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Graco 311075U User's Manual

Contents

1. Pump rod and connecting rod move during operation Moving parts can cause serious injury such as pinching or amputation Keep hands and fingers away from wet cup during operation Shut off Motor Power before filling wet cup Fill wet cups through slots in plate or loosen screws and swing plate aside Tle985a 311075U Setup O Fill fluid tanks 9 CTO NOTICE To prevent cross contamination of fluids and equipment parts never interchange compo nent A isocyanate and component B resin parts or containers Have at least two 5 gal 19 liter pails to transfer fluid from drums to supply tanks Label one pail A and the other B using the red and blue labels provided Always doublecheck which material you have before pouring it in the supply tanks Pouring is eas ier if pails are not filled to the top Open only one supply tank at a time to avoid splashing material from one tank into the other when filling Using a drill and mixing blade mix filled or a ee arte materials in the pail before add ing to the tanks Material left in the tanks overnight may need to be remixed in the tanks 19 Setup N Add thin coating of grease lubricant to tank o ring if lid is difficult d Lifthose rack Remove tank A cover and pour ISO into tank A red side with desiccant filter in cover Replace cover A TI7017a Desiccant filter is blue when fre
2. 60 311075U Nonheated Proportioners Ref 1 2 AN sa 0 NO Ol N 13 15 23 33 34 Part Description 24R382 CART see page 67 24L000 TANK with lid and outlet fitting LDPE includes item 2a 15F895 O RING lid tank SCREW cap hex hd 5 16 18x 12 111800 5 8 in 16 mm 24K984 DRYER desiccant 24K976 MUFFLER vent 101044 119973 119993 287655 287656 117493 116702 WASHER plain 1 2 in 13 mm LANYARD 14 in 356 mm sst PLUG PROPORTIONER bare 120 V Model 249576 see page 62 PROPORTIONER bare 240 V Model 249577 see page 62 SCREW machine hex washer hd 1 4 20 x 1 1 2 in 88 mm UNION 1 4 npt m x 3 8 JIC 15V420 TUBE fluid 126960 119998 116704 104641 169970 ELBOW swivel 1 4 npt m x 1 4 npsm f ADAPTER A side 1 2 JIC x 1 4 npt m ADAPTER B side 3 8 JIC x 1 4 npt m BULKHEAD FITTING FITTING air line 1 4 npt m C20479 NIPPLE 1 4 npt x 1 4 npsm 28 755 15V421 249629 249630 249537 249538 117623 MANIFOLD recirculation with valves see page 66 TUBE recirculation 3 8 10 mm OD sst HOSE component A ISO 1 4 in 6 mm ID thermoplastic hose with moisture guard 1 4 npsm f x 48 in 1219 mm HOSE component B RES 1 4 in 6 mm ID thermoplastic hose 1 4 npsm f x 48 in 1219 mm DISPLAY nonheated 120 V Model 249576 see page 65 DISPLAY nonheated 240 V Model 249577 see page
3. bar 70 if 800 psi 5 6 MPa 56 bar running 500 psi 3 5 MPa 35 bar 6096 if 800 psi 5 6 MPa 56 bar running WARNING SHUTDOWN 300 psi 2 1 MPa 21 bar 2596 if 800 psi 5 6 MPa 56 bar 500 psi 3 5 MPa 35 bar 40 if 800 psi 5 6 MPa 56 bar Status Code 4 Transducer B Failure 1 2 Check transducer B electrical connection J8 at board page 47 Heverse A and B transducer electrical con nections at board page 47 If error moves to transducer A Status Code 3 replace transducer B page 48 311075U Status Code 5 Excessive Current Draw Shut off unit and contact distributor before resuming operation 1 Locked rotor motor unable to turn Replace motor page 51 2 Short on control board Replace board page 46 3 Worn or hung up motor brush causing arc ing of brush at commutator Replace brushes page 52 311075U Troubleshooting Status Code 6 High Motor Temperature Motor is running too hot 1 Motor temperature too high Reduce pres sure duty cycle gun tip size or move Reactor E 10 to a cooler location Allow 1 hour for cooling Check fan operation Clean fan and motor housing Status Code 7 No Cycle Counter Switch Input Have not received input from cycle counter switch for 10 seconds after selecting Recirc mode 1 Check cycle counter switch connection to board J10 pins 5 6 page 47 Check that magnet 224 and cycle
4. Disconnect temperature display power cable from J14 or J15 at bottom left of con trol board 406 5 Remove four screws from rear panel studs and remove temperature display 403 from front plate 401 6 Remove screw and nut 409 holding dis play to plate 403 7 Pull sensor cable through split in bushing 411 43 Repair 8 Reassemble in reverse order Mount tem perature display so Heater Power switch off 0 position is at left when facing control Vl 66 Y L d ut A e 424 LI Ry EX amp wu 66g 66d TI7067b FiG 10 Temperature Sensor Replace Function Knob Potentiometer 44 2 AS See Before Beginning Repair page 39 Relieve pressure page 27 Remove access cover 39 from back of control module Disconnect potentiometer wires from J2 on control board 406 See FIG 12 See Fic 11 Remove two setscrews 416a and pull function knob 416 off potentiome ter 404 shaft Remove nut N part of 404 and detent plate 415 Install new potentiometer 404 in reverse order Position potentiometer so slot S is horizontal Position knob 416 so pointer P faces up Install knob on shaft so slot S engages alignment pin in knob Push knob onto shaft against detent spring before tightening setscrews 416a Reconnect potentiometer wires to J2 as shown in FIG 12 311075U Hepair Detail of Function
5. 16 A circuit Model 249806 24R984 120 Vac 1 phase 50 60 Hz 1800 W requires a single dedicated 15 A circuit Model 249808 24R985 240 Vac 1 phase 50 60 Hz 1800 W requires a single dedicated 8 A circuit Generator Size for Reac Heated 5000 W minimum Maximum Fluid Tempera 160 F 71 C ture Maximum Ambient Tem 110 F 43 C perature Maximum Output 12 Ib min 5 4 kg min at 340 cycles min Output per Cycle A and 00352 gal 0133 liter B Overpressure Relief Recirc Spray valves automatically relieve excessive fluid pressure back to supply tanks Heater Power 120V models 850 W each 1700 W total 240V models 1000 W each 2000 W total Sound Pressure 78 7 dB A in fast circulation mode 84 5 dB A at 2000 psi 14 MPa 140 bar 0 72 gpm 2 7 lpm Sound Power per ISO 88 6 dB A in fast circulation mode 2614 2 94 4 dB A at 2000 psi 14 MPa 140 bar 0 72 gpm 2 7 Ipm tor E 10 only Nonheated 2500 W minimum 70 311075U Technical Data Tank Capacity Fluid Outlets Component A ISO 5 JIC male Fluid Circulation Returns Component A ISO 5 JIC male Air Inlet 1 4 in quick disconnect industrial type pin fitting Air Outlet 1 4 npsm m Gun Compressed Air Fusion Gun purge air and operating air 4 scfm 0 112 m min Hequirements Soe ae mE MD2 Gun with disposable mixer kit 14 scfm 0 392 m min with air spray valve fully open MD2 Gun with joint fill kit 2 scfm 056 m min Hose
6. 65 NUT cap 3 8 16 24K995 CORD 120 V Model 249576 24K997 CORD 240 V Model 249577 15G458 CABLE fan see page 62 CONDUIT flexible non metallic 15G385 COVER access display 40A 15G280 LABEL warning 311075U Qty 1 2 1 1 1 1 2 2 1 Q NO st st oq Ref 41 43 51 51a 52 o3 54 55 56 57 58 59 60 61 62 63 64 64a 65 Part Description 108296 SCREW machine hex washer hd 1 4 20 x 5 8 in 16 mm 217374 LUBRICANT ISO pump not shown BOLT 10 24 x 1 in 25 mm 15G119 GUARD splash 15G461 RACK hose PLUG 109510 STRAP bungee 25 in 635 mm WASHER flat 1 4 in nylon 160327 ELBOW swivel 3 4 npt m x 3 4 npsm f 101078 Y STRAINER includes item 51a ELEMENT 20 mesh not shown 119882 VALVE ball 3 4 npt fbe t handle C20487 NIPPLE 3 4 npt 157785 UNION swivel 3 4 npt m x 3 4 npsm f 242001 ADAPTER cord Europe Model 249577 only 242005 ADAPTER cord Australia Model 249577 only 195551 RETAINER plug adapter Model 249577 only 24K999 TRANSDUCER pressure 15G292 MANIFOLD pressure trans ducer 111457 O RING ptfe 15G476 LABEL components A and B see page 55 119992 NIPPLE 3 4 npt 157350 NIPPLE 1 4 npt x 3 8 npt 24K977 AIR FILTER SEPARATOR with 3 8 npt auto drain includes item 2a 114228 ELEMENT 5 micron polypro pylene not shown 100176 BUSHING 3 8 npt m x 1 4 npt f 180199 Included in 28
7. B side drive housing cover 227 includes the cycle counter switch 223 mounted in the cover When reassembling be sure to install cover with switch on B side 0 6 in 15 2 mm from inside edge 1 0 in 25 4 mm from inside bottom edge TI7028a al SA 208 steel 207 L a 209 bronze 211 bronze 221 215 212 213 steel bronze bronze 219 A Crankshaft must be in line with crankshaft at other end of motor cran TI7029a So pumps move up and down in unison Fic 14 Drive Housing 50 311075U Electric Motor Test Motor If motor is not locked up by pumps it can be tested using a 9 V battery Open recirculating valves disconnect J4 or J11 from control board see FIG 12 page 47 Touch jumpers from battery to motor connections Motor should turn slowly and smoothly Removal If replacing a component with electrical cabling remove one supply tank page 2 AN 1 See Before Beginning Repair page 39 Relieve pressure page 27 2 Remove four screws 207 and shroud 206 See FIG 14 3 Remove drive housing pump assemblies page 49 4 Disconnect motor cables as follows a Find control board at back of control module see FIG 12 page 47 b Unplug motor power connector from J4 240 V units or J11 120 V units c Unplug motor temp switch harness from connector J7 d Unplug cable 37 from fan 202 See FIG 15 311075U R
8. Knob Potentiometer 402 o ak Er 9 A 2 o o o o r a N 408 407 e 411 410 410 413 These items are not included on the nonheated display T116979a FiG 11 Control Module Heated Model Shown 311075U 45 Repair Control Board Power Bootup Check There is one red LED D11 on the EN board Power must be on to check See FiG 12 for location Function is e Startup 1 blink for 60 Hz 2 blinks for 50 Hz e Motor running LED on e Motor not running LED off e Status code motor not running LED blinks status code WAN Vi Control Board Replacement Check motor before replacing board See Electric Motor page 51 1 See Before Beginning Repair page 39 Relieve pressure page 27 2 Remove access cover 39 at back of con trol module to expose control board 406 3 Disconnect all cables and connectors from board Remove two jumper wires 413 from J10 pins 7 8 and 9 10 4 Remove screws 408 and remove board from control module 5 Install new board in reverse order Apply thermal compound between the square steel piece on the back of the board and the main aluminum plate Order Part No 110009 Thermal Com pound 46 Table 6 Control Board Connectors see FIG 12 mr J10 Jumpered 311075U Hepair Heater Power On Off 20A Motor Power On Off 20 A Single Cord Models Only B 0 Black
9. LABEL warning Qty A Replacement Danger and Warning labels tags and cards are available at no cost Part No 287755 Recirculation Manifold Nonheated Models TI6982a 66 Ref Part Description 501 24K993 MANIFOLD recirculation 502 111763 ELBOW 1 4 npt mbe 503 239914 VALVE recirc spray includes items 503a 503b 503a 15E022 SEAT 503b 111699 GASKET 504 224807 BASE valve 505 187625 HANDLE valve drain 506 111600 PIN grooved 507 113641 GAUGE pressure fluid 508 116504 TEE 1 4 npt m x 1 4 npt f run 1 4 npt f branch 509 116704 ADAPTER 3 8 JIC x 1 4 npt m 510 119998 ADAPTER 5 16 JIC x 1 4 npt m 511 556765 ELBOW tube 1 4 npt m x 3 8 in 10 mm OD tube Qty MPOMNMNMDNDP ek 311075U Part No 249582 Cart Ref 602 603 604 605 606 607 608 609 610 611 612 Part Description 154636 WASHER flat 116411 SPRING 116477 WASHER flat nylon 116478 WHEEL pneumatic 101242 RING retaining GRIP handle 24U760 BRACKET tank mount 24U761 BRACKET crossbar 24U762 BRACKET motor mount 24T150 GUSSET 110996 NUT hex flange head 311075U Parts 607 605 604 ti24101a E lt O YONMNAN SFA 67 Suggested Spare Replacement Parts Suggested Spare Replacement Parts Keep the following spare parts on hand to reduce downtime All Units Heated Units Only Part Description Part Description 24K984 DRYER desiccant 24K981 DISPL
10. bar imbalance for 10 sec after entering pres NN inb unit does not check for pressure sure mode Unit senses pressure imbalance between components A and B and warns or shuts down depending on settings of DIP switches 1 and 2 To turn off automatic shutdown and or tighten pressure tolerances for status code 1 see Status Code 1 and 2 Settings 1 Check fluid supply of lower pressure com ponent and refill if necessary 2 Reduce pressure of higher component by slightly turning Recirc Spray valve for that component toward Recirc until gauges show balanced pressures 311075U Troubleshooting In this example B side pressure is higher so eoe use the B side valve to aud balance pressures Turn Recirc Spray valve only enough to balance pressure If turned completely all pressure will bleed off 3 Check fluid inlet strainers 51a page 28 and fluid filters at gun 4 Clean or change restrictor at mixer mani fold if using disposable mixer gun kit Status Code 2 Pressure Deviation from Setpoint The unit does not check for pressure deviation at setpoint less than 400 psi 2 8 MPa 28 bar Unit senses pressure deviation from setpoint and warns or shuts down depending on set tings of DIP switches 3 and 4 If equipment cannot maintain enough pressure for a good mix with an impingement mix gun try using a smaller mix chamber or nozzle To turn off automatic shutdown and or tighten pressure
11. counter switch 223 are in place under B side motor end cover 227 Replace if neces sary 33 Troubleshooting Troubleshooting Chart PROBLEM CAUSE SOLUTION Reactor E 10 does not operate No power Plug in power cord or Power off dU Cycle Mo t 0 then on to reset breaker Set function knob to Stop Park CN 2 then select desired func Power turned on with function knob set to a run position Motor does not operate tion Loose connection on control Check connection at J11 120 V board or J4 240 V See page 46 Worn brushes Check both sides Replace brushes worn to less than 1 2 in 13 mm see page 52 springs brush holder brush leads for free movement Check motor commutator for burn Remove motor Have motor shop spots black pitting or other dam resurface commutator or replace motor page 51 Failed control board Heplace board See page 46 Loose fan cable Check that cable is connected at age Fan not working fan and at J9 on control board See pages 52 and 46 Defective fan Test and replace if necessary page 52 Pump output low Plugged fluid inlet strainer Clear see page 28 Plugged disposable mixer Clean or replace Leaking or plugged piston valve Check valves See pump manual or intake valve in displacement pump One side doesn t come up to Dirty or damaged Recirc Spray Clean or repair page 40 pressure in spray mode val
12. improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPM
13. refilling after refilling hot equipment rial in heaters and hoses froths Leave hoses pressurized See when not under pressure page 24 One gauge shows half as many Loss of pressure on downstoke Intake valve is leaking or not clos pulses as the other when pumps ing Clean or replace valve see are cycling page 41 Loss of pressure on upstoke Piston valve is leaking or not clos ing Clean or replace valve or packings see page 41 Status indicator red LED not lit Motor Power switch off oly Cycle Motor Power off Ju Loose indicator cable Check that cable is connected at J10 pins 1 red and 2 black on control board See page 46 Failed control board Replace board See page 46 311075U 35 Troubleshooting PROBLEM CAUSE SOLUTION A side rich lack of B side A side gauge is low B side restriction downstream of gauge Check gun check valve screen mix module or mix mani fold restrictor B side gauge is low B side material supply problem Check B side inlet strainer and pump intake valve B side rich lack of A side A side gauge is low A side material supply problem Check A side inlet strainer and pump intake valve B side gauge is low A side restriction downstream of gauge Check gun check valve screen mix module or mix mani fold restrictor No temperature display heated Loose display cables on control Check cable connections to each units only board display page 46 Failed control boar
14. sensor To replace sensor see 311210 Check connections at Heater Power switch See FIG 12 page 47 Check for continuity at heater car tridge connections 16 18 6 ohms for 120 V 64 75 ohms for 240 V Clean or replace strainer page 28 Open valve 37 Troubleshooting D 38 311075U Repair Before Beginning Repair ZN A Repairing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly Have a qualified electrician connect power and ground to main power switch ter minals see page 15 Be sure to shut off all power to the equipment before repairing 1 Flush if possible see page 29 If not possi ble clean all parts with solvent immediately after removal to prevent isocyanate from crystallizing due to moisture in the atmo sphere am 2 Set function knob to Stop Park YY 3 Shut off Motor Power Disconnect power supply due oJ IO 4 Shut off Heater Power Allow equipment to cool before repairing 5 Relieve pressure page 27 311075U Hepair Removing Supply Tanks e Displacement pump repair and parts information is included in manual 311076 which is supplied with your unit 1 See Before Beginning Repair page 39 Relieve pressure page 27 N Vi 2 Close both fluid inlet ball valves 52 x L 52 bey Y P dad 51 TI7020a Use dropcloth o
15. 11075U 11 Component Identification Key for FIG 2 Zr ACIQUOU x Supply Tank A Supply Tank B Pump A Pump B Fluid Pressure Gauges Recirc Spray and Overpressure Relief Valves Control Panel see FiG 3 page 13 Electric Motor and Drive Housings Hose Bundle MD2 Cold Spray Gun with disposable static mixer or 2K Manual Gun E LI ILL JL AU N 7 j IN Lis E v M 1 O ava Nxs lt cvOVUZ Desiccant Dryer mounts on supply tank A Recirculation Tubes Air Line Inlet quick disconnect fitting Outlet Hose Connections Hose Rack and Control Shield Fluid Inlet Ball Valves 1 on each side Fluid Inlet Strainers 1 on each side Power Cord Air Filter Moisture Separator Ne TN gt DR KT Nom TR ESN NY 4 if i l C S Sey ry RAE d LF WK SS fas Sy ti24098a FiG 2 Component Identification Nonheated Packages Part No 249808 Shown 12 311075U Controls and Indicators Controls and Indicators TI7016a FiG 3 Controls and Indicators heated unit shown Motor Pump Control e Indicator ST blinking If error occurs STA TUS indicator will blink 1 to 7 times to indi Function Knob cate status code pause then repeat See TABLE 1 for a brief description of status codes For more detailed information and corrective action see page 31 Icon Setting Function Table 1 Status Codes Stop Park Stops motor and aut
16. 120 V 1 phase 50 60 Hz one Single dedicated circuit rated m One NEMA 5 15T 15 ft 4 5 m power cord Non at minimum of 15 A heated 240 V 1 phase 50 60 Hz one Single dedicated circuit rated One NEMA 6 20P 15 ft 4 5 m power cord Non at minimum of 8 A heated Table 3 Extension Cord Requirements Required Wire Size Up to 50 ft 15 m to 50 ft 15 m Up to 100 ft 30m to 100 ft 30 m Nonheated and two cord heated and two cord heated AWG14 14 AWG12 12 models Single cord heated model AWG 12 AWG 10 Cords must be 3 conductor grounded rated for your EN environment 16 311075U To avoid electric shock always unplug both cords aN before servicing Reactor E 10 A Ensure no other high amp loads are connected while running Reactor E 10 A To verify separate circuits plug in Reactor E 10 or a worklight and cycle breakers on and off LF Heater Power amp p Motor Power Setup TI7061a FiG 5 Use Two Separate Circuits for Two Cord Models 4 Connect fluid hoses Connect fluid supply hoses to outlet hose connections R FIG 6 Red hoses for component A ISO blue for compo nent B RES Fittings are sized to pre vent connection errors Connect other end of hoses to A and B inputs of gun Heated units only connect recirculation hoses from gun recirculation ports to connections S Connect gun air hose For air operated guns only Co
17. 249633 ti24100a 102 24R823 see page 60 249806 only see page 60 249808 only 2 i 49633 HOSE BUNDLE non insulated see page 63 277823 HOSE BUNDLE see page 63 255325 GUN MD2 Cold Spray see 312185 and 3A2910 24R021 VALVE dispense 2K 311075U 55 Parts Part No 249570 120 V 15 A Heated Proportioner Part No 249571 240 V 10 A Heated Proportioner Part No 249572 240 V 20 A Heated Proportioner 56 311075U Heated Proportioners Ref 1 2 AN sa 0 NO Ol N 33 34 35 Part Description 24R382 CART see page 67 24L000 TANK with lid and outlet fitting LDPE includes item 2a 15F895 O RING lid tank 111800 SCREW cap hex hd 5 16 18 x 5 8 in 16 mm 24K984 DRYER desiccant 24K976 MUFFLER vent 101044 119973 119993 28 655 28 7656 117493 116393 556765 WASHER plain 1 2 in 13 mm LANYARD 14 in 356 mm sst PLUG PROPORTIONER bare 120 V Model 249570 see page 62 PROPORTIONER bare 240 V Models 249571 and 249572 see page 62 SCREW machine hex washer hd 1 4 20 x 1 1 2 in 88 mm ADAPTER 1 4 npt m x f ELBOW 1 4 npt m x 3 8 JIC 24K998 TUBE fluid 24L007 24L008 167002 116704 104641 169970 162453 24L009 15V421 249629 249630 24L004 24L005 117623 311075U HEATER fluid 120 V Model 249570 includes items 58 and 60 see 311210 HEATER fluid 240 V Models 249571 and 249572 includ
18. 5 F 24 C Use Fast Recirc to heat tanks to 75 90 F 24 32 C then use Slow Recirc to raise hose and gun to desired spray temperature If the top of the resin in tank starts frothing IN a do not use Fast Recirc 24 any more 311075U Spraying Dispensing 4 A AN plied to spray gun with gun piston safety EN For air operated guns only Air is sup lock or trigger safety lock engaged and gun fluid manifold valves A and B closed if present If using 2K Manual Dispense Valve see dispense valve instruction manual y 2 T Fusion MD2 y Cw 1 Set function knob to Stop Park 2 2 Set Hecirc Spray valves to Spray ee 3 Turn function knob to Pressure Adjust e Keep turning to the right until fluid pressure gauges show desired pres sure 311075U Ce ti10442a NN 4 9 N Spraying Dispensing Use lower pressures for joint filling applications Check fluid pressure gauges to ensure proper pressure balance If imbalanced reduce pressure of higher component by slightly turning Recirc Spray valve for that component toward Recirc until gauges show balanced pressures The pressure imbalance alarm Status Code 1 is inactive for 10 sec after entering spray pressure mode to allow time to balance pressures pressure is higher so X use the B side valve to C balance pressures In this example B sid
19. 7718 Pump Inlet Kit one side A Heplacement Danger and Warning labels tags and cards are available at no cost Parts Qty mPa P no 4A 61 Parts Part No 287655 120 V Bare Proportioner Part No 287656 240 V Bare Proportioner 207 4 201 Ref 1221 208 209 210 201 1213 T16978a Ref Part Description Qty Ref Part Description Qty 201 24E355 MOTOR electric 120 V 1 219 24L006 PUMP displacement see 2 24E356 MOTOR electric 240 V 311076 2204 117493 SCREW machine hex washer 8 hd 1 4 20 x 1 1 2 in 38 mm 221t 15B254 COVER drive housing A side 202 24K985 FAN cooling 120 V 24K986 FAN cooling 240 V 203 115836 GUARD finger W 4 1 204 RIVET blind 5 32 x 3 8 grip 2221 15B589 COVER pump rod 2 205 SCREW machine slotted hd 223 117770 SWITCH reed w cable 1 8 32 x 2 in 51 mm 224 24K982 MAGNET 1 206 24L003 SHIELD proportioner 1 227 249854 COVER drive housing B side 1 207t 115492 SCREW machine hex washer 12 includes item 223 and 228 hd 8 32 x 3 8 in 10 mm 228 115711 TAPE mounting reed switch 1 208 116074 WASHER thrust steel not shown 209 107434 BEARING thrust bronze 210 248231 CRANKSHAFT KIT 211 180131 BEARING thrust bronze 212 116073 WASHER thrust steel 213T 116079 BEARING thrust bronze 2147 287057 GEAR REDUCER KIT 215t 287055 DRIVE HOUSING KIT 216 287053 CONNECTING ROD KIT 217 196762 PIN straight 218 195150 NUT jam pump
20. 7785 UNION swivel 3 4 npt m x 3 4 npsm f 242001 ADAPTER cord Europe Model 249571 only 242005 ADAPTER cord Australia Model 249571 only 195551 RETAINER plug adapter Model 249571 only 24K999 TRANSDUCER pressure included with item 17 111457 O RING ptfe included with item 17 15G476 LABEL components A and B see page 54 119992 NIPPLE pump inlet 3 4 npt 157350 NIPPLE 1 4 npt x 3 8 npt 24K977 AIR FILTER SEPARATOR with 3 8 npt auto drain includes item 2a 114228 ELEMENT 5 micron polypro pylene not shown 100176 BUSHING 3 8 npt m x 1 4 npt f 109510 160327 101078 1 o mB BR Po Oma aaa pe no 4 57 Parts Ref Part Description Qty 66 24E555 KIT temperature sensor 2 66a 121063 O RING fluroroelastomer 1 66b 123787 FITTING elbow 45 3 8 jic x 1 1 4 18 npt 66ct 123788 FITTING elbow 45 5 16 jic x 1 1 4 18 npt 66d 555561 RING retaining 3 8 1 66e 16C785 HOUSING thermowell 1 66f 16C786 MANIFOLD fluid 1 66g 16C787 SPACER sensor 1 66h 113641 GAUGE pressure fluid sst 1 Included in 287718 Pump Inlet Kit one side i 24E555 Kit includes A and B side adapters Install required fittings as needed A Replacement Danger and Warning labels tags and cards are available at no cost 58 311075U 311075U Parts 59 Parts Part No 249576 120 V Nonheated Proportioner Part No 249577 240 V Nonheated Proportioner 30 Ref
21. AY temperature with sensor 15F895 O RING lid tank 24K980 FUSE heater over temperature 24K983 SWITCH motor or heater power with cir 24K978 THERMOSTAT heater cuit breaker 24K989 HEATER ELEMENT 120 V units only 113641 GAUGE pressure fluid sst 24K990 HEATER ELEMENT 240 V units only 101078 Y STRAINER includes 180199 element 180199 ELEMENT Y strainer 20 mesh 114228 ELEMENT air filter 5 micron polypropyl ene 239914 VALVE recirc spray includes seat and gasket 24L002 POTENTIOMETER control knob 24G886 BOARD control 120 V units only 24G887 BOARD control 240 V units only 24K999 TRANSDUCER pressure 24L006 PUMP displacement fits either side 287718 INLET KIT tank to pump 249855 REPAIR KIT displacement pump includes seals balls bearings intake valve seat Accessories Part Description 249815 GUN Fusion MP with 4 hose manifold 255325 GUN MD2 Cold Spray 24P765 KIT Joint Fill Extension 68 311075U Dimensions 69 WW QLVV NNT All Models Imensions 311075U D Technical Data Technical Data Maximum fluid working 2000 psi 14 MPa 140 bar pressure Electrical requirements Model AP9570 CS9570 120 Vac 1 phase 50 60 Hz 3500 W requires two separate dedicated 15 A circuits Model AP9571 CS9571 240 Vac 1 phase 50 60 Hz 3800 W requires two separate dedicated 10 A circuits Model AP9572 CS9572 240 Vac 1 phase 50 60 Hz 3800 W requires a single dedicated
22. CS22WD 14 140 249806 2000 249576 249633 MD2 Gun 255325 14 140 249808 2000 249577 249633 MD2 Gun 255325 14 140 24R984 2000 249576 24R823 2K Manual 24R021 14 140 14 140 24R985 2000 249577 24R823 2K Manual 24R021 14 140 311075U Models Models The model no series letter and serial no are located on the back of the Reactor E 10 For faster assistance please have that information ready before calling Customer Service Maximum Working Bare Pressure Proportioner Electrical psi Part Series Volts Connection Application MPa bar Approvals 249570 A 120V 15A cord Polyurethane Foam 2000 motor Hot Polyureas 14 140 15 A cord heaters Ell 249571 A 240V 10Acord Polyurethane Foam 2000 C y US motor Hot Polyureas 14 140 aik 10 A cord iaka heaters Conforms to ANSI UL Std 499 Certified to 249572 A 240 V 20A cord Polyurethane Foam 2000 CAN CSA Std motor and Hot Polyureas 14 140 CARE mouse heaters 249576 A 120 V 15 A cord e Self leveling Joint Fillers 2000 motor only Cold Polyureas 14 140 C El US LISTED 249577 A 240 V 10 A cord Self leveling Joint Fillers 2000 z motor only Cold Polyureas 14 140 Intertek 9902471 Conforms to ANSI UL Std 73 Certified to CAN CSA Std C22 2 No 68 See page 16 for detailed electrical requirements 4 311075U Warnings Warnings The following general warnings are for the setup use
23. ENT 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 pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 All writte
24. Included in 248231 Crankshaft Kit T ncluded in 287057 Gear Heducer Kit t Included in 287055 Drive Housing Kit Included in 287053 Connecting Rod Kit MPMMMNMNANNNN PY 62 311075U Parts Part No 249499 Insulated Hose Bundle with recirculation lines dm 1 303 Ref 4 305 303 TI6991a Ref Part Description Qty Ref Part Description Qty 303 15G342 HOSE air 1 4 in 6 mm ID 1 4 1 301 249508 HOSE fluid Component A mois 2 npsm fbe 35 ft 10 7 m ture guard 1 4 in 6 mm ID no 5 304 buy TUBE foam insulated 1 3 8 in 1 JIC fittings mxf 35 ft 10 7 m locally 85 mm ID 31 ft 9 5 m 302 249509 HOSE fluid component B 1 4 in 2 305 156971 NIPPLE 1 4 npt for joining airline 1 6 mm ID no 6 JIC fittings mxf to another hose bundle 35 ft 10 7 m Part No 249633 Non insulated Hose Bundle without recirculation lines d g 301 ai 302 Ref 302 f ra 305 303 4 A o c AA m A TI6992a Ref Part Description Qty Ref Part Description Qty 303 15G342 HOSE air 1 4 in 6 mm ID 1 4 1 301 249508 HOSE fluid component A mois 1 npsm fbe 35 ft 10 7 m ture guard 1 4 in 6 mm ID no 5 305 156971 NIPPLE 1 4 npt for joining air line 1 JIC fittings mxf 35 ft 10 7 m to another hose bundle 302 249509 HOSE fluid component B 1 4 in 1 6 mm ID no 6 JIC fittings mxf 35 ft 10 7 m Part No 24R823 1 4 in 6 mm ID x 35 ft 10 7 m Non in
25. Instructions Parts List gt EACTGR 10 PLURAL COMPONENT PROPORTIONER 311075U EN For spraying or dispensing 1 1 mix ratio materials including epoxies polyurethane foam polyurea coatings and joint fill materials For professional use only Not approved for use in European explosive atmosphere locations Important Safety Instructions Read all warnings and instructions in this manual Save these instructions e See page 4 for a list of models and maximum working pressures Heated Package with Fusion Gun Se Wl Nonheated Package MD2 Cold Spray Gun ti24095a ti24098a CE PROVEN QUALITY LEADING TECHNOLOGY Contents Related Manuals 3 SVSICMS uo Hide See eae eo bee tona 3 Models 445a ieee Raw eae cn 4 WVAMDINGS xeu ER ees fae E E eet a8 5 OVOLVIe WW uou a eae ed ee eee eee rod ds 8 Isocyanate Hazard 9 Foam Self ignition 9 Moisture Sensitivity of Isocyanates 9 Keep Components A and B Separate 10 Changing Materials 10 Component Identification 11 Controls and Indicators 13 Motor Pump Control Function Knob 13 STATUS Indicator 000 eee eee 13 Motor Power Switch Circuit Breaker 14 Heater Power Switch Circuit Breaker 14 Heater Temperature Co
26. Markings A Side Red Weight empty approximately 160 Ib 72 kg depending on model Wetted Parts Aluminum stainless steel carbon steel brass carbide chrome chemically resistant o rings PTFE ultra high molecular weight poly ethylene All other brand names or marks are used for identification purposes and are trademarks of their respective owners 311075U 71 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the
27. Ref 401 402 403 404 405 406 413 421 Part Description 15F984 PLATE Qty 1 24K983 SWITCH motor power with cir 1 cuit breaker 15G408 COVER display 24L002 POTENTIOMETER 119930 INDICATOR status LED 24G886 BOARD control 120 V units only 24G887 BOARD control 240 V units only 15G230 CABLE harness 107156 SCREW machine pan hd 113505 NUT keps hex hd 119897 BULKHEAD FITTING cable 101765 GROMMET 116773 CONNECTOR plug WIRE jumper 311075U o ae N oN Ref 414 415 416 417 421 Parts 405 404 Ref 415 417 406 T16983a Part Description Qty 15G279 LABEL display 1 15G053 PLATE detent 1 24L001 KNOB function includes item 1 416a 416a 101118 SCREW set no 10 x 1 4 in 2 6 mm 15G281 LABEL startup unheated 1 15G384 ENCLOSURE 1 PLUG 1 423 65 Parts Part No 24L009 Recirculation Manifold Heated Models re 503a GY A512 fc a 503b 501 510 509 TI6977a Ref Part Description 501 24K993 MANIFOLD recirculation 502 111763 ELBOW 1 4 npt mbe 503 239914 VALVE recirc spray includes items 503a 503b 503a 15E022 SEAT 503b 111699 GASKET 504 224807 BASE valve 505 187625 HANDLE valve drain 506 111600 PIN grooved 507 100721 PLUG pipe 1 4 npt m 508 100840 ELBOW street 1 4 npt m x 1 4 npsm f 509 116704 ADAPTER 3 8 JIC x 1 4 npt m 510 119998 ADAPTER 5 16 JIC x 1 4 npt m 512A 189285
28. Twin Flat Cable Fa Motor i n o J11 120 V B mE end CONTROL Function c ud Knob Cycle He BOARD Yellow o Counter RE PE OFF ON ET NA ds Hi SW 2 seepage Indicator E s ER 32 to adjust J10 Black Sheath HES Black GT Black Sheath White G LE Jumper HE D11 not used Red OT Jumper CLES J14 J 59 amp ps 8 J3 ka ral E 20004 Eas O 2 pin red connectors 2 pin red em gens Gray Sheath Gray Sheath Pressure Transducer A Calibration Calibration Screw Screw H ih C C oF oF Black Phone Cable and Plug Temperature Temperature Display B 3 9 Display A 3 99 F TER i 1 i H lie Pressure Transducer B Gray Sheath Temperature Temperature Sensor B Sensor A Heated Models FiG 12 Control Module Wiring Connections 311075U 47 Repair Fluid Heaters if supplied Fluid heater repair and parts e information is included in manual 311210 which is supplied with heated units To replace a pressure transducer see at right A 74 1 See Before Beginning Repair page 39 Relieve pressure page 27 WA i 2 Control section of heater can be repaired in place Remove heater to clean fluid section See manual 311210 for heater repair and parts 58 60 m s Heated Units FiG 13 Transducers 48 TI7026a Nonheated Units Pressure Transducers AN Vig 1 See Before Beginning Repair page 39 Relie
29. ange com ponent A isocyanate and component B resin parts Changing Materials e When changing materials flush the equip ment multiple times to ensure it is thor oughly clean e Always clean the fluid inlet strainers after flushing see page 28 e Check with your material manufacturer for chemical compatibility e Most materials use ISO on the A side but some use ISO on the B side e Epoxies often have amines on the B hard ener side Polyureas often have amines on the B resin side 10 311075U Component Identification Key for FIG 1 Supply Tank A Supply Tank B Pump A Pump B Heater A Heater B Fluid Pressure Gauges Recirc Spray and Overpressure Relief Valves Control Panel see FiG 3 page 13 Electric Motor and Drive Housings Insulated Hose Bundle includes circulation return hoses T ACTQOnmoou U N A P EI T H e Ta ty S INA n L r f H IBN md lt xs lt CHHMHDOVZE Component Identification Fusion Air Purge Spray Gun Desiccant Dryer mounts on supply tank A Recirculation Tubes Air Line Inlet quick disconnect fitting Outlet Hose Connections Return Hose Connections Fluid Temperature Sensors Hose Rack and Control Shield Fluid Inlet Ball Valves 1 on each side Fluid Inlet Strainers 1 on each side Power Cord Air Filter Moisture Separator ti24095a FiG 1 Component Identification Heated Packages Part No AP9572 Shown 3
30. by hitting firmly with non sparking hammer A Lubricate threads with ISO oil or grease TI7025a Fic 9 Displacement Pump 311075U Control Module Change Display Temperature Units F C Unit is shipped with temperature displays set to F aN 1 Shut off Motor Power Disconnect power supply c 2 Remove access cover 39 from back of control module 3 See FIG 11 Locate slide switch FC at right edge of each temperature display board Unit is shipped set to F down To change to C move both switches to up position Calibrate Temperature Displays aN 1 Remove access cover 39 from back of control module 2 See FIG 11 Locate calibration screw CS at upper right corner of each temperature display board Turn screw slightly to correct temperature display Temperature displays do not read lower than 50 F 10 C 311075U Repair Replace Temperature Display and Sensor Heated Units Only WA Vi 1 See Before Beginning Repair page 39 Relieve pressure page 27 2 Remove temperature sensor 424 a Remove snap ring 66d in thermowell housing 666 See FiG 10 b Pull sensor 424 and spacer 669 out of thermowell housing c Work sensor and wire out of cable channel between tanks It may be eas ier to remove one tank See page 39 eo Remove access cover 39 from back of control module 4
31. cal Data errens 70 Graco Standard Warranty 72 Graco Information eren 72 311075U Related Manuals Helated Manuals The following manuals are for Reactor E 10 components and accessories Some are supplied with your package depending on its configuration Manuals are also available at www graco com Displacement Pump PartNo Description 311076 Instruction Parts Manual English Fluid Heater PartNo Description 311210 Instruction Parts Manual English Fusion Air Purge Spray Gun PartNo Description 309550 Instruction Parts Manual English Systems Maximum Working Pressure psi Proportioner MPa bar see page 4 Fusion Mechanical Purge Spray Gun PartNo Description 309856 Instruction Parts Manual English Fusion CS Spray Gun PartNo Description 312666 Instruction Parts Manual English MD2 Dispense Valve 312185 Instruction Parts Manual English 3A2910 MD2 Cold Spray and Joint Fill Kits English 2K Manual Dispense Valve PartNo Description 332198 Instruction Parts Manual English Unheated Hose 35 ft 10 6 m AP9570 2000 249570 249499 Fusion Air Purge 249810 14 140 AP9571 2000 249571 249499 Fusion Air Purge 249810 ee p esu E Bossi AP9572 2000 249572 249499 Fusion Air Purge 249810 ee eee eS d CS9570 2000 249570 249499 Fusion CS CS22WD 14 140 CS9571 2000 249571 249499 Fusion CS
32. contamination of fluids and equipment parts never interchange component A isocyanate and component B resin parts or containers Have at least two 5 gal 19 liter pails to transfer fluid from drums to supply tanks Label one pail A and the other B using the red and blue labels provided Always doublecheck which material you have before pouring it in the supply tanks Pouring is easier if pails are not filled to the top Open only one supply tank at a time to avoid splashing material from one tank into the other when filling 311075U Pressure Relief Procedure N A Vg 1 Engage piston safety lock or trigger safety lock T Fusion MD2 ti10442a A CUN 2 Setfunction knob to Stop Park 2 3 Turn Recirc Spray valves to Recirc Fluid will be dumped to supply tanks Pumps will move to the bottom of their stroke Ensure gauges drop to O e e 311075U Pressure Relief Procedure Shutdown For longer breaks more than 10 min utes use the following procedure If you will be shut down for more than 3 days first see Flushing page 29 Follow all steps of Pressure Relief Pro cedure at left If using an impingement mix gun close gun fluid valves A and B Doing this will keep the internal parts of the gun cleaner and prevent crossover T Shut off Heater Power heated units only Refer to your separate gun manual and perform the Shutdow
33. d displays get Remove access panel Check if power from control board board LED is lighted If not replace board page 46 Inadequate power to control Check that power supply meets board requirements Loose power cable Check cable connections page 46 Motor Power switch circuit Display is powered from Motor breaker tripped Power circuit breaker Cycle Motor Power off dU then on TPR to reset breaker Wrong temperature displayed F C switch in wrong position Set switch see page 43 Temperature displays do not Displays need calibration Turn calibration screw on back of match at ambient temperature displays to correct reading see page 43 36 311075U PROBLEM CAUSE No heat and heater indicator light Heater Power shut off or circuit breaker tripped Bad thermostat Bad overtemperature sensor this is a high temperature limit fuse and must be replaced if blown Loose heater cable connections No heat but heater indicator light Bad heater cartridge Heater on one side shuts off early Y strainer is plugged on that side or continuously during recircula tion 311075U Fluid inlet valve 52 closed Troubleshooting SOLUTION Cycle Heater Power off J u then on to reset circuit breaker With power on check for continu ity at clicks of heater control knob To replace thermostat see 311210 With power on check for continu ity at overtemperature
34. e Watch gauges for 10 sec to be sure pressure holds on both sides and pumps are not moving Open gun fluid manifold valves A and B impingement mix guns only Li On impingement guns never open fluid manifold valves or trigger gun if pres sures are imbalanced 25 Pause Heated Units 6 Disengage piston safety lock or trigger safety lock ti10441a Fusion f Test spray onto cardboard or plastic sheet Verify that material fully cures in the required length of time and is the correct color Adjust pressure and tem perature to get desired results Equip ment is ready to spray ma Pause Heated Units spray temperature after a brief break EN To bring the hose and gun back to use the following procedure 1 Engage piston safety lock or trigger safety lock T Fusion ti10442a 2 Set function knob to Slow Recirc 26 3 Set Recirc Spray valves to Recirc until temperature readouts come back up e e 4 If you stop spraying for more than 2 min utes when using an impingement mix gun close gun fluid valves A and B Doing this will keep the internal parts of the gun cleaner and prevent crossover T Refilling Tanks Material can be added to the tanks at any time See page 19 If you are operating at high tempera AL tures or flow rates follow instructions under Pause Heated Units to bring tanks up to temperature NOTICE To prevent cross
35. e Allow equipment to cool completely before touching it e Wear gloves if fluid temperature exceeds 110 F 43 C Temporarily set heater control Knobs to maximum setting 1 5 Circulate through heaters until tempera Perform Setup pages 15 21 ture readouts display desired tempera ture See TABLE 4 below 2 Set function knob to Slow Recirc or 6 Adjust heater control knobs as neces 26 Fast Recirc Q4 See Heatup Guide sary for a stable spray temperature lines page 23 then continue with steps 3 6 Table 4 Heatup Time Guidelines for starting a cold machine with 5 gal 19 I per side see Notes below Fluid Spray Target 35 ft 10 7 m Hose 70 ft 21 m Hose Temperature 1 bundle 2 bundles 125 F 52 C 150 F 65 C Use fast circulation until temperature is within 20 F 11 C of target EN then use slow circulation to reach final temperature Different fluids will absorb heat at different rates When refilling a warm machine heatup times will be less 22 311075U Heatup Guidelines The fluids must be circulated from the pumps through the heaters hoses and back to the tanks to ensure warm fluids are supplied to the gun Slow Recirculation T e Slow Recirc results in a higher temperature transfer in the heater so hoses and gun heat up quicker e Good for touchup or low flow spraying up to moderate temperature e Not used to circulate full tank
36. e from crankshaft 210 4 Examine crankshaft 210 gear reducer 214 thrust washers 208 212 and bear ings 209 211 213 Installation 1 Apply grease liberally to washers 208 212 bearings 209 211 213 gear reducer 214 crankshaft 210 and inside drive housing 215 Grease is supplied with replacement parts kits 311075U Hepair B side crankshaft 210 includes the cycle counter magnet 224 When reassembling be sure to install crank shaft with magnet on B side BS If replacing crankshaft remove magnet 224 Reinstall magnet in center of off set shaft on new crankshaft Position shaft in Park position 2 Install bronze bearings 211 213 in drive housing 215 as shown 3 Install bronze bearings 209 211 and steel washer 208 on crankshaft 210 Install bronze bearing 213 and steel washer 212 on gear reducer 214 4 Install gear reducer 214 and crankshaft 210 into motor end bell MB Crankshaft 210 must be in line with crankshaft at other end of motor Pumps will move up and down together If connecting rod 216 or pump 219 were removed reassemble rod in hous ing and install pump page 41 5 Push drive housing 215 onto motor 201 Install screws 220 6 Install drive housing covers 221 on A side 227 on B side and screws 207 Pumps must be in phase both at same position in stroke 49 Repair Cycle Counter Switch Replacement
37. epair e Thread motor power switch harness out bottom of control module and cable channel to free motor NOTICE Motor is heavy Two people may be required to lift 9 Remove screws holding motor to bracket Lift motor off unit Installation 1 If replacing motor install fan assembly and fan mount threaded bushing on new motor Place motor and fan on unit Thread motor switch harness into control module Fasten motor with screws underneath Do not tighten yet Plug 3 pin connector J7 to board Plug Motor Power switch harness to con nector J4 240 V units or J11 120 V units Install drive housing pump assemblies page 49 Reconnect inlet assemblies to pumps Tighten motor mounting screws Return to service 51 Repair Motor Brushes Replace brushes worn to less than 1 2 EN in 13 mm Brushes wear differently on each side of motor check both sides Brush Repair Kit 287735 is available kit includes instruction sheet 406582 Motor commutator should be smooth If not resurface commutator or replace motor AAN Vg E 1 See Before Beginning Repair page 39 Relieve pressure page 27 2 See instruction sheet 406582 included with Brush Repair Kit 287735 Remove old brushes and install new ones supplied in kit Fan 1 Disconnect fan cable 37 from fan 202 With Motor Power on test cable connector for line voltage 120 V or 240 V 2 If voltage
38. es items 58 and 60 see 311210 INSULATOR heat ADAPTER B side 3 8 JIC x 1 4 npt m BULKHEAD FITTING FITTING air line 1 4 npt m NIPPLE 1 4 npt x 1 4 npsm MANIFOLD recirculation with valves see page 66 TUBE recirculation 3 8 10 mm OD sst HOSE component A ISO 1 4 in 6 mm ID thermoplastic hose with moisture guard 1 4 npsm f x 48 in 1219 mm HOSE component B RES 1 4 in 6 mm ID thermoplastic hose 1 4 npsm f x 48 in 1219 mm DISPLAY heated 120 V Model 249570 see page 64 DISPLAY heated 240 V Models 249571 and 249572 see page 64 NUT cap 3 8 16 N N iN ho PM n5 n9 no 4 o Ref 36 51 51a 52 o3 54 55 56 57 58 60 61 62 64 64a 65 Parts Part Description 24K995 CORD 120 V Model 249570 24K997 CORD 240 V Model 249571 24K996 CORD 240 V Model 249572 15G458 CABLE fan see page 62 CONDUIT flexible non metallic 15G385 COVER access display 15G280 LABEL warning 108296 SCREW machine hex washer hd 1 4 20 x 5 8 in 16 mm 217374 LUBRICANT ISO pump not shown BOLT 10 24 x 1 in 25 mm 15G119 GUARD splash 15G461 RACK hose PLUG STRAP bungee 25 in 635 mm WASHER flat 1 4 in nylon ELBOW swivel 3 4 npt m x 3 4 npsm f Y STRAINER includes item 51a 180199 ELEMENT 20 mesh not shown 119882 VALVE ball 3 4 npt fbe t handle C20487 NIPPLE 3 4 npt 15
39. g with flammable solvents e Generally flush if you will be shut down for more than 3 days Flush more often if material is moisture sensitive and humidity is high in the storage area or if material may separate or settle out over time e Flush out old fluid with new fluid or flush out old fluid with a compatible solvent before introducing new fluid e Use the lowest possible pressure when flushing e Always leave some type of fluid in system Do not use water e For long term storage flush out the solvent with a storage fluid such as Bayer Mesa moll plasticizer or at minimum clean motor oil 1 Engage piston safety lock or trigger safety lock Close fluid valves A and B Leave air on T Fusion ti10442a 311075U Flushing N Set function knob to Stop Park D Shut off Heater Power heated units only Allow system to cool Remove recirculation tubes 31 from supply tanks and place in original con tainers or waste containers TI7022a Turn Recirc Spray valves to Recirc e e Set function knob to Fast Recirc Pump material from supply tanks until no more comes out 29 Flushing CUN f Setfunction knob to Stop Park Ww 8 Wipe out any remaining material from the supply tanks Fill each supply tank with 1 2 gal 3 8 7 6 I of solvent recom mended by your material manufacturer 9 Set function knob to Fast Recirc Pump solvent through s
40. grounding maintenance and repair of this equipment Additional more specific warnings may be found throughout the body of this manual where applicable Symbols appearing in the body of the manual refer to these general warnings When these symbols appear throughout the manual refer back to these pages for a description of the specific hazard ELECTRIC SHOCK HAZARD Improper grounding setup or usage of the system can cause electric shock e Turn off and disconnect power cord before servicing equipment Use only grounded electrical outlets Use only 3 wire extension cords Ensure ground prongs are intact on sprayer and extension cords Do not expose to rain Store indoors TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed Head MSDSs to know the specific hazards of the fluids you are using Store hazardous fluid in approved containers and dispose of it according to applicable guidelines Always wear chemically impermeable gloves when spraying dispensing or cleaning equipment PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you from serious injury including eye injury inhalation of toxic fumes burns and hearing loss This equip ment includes but is not limited to e Protective eyewear e Clothing and respirator as
41. ing tempera tures back up e Each 35 ft 10 7 m hose bundle adds about 5 minutes to heatup time with most materials Water based materials take lon ger to heat up Maximum recommended hose length is 105 ft 32 m OA e Use Fast Recirc 25 until tanks are warm to the touch then use Slow Recirc T until displays read desired temperature e Fora quicker start do initial heatup circula tion with the tanks 1 4 to 1 3 filled then add more material 23 Startup of Heated Units Heating Foam Resins with 245 fa Blowing Agents New foam blowing agents will froth at tempera tures above 90 F 33 C when not under pres sure especially if agitated Never fill the 7 gal 26 I supply tanks beyond the 5 gal 19 I line on the tanks to leave room for some frothing At High Ambient Temperature above 75 F 24 C 2 Fill tanks page 19 d Set Recirc Spray valves to Recirc SSES A e Set function knob to Slow Recirc 9 x L f Turn on Heater Power GY O amp A e Pour resins slowly to avoid frothing At Cool Ambient Temperature below e Only use Slow Recirc SF to avoid heating and agitating the tank If temperature doesn t keep up set function knob to f__ N Stop Park 2 then set to Slow Recirc T again e When you stop to refill the tanks avoid boil ing off fluid in the heaters by following these steps SAND a Shut off Heater Power E b Leave hoses under pressure 24 7
42. is correct fan is defective Hemove screws holding fan to shield 206 Install new fan in reverse order 3 If voltage is not correct check fan cable connection at J9 on control board see FIG 12 page 47 52 202 TI7030a FiG 15 Fan 311075U Hepair 311075U 53 Parts Parts Part No AP9570 or CS9570 120 V 15 A Heated Package Part No AP9571 or CS9571 240 V 10 A Heated Package Part No AP9572 or CS9572 240 V 20 A Heated Package 61 61 7 NZ A EE zs PUE Un CY y 101 Q i ES i S fi A 2 CES x dE MER ff S Ge 12 5 ath TURN tty L T y RS A l 103 J P ti24099a Proportioner AP9570 CS9570 Been 0 we 120 V 15 A Heated 249570 249499 Package see page 56 see page 63 249810 See 309550 CS22WD See 312666 AP9571 240 V 10 A Heated Package CS9571 AP9572 240 V 20 A Heated Package CS9572 54 249571 see page 56 249572 see page 56 249499 see page 63 249499 see page 63 249810 see 309550 CS22WD see 312666 249810 see 309550 CS22WD see 312666 311075U Parts Part No 249806 120 V 15 A Nonheated Package MD2 Part No 249808 240 V 10 A Nonheated Package MD2 Part No 24R984 120 V 15 A Nonheated Package 2K Dispense Part No 24R985 240 V 10 A Nonheated Package 2K Dispense 61 101 24R021 102
43. l react with moisture such as humidity to 311075U Isocyanate Hazard form small hard abrasive crystals which become suspended in the fluid Eventually a film will form on the surface and the ISO will begin to gel increasing in viscosity If used this partially cured ISO will reduce perfor mance and the life of all wetted parts The amount of film formation and rate of EN crystallization varies depending on the blend of ISO the humidity and the tem perature To prevent exposing ISO to moisture e Always use a sealed container with a des iccant dryer in the vent or a nitrogen atmo sphere Never store ISO in an open container e Keep the felt washers in the pump wet cups saturated with Graco ISO pump oil Part No 217374 The lubricant creates a barrier between the ISO and the atmo sphere e Use moisture proof hoses specifically designed for ISO such as those supplied with your system see page 63 e Never use reclaimed solvents which may contain moisture Always keep solvent con tainers closed when not in use e Never use solvent on one side if it has been contaminated from the other side e Always park pumps when you shutdown see page 27 e Always lubricate threaded parts with Part No 217374 ISO pump oil or grease when reassembling Keep Components A and B Separate Keep Components A and B Separate NOTICE To prevent cross contamination of the equip ment s wetted parts never interch
44. l valves 52 Open filter drain plug on Y strainer 51 m ME AN l 2 51 ET A nj 311075U Hepair To Remove Intake Valve Only If pump is not generating any pressure the intake ball check may be stuck closed with dried material If the pump is not generating pressure on the downstroke intake ball check may be stuck open Either of these conditions can be serviced with the pump in place Disconnect fluid inlet C and swing it aside Remove intake valve by hitting ears E firmly right to left with a non sparking ham mer Unscrew from pump See manual 311076 for repair and parts 41 Repair To Remove Entire Pump Assembly 5 Disconnect fluid inlet C and outlet D lines Also disconnect steel outlet tube 16 from heater inlet 6 Remove pump rod cover 222 Push clip up in back and push pin 217 out Loosen locknut 218 by hitting firmly right to left with a non sparking hammer Unscrew pump See manual 311076 for pump repair and parts 7 Install pump in reverse order of disassem bly following all notes in FiG 9 Clean strainer 51 Reconnect fluid inlet C and outlet D lines 8 Tighten fluid outlet fitting D then tighten locknut 218 by hitting firmly with a non sparking hammer 9 Open fluid inlet valve 52 Set function knob to Slow Recirc ae Purge air and prime See page 20 42 217 16 222 D A E AC AA Flat side faces up Tighten
45. l you identify and correct the problem Keep a fire extinguisher in the work area SKIN INJECTION HAZARD N High pressure fluid from gun hose leaks or ruptured components will pierce skin r THERMAL EXPANSION HAZARD d 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 G2 equipment rupture and serious injury e Open a valve to relieve the fluid expansion during heating e Replace hoses proactively at regular intervals based on your operating condi tions MPa bar PSI PRESSURIZED ALUMINUM PARTS HAZARD Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocar bon 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 6 311075U 74 311075U Warnings EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury e This equipment is for professional use only e Do not leave the work area while equipment is energized or under pressure Turn off all equipment and follow the Pressure Relief Procedure in this manual when equipment is not in use Do not exceed the maximum working pressure or temperature rating of the low est rated system component See Technical Data in all equipment manuals Use fluids and solvents that are compatible wi
46. llow your local code Start and stop gener ator with power cord s discon nected Spray gun grounded through the supplied fluid hoses connected to a properly grounded Reactor E 10 Do not operate without at least one grounded fluid hose Object being sprayed follow your local code Solvent pails used when flushing follow your local code Use only metal pails which are conduc tive placed on a grounded sur face Do not place pail on a nonconductive surface such as paper plastic or cardboard which interrupts grounding conti nuity To maintain grounding continuity when flushing or relieving pres sure hold a metal part of spray gun firmly to the side of a grounded metal pail then trigger gun 15 Setup Table 2 Electrical Requirements Mode Required Power Source Required Power Source Power Power Cord Connector Connector 120 V 1 phase 120 V 1 phase 50 60 Hz two Hz two Two separate dedicated cir separate dedicated cir LU TwoNEMAS 5T Two NEMA 5 15T 15 ft 4 5 m power cords cuits rated at minimum of 15 ike A each 240 V 1 phase 50 60 Hz two Two separate dedicated cir Two IEC 320 with 15 ft 4 5 m power cords cuits rated at minimum of 10 UJ uu two local adapters Heated A each Euro CEE74 Adapter Australia China Adapter 240 V 1 phase 50 60 Hz one Single dedicated circuit rated 1 One NEMA 6 20P 15 ft 4 5 m power cord at minimum of 16 A Heated
47. ms to minimize heat returned to tank and reduce frothing Fast Recirculation e Use to support higher flow rates or higher temperatures by preheating the tanks e Agitates fluid within tanks to avoid heating only the fluid at the top of the tank e Use for flushing Pressure Adjust Automatically maintains selected pressure out put for dispensing or spraying 311075U Isocyanate Hazard 2 A MAN 9 Spraying materials containing isocyanates creates potentially harmful mists vapors and atomized particulates Read material manufacturer s warnings and material MSDS to know specific hazards and precautions related to isocyanates Prevent inhalation of isocyanate mists vapors and atomized particulates by provid ing sufficient ventilation in the work area If sufficient ventilation is not available a sup plied air respirator is required for everyone in the work area To prevent contact with isocyanates appro priate personal protective equipment includ ing chemically impermeable gloves boots aprons and goggles is also required for everyone in the work area Foam Self ignition AN Some materials may become self igniting if applied too thickly Read material manufac turers warnings and material MSDS Moisture Sensitivity of Isocyanates Isocyanates ISO are catalysts used in two component foam and polyurea coatings ISO wil
48. n 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 311075 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2005 Graco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com Revised July 2014
49. n procedure 27 Maintenance Maintenance 28 Check pump wet cups fluid level daily page 19 Do not overtighten packing nut wet cup Throat u cup is not adjustable Keep component A from exposure to mois ture in atmosphere to prevent crystalliza tion Wipe supply tank lid o ring and inner rim daily to prevent ISO crystallization Keep film of grease on o ring and inside of lid Check desiccant filter weekly Filter is blue when fresh and turns pink when saturated Remove plug X and clean fluid inlet strainer 51a as needed Always clean the fluid inlet strainers after flushing TI7021a Generally flush if you will shutdown for more than three days Flush more often if material is moisture sensitive and humidity is high in the storage area or if material may separate or settle out over time If using an impingement mix gun close gun fluid valves A and B when not spraying Doing this will keep the internal parts of the gun cleaner and prevent crossover Clean gun mix chamber ports and check valve screens regularly See gun manual T If using an Fusion Air Purge impingement mix gun always grease the gun after use until purge air carries grease mist out the front of the gun Use Part No 117773 Grease See gun manual 309550 311075U Flushing 4 NW AN Flush equipment only in a well ventilated area Do not spray flammable fluids Do not turn on heaters while flushin
50. nnect gun air hose to the gun air input and to the air filter outlet Z If you are using more than one hose bundle join the air hoses with the nipple 305 provided with the hose bundle On heated units with Fusion guns con nect the supplied ball valve and quick disconnect coupler to the gun air hose then connect the coupler to the gun air fitting 311075U 6 Connect main air supply Connect the main air supply to the quick disconnect fitting Q on the unit Air supply hose must be at least 5 16 in 8 mm ID up to 50 ft 15 m or 3 8 in 10 mm ID up to 100 ft 30 m Air Filter Moisture Separator Z is equipped with an automatic moisture drain Flush before first use The Reactor E 10 is tested with a plasti cizer oil at the factory Flush out the oil with a compatible solvent before spray ing See page 29 17 Setup Heated Units Bi NE eJ Y 2 C Fic 6 Hose Connections 18 ti24099a NY IN Ly A ISO Q EL ig 2 i ava fA RY T 4 EN TIL A Ld S L Ce AS d i BN D So Ar i Oe d Jl A E Ji Mi Ly ae y KQ M KE paa e 7 I ti24098a 311075U 8 Fill wet cups Keep the felt washers in the pump wet cups saturated with Graco ISO pump oil Part No 217374 The lubri cant creates a barrier between the ISO and the atmosphere NV
51. ntrols 14 Fluid Temperature Sensors and Displays 14 SEUD lt 4 oe oe dee hate eee eet 15 Startup of Heated Units 22 Heatup Guidelines 23 Heat Management Tips 23 Heating Foam Resins with 245 fa Blowing Agents 24 Spraying Dispensing 25 Pause Heated Units 26 Refilling Tanks eese 26 Pressure Relief Procedure 27 SDUICOWEE 5o descr vox rn fa RC ORE D deat tu qu Satna 27 Maintenance 00 0c ee eee ees 28 FUSANO ub Se te tubes tee thesi eee 29 Troubleshooting 31 Status COES xakbredmc Xa pb XS 31 Troubleshooting Chart 34 MOD AM cus iubes o E atu unies oe edd e 39 Before Beginning Repair 39 Removing Supply Tanks 39 Recirc Spray Valves Ln 40 Displacement Pump 41 Control Module sssn 43 Fluid Heaters if supplied 48 Pressure Transducers 000055 48 Drive HOUSING 0 ee ees 49 Cycle Counter Switch Replacement 50 Electric Motor ic ate a ea dae 51 Motor Brushes s oscura dC RS des 52 p gcn 52 ONS ce gas ee oe ae eae bee eas eae 54 Suggested Spare Replacement Parts 68 AGCOSSOTIGS 2 gn uo ndr cd oae cit Je ee de da 68 Dimensions ree n n RI nnn 69 Techni
52. o see also the label on back of the control matically parks pumps enclosure Slow Slow recirculation Code No Code Name 1 Pressure imbalance between A and B sides Unable to maintain pressure setpoint Use knob CF to select desired function Recirc speed Fast Recirc Fast recirculation speed Pressure Adjusts fluid pressure Adjust to gun in spray mode Pressure transducer A failure mE Pressure transducer B failure STATUS Indicator Indicator ST stead Motor P High motor temperature dil dd eene elis HMM E OWE No cycle counter switch input switch is turned on and control board is y P working The default is to shut down if a status code indication occurs Codes 1 and 2 may be set to disable automatic shut down if desired see page 32 The other codes are not settable fo 311075U 13 Controls and Indicators Motor Power Switch Circuit Breaker Switch MP turns power on to control board and function knob The switch includes a 20 A circuit breaker Heater Power Switch Circuit Breaker See FIG 3 Switch HP turns power on to heater thermostats The switch includes a 20 A circuit breaker Present on heated units only Fic 4 Heater Temperature Controls Heater Temperature Controls See FIG 4 Control knobs HC set tempera ture of component A and B heaters Indicator lights HL turn on when thermostats are heat ing and off when heater reaches setpoint Present on heated units onl
53. r rags to protect Reactor E 10 and surrounding area from spills 3 Open filter drain plug on Y strainer 51 4 Disconnect swivel elbow 50 at pump fluid inlet 5 Remove screws 4 holding tank to cart frame 6 Pivot top of tank to side and lift it and fluid inlet fittings off cart 39 Repair Recirc Spray Valves We 1 See Before Beginning Repair page 39 Relieve pressure page 27 Heated Models Fam 503a A Sae 501 502 507 510 509 T16977a 2 See FIG 8 Disassemble Recirc Spray valves Clean and inspect all parts for dam age Ensure that the seat 503a and gas ket 503b are positioned inside each valve cartridge 503 3 Apply PTFE pipe sealant to all tapered pipe threads before reassembling 4 Reassemble in reverse order following all notes in FIG 8 Nonheated Models Z Aa 5 04 503 AA 507 TI6982a 509 N Torque to 250 in Ib 28 Nem PAN Use blue threadlocker on valve cartridge threads into manifold AN Part of item 503 Fic 8 Recirc Spray Valves 40 311075U Displacement Pump e Displacement pump repair and parts information is included in manual 311076 which is supplied with your unit Use dropcloth or rags to protect Reactor E 10 and surrounding area from spills M A Vi 1 See Before Beginning Repair page 39 Relieve pressure page 27 2 Close both fluid inlet bal
54. recommended by the fluid and solvent manufacturer e Gloves e Hearing protection 311075U 5 Warnings This may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment e Engage trigger lock when not spraying Do not point gun at anyone or at any part of the body Do not put your hand over the spray tip Do not stop or deflect leaks with your hand body glove or rag duis Follow the Pressure Relief Procedure when you stop spraying and before cleaning checking or servicing equipment Tighten all fluid connections before operating the equipment Check hoses and couplings daily Replace worn or damaged parts immediately FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and explosion Use equipment only in well ventilated area Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present Ground all equipment in work area See Grounding instructions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail If there is static sparking or you feel a shock stop operation immediately Do not use equipment unti
55. rtioner for use with a wide variety of coatings foams sealants and adhesives Materials must be self leveling and pourable and may be applied with impinge ment mix spray guns disposable mixer guns or flush type mix manifolds Reactor E 10 is gravity fed from 7 gal 26 5 liter supply tanks mounted on the unit The tanks are translucent to allow monitoring of fluid level Severe duty positive displacement reciprocat ing piston pumps meter fluid flow to the gun for mixing and applying When set to recirculation mode Reactor E 10 will circulate fluids back to the supply tanks Heated models include separate thermostati cally controlled heaters for each fluid and an insulated hose bundle with circulation return hoses This allows the hoses and gun to be preheated to the desired temperature before spraying Digital displays show the tempera tures of the two fluids An electronic processor controls the motor monitors fluid pressures and alerts the opera tor if errors occur See STATUS Indicator page 13 for further information Reactor E 10 has two recirculation speeds slow and fast and an adjustable pressure out put Slow Recirculation e Slow circulation results in a higher tem perature transfer in the heater so hoses and gun heat up quicker e Good for touchup or low flow spraying up to moderate temperature e Not used to circulate full tanks up to tem perature Use with 245 fa blowing agent foa
56. s up to tem perature e Use with 245 fa blowing agent foams to minimize heat returned to tank and reduce frothing Fast Recirculation e Fast Recirc keeps heaters on fulltime to bring fluid tanks up to temperature The higher your usage rate the more heat needed in the tanks before spraying e For normal usage rates Use Fast Recirc to get tanks to approximately 50 F 28 C below desired spray tem perature then use Slow Recirc to raise hose and gun to desired temperature e For higher flow rates or continuous spraying Use Fast Recirc to bring tem perature of tanks to approximately 20 F 11 C below desired spray tempera ture then use Slow Recirc to raise hose and gun to desired temperature e Volume in tanks Use only what you need For example 2 5 gal 10 1 in each tank will heat up almost twice as fast as 5 gal 20 I Mixes fluid within tanks to avoid heating only the fluid at the top of the tank e Use for flushing 311075U Startup of Heated Units Heat Management Tips Heaters perform better with lower flow rates or smaller mix modules e Triggering the gun for short periods helps maintain efficient heat transfer keeping material at the desired temperature Trig gering the gun for a long period does not allow enough heating time and cold mate rial will enter the hose e If temperature displays fall below accept able limits set function knob to Slow Recirc T and circulate again to br
57. sh and turns pink when saturated Be sure shipping plugs are removed from open ings on desiccant filter b Remove tank B cover and pour resin into tank B blue side Replace cover A TI7018a to assemble to tank 20 10 Purge air and flush fluid from lines Remove both recirculation tubes P from the tanks and secure each one in a dedicated waste container TI7022a S Plug in power cord s See TABLE 2 page 16 Open both pump fluid inlet valves V shown in open position TI7019a 311075U 311075U Setup e Turn on Motor Power h When clean fluids exit both recir culation tubes P set function knob to Stop Park Ww f Set Recirc Spray valves to Recirc I Replace recirculation tubes in supply tanks Q Set function knob to Slow Recirc J On nonheated units purge the on hoses through the gun without a C35 or Fast Recirc 94 static mixer installed For heated units continue with Startup of Heated Units page 22 Nonheated units are ready to spray dis pense Go to Spraying Dispensing page 25 21 Startup of Heated Units Startup of Heated Units 3 Turn on Heater Power pin DEED UU x L Some models heat the fluid which can O OA cause equipment surfaces to become very hot To avoid severe burns e Do not operate Reactor E 10 without all 4 covers and shrouds in place e Do not touch hot fluid or equipment
58. sulated Hose Bundle without Recirculation Lines and Air Hose Ref Part Description Qty 301 249508 HOSE fluid component A 1 4 in 6 mm ID 35 ft 10 7 m 1 2 20 UNF moisture guard 1 static dissipative 302 249509 HOSE fluid component B 1 4 in 6 mm ID 35 ft 10 7 m 9 16 18 UNF moisture guard 1 static dissipative 311075U 63 Parts Part No 24L004 120 V Heated Display Part No 24L005 240 V Heated Display Ref Part Description 401 15F984 PLATE 402 24K983 SWITCH motor or heater power with circuit breaker 403 15G386 MODULE display tempera ture includes 1 item 402 and 2 item 424 404 24L002 POTENTIOMETER 405 119930 INDICATOR status LED 406 24G886 BOARD control 120 V units only 24G887 BOARD control 240 V units only 407 15G230 CABLE harness 408 107156 SCREW machine pan hd 409 113505 NUT keps hex hd 410 119898 BULKHEAD FITTING cable 410 410 Ref 411 412 413 414 415 416 416a 417 421 424 425 TI6979a Part Description Qty 101765 GROMMET 116773 CONNECTOR plug 15C866 WIRE jumper 15G279 LABEL display 15G053 PLATE detent 24L001 KNOB function includes item ait i i N eo 416a 101118 SCREW set no 10 x 1 4 in 2 6 mm 15G454 LABEL startup heated 1 15G384 ENCLOSURE 1 24K981 DISPLAY temperature with 2 sensor DUAL TERMINAL not shown 2 311075U Part No 249537 120 V Nonheated Display Part No 249538 240 V Nonheated Display
59. th equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufac turer s warnings For complete information about your material request MSDS from distributor or retailer Check equipment daily Repair or replace worn or damaged parts immediately with genuine Graco replacement parts only Do not alter or modify equipment Use equipment only for its intended purpose Call your Graco distributor for infor mation Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not kink or over bend hoses or use hoses to pull equipment Keep children and animals away from work area Do not operate the unit when fatigued or under the influence of drugs or alcohol Comply with all applicable safety regulations MOVING PARTS HAZARD Moving parts can pinch or amputate fingers and other body parts Keep clear of moving parts Do not operate equipment with protective guards or covers removed Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure in this manual Dis connect power or air supply BURN HAZARD Equipment surfaces and fluid that s heated can become very hot during operation To avoid severe burns do not touch hot fluid or equipment Wait until equip ment fluid has cooled completely Overview Overview The Reactor E 10 is a portable electric pow ered 1 1 mix ratio propo
60. tolerances for status code 2 see Sta tus Code 1 and 2 Settings 31 Troubleshooting Status Code 1 and 2 Settings OFF ON 1 Locate switch SW2 on the control board f Default pagesi Cmm 70238 z TI7024a 2 Set the four DIP switches to the desired positions See FIG 7 and TABLE 5 on page 32 FiG 7 DIP Switch SW2 Settings Table 5 Status Code 1 and 2 Settings Right default DIP Switch and Function Left setting DIP Switch 1 Switch 2 DIP Switch 2 ance is greater than DIP Switch 3 DIP Switch 4 Status Code 3 Transducer A Failure 1 32 Check transducer A electrical connection J3 at board page 47 Reverse A and B transducer electrical con nections at board page 47 If error moves to transducer B Status Code 4 replace transducer A page 48 If selected causes shutdown if A and B pressure imbal If selected causes warning if A and B pressure imbal ance is greater than If selected causes shutdown or displays a warning due to deviation of pressure from setpoint exceeds selection made in DIP Switch 4 Causes warning if deviation of pressure from setpoint is greater than If selected causes shutdown or displays a warning if the WARNING SHUTDOWN pressure imbalance exceeds selection made in DIP 500 psi 3 5 MPa 35 bar 6096 if 800 psi 5 6 MPa 56 bar running 300 psi 2 1 MPa 21 bar 50 if 800 psi 5 6 MPa 56 bar running 800 psi 5 6 MPa 56
61. ve stuck open page 41 with unheated unit tanks 34 311075U Troubleshooting PROBLEM CAUSE SOLUTION Pump intake valve partially Clean pump intake valve See plugged page 41 Pressure is higher on one side when setting pressure with func tion knob Air in hose Fluid is compressible Purge air from hose Unequal size hoses or unequal Use matching hoses or balance hose construction pressures before spraying Pressures are not balanced when Unequal viscosities Change temperature setting to running but pressure is gener ated and holds on both strokes balance viscosities Change restrictor at mix point to balance back pressure Restriction on one side Clean mix module or restrictor at mix manifold Clean gun check valve screens Fluid leak in pump packing nut Worn throat seals Replace See pump manual area Pressure doesn t hold when Leaking Recirc Spray valve Repair page 40 stalled against gun in spray mode Leaking piston valve or intake Repair See pump manual valve in displacement pump Leaking gun shutoff Repair See gun manual Pressure is higher on B side This is normal Component Bis No action required during startup of recirculation typically higher viscosity than especially in High Recirc mode component A until the material is heated during recirculation Resin froths and overflows tank Agitation from pouring Hot mate Turn heaters off before
62. ve pressure page 27 2 Remove access cover 39 at back of con trol module to expose control board 406 3 Disconnect transducer cables from J3 and J8 at board see FIG 12 page 47 Reverse A and B connections and check if status code follows the bad transducer page 32 4 Reconnect good transducer to proper con nector Disconnect failed transducer from board and unscrew from base of fluid heater heated units or transducer mani fold nonheated units 5 Install o ring 60 on new transducer 58 FIG 13 6 Install transducer in heater or manifold Mark board end of cable with tape red transducer A blue transducer B 7 Route cable through channel to control module 8 Connect transducer cable at board see FIG 12 page 47 58 60 TI7027a 311075U Drive Housing Removal N Vi 1 See Before Beginning Repair page 39 Relieve pressure page 27 2 Remove screws 207 and end covers 221 227 FIG 14 Examine connecting rod 216 If rod needs replacing first remove the pump 219 page 41 NOTICE Do not drop gear reducer 214 and crank shaft 210 when removing drive housing 215 These parts may stay engaged in motor end bell MB or may pull away with drive housing 3 Disconnect pump inlet and outlet lines Remove screws 220 and pull drive hous ing 215 off motor 201 Connecting rod 216 will disengag
63. y Fluid Temperature Sensors and Displays See FIG 3 Fluid temperature sensors T monitor actual temperature of component A and B fluid going to spray gun Temperatures are then displayed TD Present on heated units only Unit is shipped set to F To change to C see page 43 HL HC TI6984b 311075U Setup 1 Locate Reactor E 10 d Locate Reactor E 10 on a level surface b Do not expose Reactor E 10 to rain 2 Electrical requirements aN Improper wiring may cause electric shock or other serious injury if work is not performed properly Have a qualified electrician perform any electrical work Be sure your installation complies with all National State and Local safety and fire codes Connect Reactor E 10 to the correct power source for your model See TABLE 2 Models with two power cords must be connected to two separate dedicated circuits See FIG 5 Some models include cord adapters 55 56 for use outside North America Connect the appropriate adapter to the unit s power cord before connecting to your power source 3 Ground system The equipment must be grounded Grounding reduces the risk of static and electric shock by providing an escape wire for the electrical cur rent due to static build up or in the event of a short circuit 311075U Setup ML CE Reactor E 10 grounded through power cord Generator if used fo
64. ystem to waste containers 1 0 When nearly clear solvent comes from recirculation tubes set function knob to A ow Stop Park 2 Return recirculation tubes to supply tanks 11 Set function knob to Fast Recirc 6 Circulate solvent through system for 10 20 minutes to ensure thorough cleaning 30 To flush gun refer to gun instruction manual Purge Gun Hoses Nonheated L Units Only Disconnect hoses from gun and secure back into the tanks for thorough clean ing with solvent e Turn Recirc Spray valve A to Spray 9e e Open gun into waste container A e Set function knob to Slow Recirc T until hose is flushed e Set function knob to Stop Park O e Repeat for B side 7 Set function knob to Stop Park YY Solvent flushing is a two step process Go back to step 4 drain solvent and flush again with fresh solvent Leave unit filled with solvent plasticizer clean motor oil or refill supply tanks with new material and reprime Never leave the unit dry unless it has been disassembled and cleaned If fluid residue dries in the pumps the ball checks may stick the next time you use the unit 311075U Troubleshooting Status Codes Determine the status code by counting the number of times the status indicator ST blinks TI7016a Status Code 1 Pressure Imbalance The unit does not check for pressure EN imbalance at setpoints less than 250 psi 1 75 MPa 17 5

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