts that Vary by Model 56 E30 Momentary loss of communication 14 Sub Assemblies 59 E31 Pumpline reversing switch Proportioner Assembly 59 failure high cycle rate 14 10 2 kW and 6 0 kW Heaters oo 61 E99 Loss of communication 15 8 0 kW Dual Zone Heater 62 Troubleshooting 16 7 65 kW Single Zone Heater 63 Reactor Electronics 16 Hydraulic Cylinder
61. nt Warning labels signs tags and cards are available at no cost 1 Included in the following complete valve kits ISO Valve Kit left red handle 255149 Resin Valve Kit right blue handle 255150 Valve Set Kit both handles and grease gun 255148 ND sch NN NI YO sch Complete valve kits also include thread sealant Purchase kits separately 3120635 67 Parts Circuit Breaker Modules A 230V 3 Phase Circuit Breaker Modules 810 For wiring and cable connections refer to electrical Pa diagrams manual 312064 supplied See page 71 820 805 806 811 8 817 for parts E 803 804 815 Ge Ee Ii ECH 808 NI 813 819 818 B 400V 3 Phase Circuit Breaker Modules For wiring and cable connections refer to electrical diagrams manual 312064 supplied See page 71 810 817 for parts 820 805 806 811 iki HT DEER ER Tow S F VIEN d 3120635 68 Parts C 230V 1 Phase Circuit Breaker Modules 810 For wiring and cable connections refer to electrical 820 805 806 diagrams manual 312064 supplied See page 71 811 for parts x 814 817 Y Y H L1 T 808 802 i A LE 801 816 818 819 D 230V 3 Phase Circuit Breaker Modules For wiring and cable connections refer to electrical diagrams manual 312064 supplied See page 71 810 for parts 820 805 806 54 814 817 821 AS 81 P LE ug Cr an J E E
62. ntrol module and circuit breaker 809 Use an ohmmeter to test for continu 1 Turn main power OFF ity between two wires there should be continuity supply Disconnect power If you are not sure which wire in green plug under hose module connects to transformer test both wires One wire should have continuity with the other transformer wire in breaker 809 and the other wire should not 2 Open Reactor cabinet 3 Remove bolts holding transformer to cabinet floor Slide transformer forward 4 Disconnect the transformer wires see Reactor Elec trical Diagrams manual 312064 5 Remove transformer from cabinet 6 Install new transformer in reverse order FIG 12 Circuit Breaker Module 3120638 41 Repair Display Module between cable bushing and cover 504 with screws 512 Temperature and Pressure Displays Red Stop Button CAUTION Before handling board put on a static conductive CAUTION Before handling board put on a static conductive wrist strap to protect against static discharge which can damage board Follow instructions provided with wrist strap wrist strap 1 Turn main power OFF ep Disconnect power 1 Turn main power OFF Disconnect power supply supply wrist strap to protect against static discharge which can damage board Follow instructions provided with 2 Relieve pressure page 27 AN 3 Refer to electrical diagrams 4 Puton static conductiv
63. ot overtighten Let the gasket make the seal 5 Open the material supply valve ensure that there are no leaks and wipe the equipment clean 6 Proceed with operation 44 ti9886a Fic 14 Y Strainer Components Fluid filter screen 59g replacements Part Description 180199 20 mesh standard 1 pack 255082 80 mesh optional 2 pack 255083 80 mesh optional 10 pack Pump Lubrication System A Ab N 7 Check the condition of the ISO pump lubricant daily Change the lubricant if it becomes a gel its color dark ens or it becomes diluted with isocyanate Gel formation is due to moisture absorption by the pump lubricant The interval between changes depends on the environment in which the equipment is operating The pump lubrication system minimizes exposure to mois ture but some contamination is still possible Lubricant discoloration is due to continual seepage of small amounts of isocyanate past the pump packings during operation If the packings are operating properly lubricant replacement due to discoloration should not be necessary more often than every 3 or 4 weeks To change pump lubricant 1 Relieve pressure page 27 2 Liftthe lubricant reservoir LR out of the bracket RB and remove the container from the cap Hold ing the cap over a suitable container remove the check valve and allow the lubricant to drain Reat tach the check valve to the inlet hose See F
64. ousing H Do not remove the thermocouple adapter 305 unless necessary If adapter must be removed ensure that mixer 309 is out of the way when replacing the adapter o 310 ANKE N a 305 309 FIG 9 Thermocouple 38 H 301 Bx Replace thermocouple FIG 9 a Remove protective tape from thermocouple tip T b Apply PTFE tape and thread sealant to male threads and tighten thermocouple housing H into adapter 305 c Pushin 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 Houte wires S into cabinet and thread into bundle as before Reconnect wires to board 0 Replace heater shroud Turn on heaters A and B simultaneously to test Temperatures should rise at same rate If one heater is low loosen ferrule nut N and tighten ther mocouple housing H to ensure thermocouple tip T contacts element 307 A Apply PTFE tape and thread sealant VEN Apply 110009 thermal heatsink compound 307 A 308 ti7924a 3120635 Overtemperature Switch 1 Turn main power OFF Disconnect power supply 2 Relieve pressure page 27 A 74 3 Wait for heaters to cool 4 Remove heater shroud 5 Disconnect one leadwire from overtemperature switch 308 FiG 9 Test across switch with ohm meter Resistance must be approximately O ohms
65. perature d Turn on heat zone by pressing o e Using a voltmeter carefully measure the volt age at the hose connector You should not get a voltage reading If you do the SCR on the tem perature control board is bad Replace the tem perature control assembly CAUTION Before handling assembly put on a static conductive wrist strap to protect against static discharge which can damage assembly Follow instructions provided with wrist strap 1 Turn main power OFF Disconnect power supply Ki 2 Relieve pressure page 27 3 Refer to electrical diagrams see Electrical Dia grams manual 312064 Temperature control assem bly is on left side inside cabinet 4 Remove bolts that secure transformer assembly and slide assembly to side in cabinet 5 Put on static conductive wrist strap 6 Disconnect all cables and connectors from assem bly see Parts Temperature Control page 66 7 Remove nuts and take entire temperature control assembly to workbench 8 Replace defective module 9 Install assembly in reverse order 3120635 Primary Heaters Heater Element 1 Turn main power OFF 74 Disconnect power supply 2 Relieve pressure page 27 3 Wait for heaters to cool 4 Remove heater shroud 5 See pages 61 63 for illustrations of each heater Disconnect heater element wires from heater wire connector Test with ohmmeter 1500
66. play cable damaged or corroded Clean connections replace cable if is damaged Defective circuit board Swap display connection to motor control board with connection to heater control board If pressure dis play illuminates motor control board is causing problem Otherwise dis play cable or display is failing Low voltage Ensure input voltage is within specifi cations page 42 Poor display connection Check cable connections page 42 Erratic display display turns on and Replace damaged cable off Display cable damaged or corroded Clean connections replace cable if is damaged Display cable not grounded Ground cable page 42 Display extension cable too long Must not exceed 100 ft 30 5 m 16 3120635 Pressure display does not illuminate Troubleshooting PROBLEM CAUSE SOLUTION Hose display reads OA at startup FTS disconnected or not installed Verify proper installation of FTS see Operation manual 312062 or adjust FTS to desired current setting Poor display connection Check cable connections page 42 Replace damaged cable Display cable damaged or corroded Clean connections replace cable if is Display does not respond properly to damaged button pushes Ribbon cable on display circuit board Connect cable page 42 or replace disconnected or broken Broken display button Replace page 42 Red stop button does not work Broken button fused contact Replace page 42 Blown fuse
67. rmocouple yellow SES HEATER T C B R hermocouple red T 7 HEATER T C A Y hermocouple yellow 5 HEATER T C A R hermocouple red Overtemperature switch B Overtemperature switch A F DISPLAY Display RE Right Side of C PROGRAM E Software programming Control Heater Module BOOT F Software bootloader POWER RELAY G Circuit board power input and ontactor control output ti9843a1 Table 7 Temperature Power Module Connections H COMMUNICATION Communication to control board ti9843a4 POWER J Power to heater Bottom of Power Modules FIG 8 Temperature Control Module Connections 3120635 35 Repair Test SCR Circuit Replacing Temperature Control Assembly 1 Testthe SCR circuit in the on position Modules a Make sure everything is connected including the hose b Turn main power ON c Adjust the hose heat setpoint above the ambi ent hose temperature d Turn on heat zone by pressing o e Hold down D to view electrical current Hose current should ramp up to 45A If there is no hose current see E03 No zone current page 9 If hose current exceeds 45A see E02 High zone current page 9 If hose current stays several amps below 45A hose is too long or voltage is too low Test the SCR circuit in the off position a Make sure everything is connected including the hose b Turn main power ON c Adjust the hose heat setpoint below the ambi ent hose tem
68. rs one side of the gun is plugged a pressure transducer has failed damaged pump seals or check valve no feed pressure or empty material drum plugged heater plugged hose plugged manifold one PRESSURE RELIEF SPRAY valve is leaking or is set to PRESSURE RELIEF CIRCULATION Oy Checks for Fast E24 Errors If a fast E24 error occurs first check the readings of the analog gauges e If the gauge readings are very close 1 Clear the error page 11 and try running the unit again 2 f E24 recurs and the gauge readings are still very close a pressure transducer has failed 3120635 The digital display always shows the higher of the two pressures As soon as the higher analog pres sure drops below the lower analog pressure the display changes to the new higher reading Knowing this the following checks will show which trans ducer has failed or if the motor control board has failed For testing purposes only set DIP switch 2 on the motor control board to OFF See page 32 This will allow the Reactor to continue to run with a pressure imbalance c Run the unit until pressure is 1000 1500 psi 7 10 5 MPa 70 105 bar Shut down the unit clear the alarm and power back up but do not depressurize the unit d Check the analog gauges to see which pressure is higher and check if the display matches If the higher gauge and display match that transducer is communicating with the motor control board
69. se e bottom of drum is damaged causing blockage of feed pump inlet e drum is not vented E27 High motor temperature Causes of E27 Errors e Motor temperature is too high Reduce pressure gun tip size or move Reactor to a cooler location Allow 1 hour for cooling e Make sure there is no obstruction to fan airflow Ensure that the motor fan shroud is installed e Check that the motor overtemperature wire assem bly is plugged into J9 on the motor control board page 33 e If the preceding checks do not correct the problem perform the following tests 14 1 Turn main power OFF 2 Allow motor to cool completely Check continuity between pins 1 and 2 on connector J9 on the motor control board page 32 If the resistance is infinity the motor thermal switch or the wire harness is bad Check wiring measure thermal switch continuity at motor and replace failed part 3 Unplug motor from J9 on motor control board Install jumper across pins 1 and 2 on board If error still occurs replace motor control board 4 fthe E27 error is still occurring the problem is with the motor control board E30 Momentary loss of communication If communication is lost between the display and the motor control board the display will normally show E99 The motor control board will register E30 the red LED will blink 30 times When communications are recon nected the display may show E30 briefly no more than 2 seconds
70. sible problems with the directional valve a If D19 and D20 do not alternately illuminate the possible causes include e faulty reversing switch wiring e faulty reversing switch or e faulty motor board To resolve this problem e verify the continuity of each reversing switch wire Replace faulty wires e verify reversing switch Unplug the J5 reversing switch connector Verify that con tinuity alternates between NC2 to com and NO3 to com by toggling the reversing switch see Electrical Diagrams manual 312064 If continuity does not alternate replace the reversing switch and reconnect the J5 reversing switch connector e ifthe reversing switch and wiring are not the cause and D19 and D20 will not alternately illuminate replace the motor board b If D19 and D20 do illuminate but the direction indication lights do not the possible causes include e faulty motor board e faulty directional valve wiring or e faulty directional valve To resolve this problem e verify the motor board output voltages at the J18 directional valve connector When the reversing switch is toggled one direc tion there should be 230V output between pins 1 and 2 A and A When it is toggled the other direction there should be 230V output between pins 3 and 4 B and B If output voltages are not present replace the motor board e verify continuity of each directional valve wire and verify wiring connections see Electrical D
71. sizes may be less T Total system watts based on maximum hose length for each unit e Parts 255400 through 255408 310 ft 94 6 m maximum heated hose length including whip hose e Parts 253400 through 253408 253725 through 25372 256505 and 256506 410 ft 125 m maximum heated hose length including whip hose Maximum flow rate given for 60 Hz operation For 50 Hz operation maximum flow rate is 5 6 of 60 Hz maximum flow CE approval does not apply 4 3120635 Supplied Manuals Supplied Manuals Related Manuals The following manuals are shipped with the Reactor The following manuals are for accessories used with the Proportioner Refer to these manuals for detailed equip Reactor ment information Order Part 15M334 for a compact disk of Reactor manu Order Part 15M334 for a compact disk of Reactor manu als translated in several languages Order Part 15B381 als translated in several languages for a compact disk of Fusion manual translated in sev eral languages Manuals are also available at www graco com Feed Pump Kits 309815 Instruction Parts Manual English Air Supply Kit 309827 Instruction Parts Manual English for Feed Pump Air Supply Kit Circulation and Return Tube Kits Description 309852 309572 Instruction Parts Manual English Translations Circulation Kit The Reactor Repair Parts manual is available in the fol Description lowing languages See the Tollowing chart for specific 3098
72. 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 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 in this manual Disconnect power or air supply BURN HAZARD Equipment surfaces and fluid that s heated can become very hot during operation To avoid severe burns do not touch hot fluid or equipment Wait until equipment fluid has cooled completely Temperature Control Diagnostic Codes Temperature Control Diagnostic Codes NOTICE To prevent damage to soft key buttons do not press the buttons with sharp objects such as pens plastic cards or fingernails Temperature control diagnostic codes appear on tem perature display These alarms turn off heat E99 clears automatically when communication is regained Codes E03 through E06 can be cleared by pressing For other codes turn main power OFF then ON to clear E01 High fluid temperature Causes of E01 Errors e Thermocouple A or B 310 senses a fluid tempera ture above 230 F 110 C e Fluid temperature sensor FTS senses a fluid tem perature above 230 F 110 C
73. uipment Check hoses and couplings daily Replace worn or damaged parts immediately FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and explosion Use and clean 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 lights on or off when flammable fumes are present Ground equipment personnel object being sprayed and conductive objects in work area See Grounding instructions Use only Graco grounded hoses Check gun resistance daily If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem Do not flush with gun electrostatics on Do not turn on electrostatics until all solvent is removed from system Keep a working fire extinguisher in the work area 6 3120635 747 3120635 Warnings 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 a valve to relieve the fluid expansion during heating e Replace hoses proactively at regular intervals based
74. ure b Turn zone on If temperature rises steadily power board is failing c Verify by swapping with another power module See Replacing Temperature Control Assem bly Modules page 36 d Ifthe swapped module does not fix the problem the power module is not the cause 8 Verify continuity of heater elements with an ohmme ter see page 37 3120635 Temperature Control Diagnostic Codes E02 High zone current 1 Turn main power OFF 2 Relieve pressure page 27 EN Disconnect whip hose 3 Disconnect hose connector D at Reactor 4 Using an ohmmeter check between the two termi nals of the connector D There should be no conti nuity 5 Exchange zone module with another one Turn zone on and check for error If error disappears replace faulty module For hose zone If error still occurs perform Trans former Primary Check and Transformer Secondary Check starting on page 41 When there is a a high current error the LED on that zone s module will turn red while the error is displayed E03 No zone current Check for tripped circuit breaker inside electrical cabinet or at power source for that zone Replace circuit breaker if it trips habitually 2 Check for loose or broken connection at that zone Exchange zone module with another one Turn zone on and check for error see page 36 If error disappears replace faulty module 4 f E03 occurs for all zones the contactor may not b

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