Graco 313540G Reactor H Vr Proprortioners And Parts Users Manual 313540G, Proprortioners, Repair Parts, English
2015-04-02
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Repair - Parts H-VR 313540G EN Hydraulic Variable Ratio, Heated, Plural-Component Proportioner For spraying polyurethane foam and polyurea coatings. Not for use in explosive atmospheres. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. See page 3 for model information, including maximum working pressure and approvals. U.S. Patent Pending Russian Patent No. 2359181 r_256886_313539_1 #ONFORMS TO !.3)5, 3TD #ERTIFIED TO #!.#3! 3TD # .O Contents Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Supplied Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . . 7 Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . . . 7 Moisture Sensitivity of Isocyanates . . . . . . . . . . . . 7 Keep Components A and B Separate . . . . . . . . . . 8 Foam Resins with 245 fa Blowing Agents . . . . . . . 8 Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . . 8 Temperature Control Diagnostic Codes . . . . . . . . 9 E01: High fluid temperature . . . . . . . . . . . . . . . . 9 E02: High zone current . . . . . . . . . . . . . . . . . . . 10 E03: No zone current . . . . . . . . . . . . . . . . . . . . 10 E04: Fluid Temperature Sensor (FTS) or thermocouple disconnected . . . . . . . . . . . . 11 E05: Circuit board overheated . . . . . . . . . . . . . 11 E06: Communication cable unplugged . . . . . . . 11 Motor Control Diagnostic Codes . . . . . . . . . . . . . 12 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 E21: No component A transducer . . . . . . . . . . . 12 E22: No component B transducer . . . . . . . . . . . 12 E23: High fluid pressure . . . . . . . . . . . . . . . . . . 12 E24: Pressure imbalance . . . . . . . . . . . . . . . . . 13 E27: High motor temperature . . . . . . . . . . . . . . 14 E30: Momentary loss of communication . . . . . . 15 E31: Pumpline reversing switch failure/high cycle rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 E99: Loss of communication . . . . . . . . . . . . . . . 15 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Reactor Electronics . . . . . . . . . . . . . . . . . . . . . . 16 Primary Heaters (A and B) . . . . . . . . . . . . . . . . 18 Hose Heat System . . . . . . . . . . . . . . . . . . . . . . 19 Hydraulic Drive System . . . . . . . . . . . . . . . . . . . 21 Proportioning System . . . . . . . . . . . . . . . . . . . . 23 2 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Pressure Relief Procedure . . . . . . . . . . . . . . . . 27 Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Proportioning Pumps . . . . . . . . . . . . . . . . . . . . . 28 Circuit Breaker Module . . . . . . . . . . . . . . . . . . . 30 Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Motor Control Board . . . . . . . . . . . . . . . . . . . . . 32 Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Electric Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Temperature Control Module . . . . . . . . . . . . . . . 35 Primary Heaters . . . . . . . . . . . . . . . . . . . . . . . . 37 Heated Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Fluid Temperature Sensor (FTS) . . . . . . . . . . . . 40 Display Module . . . . . . . . . . . . . . . . . . . . . . . . . 42 Inlet Fluid Strainer Screen . . . . . . . . . . . . . . . . . 44 Change Hydraulic Fluid and Filter . . . . . . . . . . . 44 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Sub Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . 57 Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 57 Hydraulic Directional Valve Assembly . . . . . . . . 59 7.65 kW Single Zone Heater . . . . . . . . . . . . . . . 60 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Temperature Control . . . . . . . . . . . . . . . . . . . . . 62 Fluid Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Circuit Breaker Modules . . . . . . . . . . . . . . . . . . 64 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 68 Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 68 313540G Models Models H-VR SERIES Part, Series 256886 256887 * ◆ Full Load Peak Amps* Per Phase 71 41 Voltage (phase) System Watts† 230V (3) 26,600 400V (3) 26,600 Primary Heater Watts Max Flow Rate◆ lb/min (kg/min) Approximate Output per Hydraulic Cycle (A+B) Pressure gal. (liter) Ratio Maximum Fluid Working Pressure psi (MPa, bar) 15,300 15,300 30 (13.6) 30 (13.6) Variable Variable 3500 (24.1, 241) 3500 (24.1, 241) Variable Variable Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less. Maximum flow rate given for 60 Hz operation. For 50 Hz operation, maximum flow rate is 5/6 of 60 Hz maximum flow. 313540G 3 Supplied Manuals Supplied Manuals Related Manuals The following manuals are used with the Reactor™ HV-R Proportioner. Refer to these manuals for detailed equipment information. The following manuals are for accessories used with the Reactor™. Order Part 15M334 for a compact disk of Reactor manuals. Feed Pump Kits Part Description 309815 Instruction-Parts Manual (English) Reactor Hydraulic Proportioner Air Supply Kit Part Description Part Description Reactor H-VR Proportioner, Operation Manual (English) 309827 Instruction-Parts Manual (English) for Feed Pump Air Supply Kit 313539 Reactor Electrical Diagrams Circulation and Return Tube Kits Part Description Part Description Reactor Hydraulic Proportioner, Electrical Diagrams (English) 309852 Instruction-Parts Manual (English) 312064 Fluid Pump Heated Hose Part Description Instruction-Parts Manual (English) Part Description 309572 313485 Pump Instructions-Parts Manual (English) Circulation Kit Part Description 309818 Instruction-Parts Manual (English) Circulation Valve Kit Part Description 312070 Instruction-Parts Manual (English) Data Reporting Kit Part Description 309867 Instruction-Parts Manual (English) Rupture Disk Assembly Kit 4 Part Description 309969 Instruction-Parts Manual (English) 313540G Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation 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. WARNING ELECTRIC SHOCK HAZARD This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock. • Turn off and disconnect power cord before servicing equipment. • Use only grounded electrical outlets. • Use only 3-wire extension cords. • Ensure ground prongs are intact on power and extension cords. • Do not expose to rain. Store indoors. TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed. • Read MSDS’s to know the specific hazards of the fluids you are using. • Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines. • Always wear impervious gloves when spraying or cleaning equipment. • If this equipment is used with isocyanate material, see additional information on isocyanates in Isocyanate Conditions Section of this manual. PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to: • Protective eyewear • Clothing and respirator as recommended by the fluid and solvent manufacturer • Gloves • Hearing protection SKIN INJECTION HAZARD High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment. • Do not point gun at anyone or at any part of the body. • Do not put your hand over the spray tip. • Do not stop or deflect leaks with your hand, body, glove, or rag. • Do not spray without tip guard and trigger guard installed. • Engage trigger lock when not spraying. • Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment. 313540G 5 Warnings WARNING FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion: • Use equipment only in well ventilated area. • Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc). • Keep work area free of debris, including solvent, rags and gasoline. • Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present. • Ground all equipment in the work area. • Use only grounded hoses. • Hold gun firmly to side of grounded pail when triggering into pail. • If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem. • Keep a working fire extinguisher in the work area. 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. • 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. • 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. • Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only. • Do not alter or modify equipment. • Use equipment only for its intended purpose. Call your distributor for information. • Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces. • Do not kink or over bend hoses or use hoses to pull equipment. • Keep children and animals away from work area. • Comply with all applicable safety regulations. OR 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. 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. 6 313540G Isocyanate Conditions Isocyanate Conditions 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 providing sufficient ventilation in the work area. If sufficient ventilation is not available, a supplied-air respirator is required for everyone in the work area. To prevent contact with isocyanates, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons, and goggles, is also required for everyone in the work area. Moisture Sensitivity of Isocyanates Isocyanates (ISO) are catalysts used in two component foam and polyurea coatings. ISO will react with moisture (such as humidity) to form small, hard, abrasive crystals, which become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts. NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature. To prevent exposing ISO to moisture: • Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container. • Use moisture-proof hoses specifically designed for ISO, such as those supplied with your system. • Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use. • Never use solvent on one side if it has been contaminated from the other side. • Always park pumps when you shutdown. • Always lubricate threaded parts, except for GC1128, GC0697, and GC2150, with Part 217374 ISO pump oil or grease when reassembling. Material Self-ignition Some materials may become self-igniting if applied too thickly. Read material manufacturer’s warnings and material MSDS. 313540G 7 Keep Components A and B Separate Keep Components A and B Separate NOTICE To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (isocyanate) and component B (resin) parts. Foam Resins with 245 fa Blowing Agents Some foam blowing agents will froth at temperatures above 90°F (33°C) when not under pressure, especially if agitated. To reduce frothing, minimize preheating in a circulation system. 8 Changing Materials • When changing materials, flush the equipment multiple times to ensure it is thoroughly clean. • Always clean the fluid inlet strainers after flushing. • Check with your material manufacturer for chemical compatibility. • Most materials use ISO on the A side, but some use ISO on the B side. • Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the B (resin) side. 313540G Temperature Control Diagnostic Codes Temperature Control Diagnostic Codes Temperature control diagnostic codes appear on temperature display. These alarms turn off heat. E99 clears automatically when communication is regained. Codes E03 through E06 can be cleared by pressing turn main power OFF . For other codes, then ON to clear. Code Code Name Alarm Zone Corrective Action page 01 High fluid temperature Individual 9 02 High zone current Individual 10 03 No zone current with hose heater on Individual 10 04 FTS not connected Individual 11 05 Board overtemperature Individual 11 06 Communication cable unplugged from module Individual 11 99 Loss of communication A 15 NOTE: For hose zone only, if FTS is disconnected at startup, display will show hose current 0A. E01: High fluid temperature Causes of E01 Errors • Thermocouple A or B (310) senses a fluid temperature above 230°F (110°C). • Fluid temperature sensor (FTS) senses a fluid temperature above 230°F (110°C). • Overtemperature switch A or B (408) senses a fluid temperature above 230°F (110°C) and opens. At 190°F (87°C) the switch closes again. • Thermocouple A or B (410) fails, is damaged, is not touching the heater element (407), or has a poor connection to the temperature control board. • Overtemperature switch A or B (408) fails in the open position. • The temperature control board fails to turn off any heat zone. Checks Troubleshooting this equipment requires access to parts that may cause electric shock or other serious injury if work is not performed properly. Have a qualified electrician perform all electrical troubleshooting. Be sure to shut off all power to the equipment and relieve all pressure (see Pressure Relief Procedure, page 27) before repairing. Check which zone is displaying the E01 error. 1. Check that connector B is firmly plugged into temperature control module (see FIG. 9, page 35). 2. Clean and re-plug connections. • Zone power wires or thermocouples are switched from one zone to another. • Failed heater element where thermocouple is installed. • Loose wire 313540G 3. Check connections between the temperature control module and overtemperature switches A and B (308), and between temperature control module and thermocouples A and B (410) or FTS (21) [depending on which zone is displaying E01]. See TABLE 6, page 35. Ensure that all wires are securely connected to connector B. 9 Temperature Control Diagnostic Codes 4. Remove connector B from temperature control module, 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. NOTE: 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 1&2 3&4 5&6 8&9 11 & 12 OT switch A OT switch B Thermocouple A Thermocouple B FTS 10 & 12 FTS Reading nearly 0 ohms nearly 0 ohms 4-6 ohms 4-6 ohms approximately 35 ohms per 50 ft (15.2 m) of hose, plus approximately 10 ohms for FTS open 5. Verify fluid temperature, using an external temperature sensing device. • If temperature is too high (sensor reading is 229°F [109°C] or above): E02: High zone current 1. Check hose connections for electrical short, page 39. 2. Exchange zone module with another one. Turn zone on and check for error (see page 36). If error disappears, replace faulty module. a. For hose zone: If error still occurs, perform Transformer Primary Check and Transformer Secondary Check, starting on page 41. NOTE: When there is a high current error, the LED on that zone’s module will turn red while the error is displayed. E03: No zone current 1. Check for tripped circuit breaker inside electrical cabinet or at power source for that zone. Replace circuit breaker if it trips habitually. 2. Check for loose or broken connection at that zone. 3. Exchange zone module with another one. Turn zone on and check for error (see page 36). If error disappears, replace faulty module. 4. If E03 occurs for all zones, the contactor may not be closing. Verify wiring from heater control to contactor coil. 6. Check if thermocouples A and B are damaged, or not contacting the heater element, page 38. a. Hose zone: test hose continuity, page 39. 7. To test that temperature control module turns off when equipment reaches temperature setpoint: b. a. Set temperature setpoints far below displayed temperature. b. Turn zone on. If temperature rises steadily, power board is failing. c. Verify by swapping with another power module. See Replacing Temperature Control Assembly Modules, page 36. Perform Transformer Primary Check and Transformer Secondary Check, starting on page 41. NOTE: When a no current error occurs, the LED on the specific zone’s module turns red when the error is displayed. d. If the swapped module does not fix the problem, the power module is not the cause. 8. Verify continuity of heater elements with an ohmmeter, see page 37. 10 313540G Temperature Control Diagnostic Codes E04: Fluid Temperature Sensor (FTS) or thermocouple disconnected E05: Circuit board overheated NOTE: 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 temperature sensor connections to long green connector (B) on temperature control module, page 34. Unplug and re-plug sensor wires. 1. Check that fan above electrical cabinet is operating. 2. Test fluid temperature sensor continuity with ohmmeter, page 9. 2. Check that electrical cabinet door is properly installed. 3. If an error occurred for the hose zone, check FTS connections at each section of hose. 3. Check for obstructions blocking cooling holes in bottom of electrical cabinet. 4. If an error occurred for the hose zone, test FTS by plugging directly into machine. 4. Clean heatsink fins behind heater control modules. 5. Ambient temperature may be too high. Allow Reactor to cool by moving to a cooler location. F E06: Communication cable unplugged ti9878a 5. To verify heater control module is not causing the problem, use a wire to short-circuit the two pins corresponding 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. 1. Unplug and re-plug cable that connects heater control module to heater module. 2. Replace communication cable if problem persists. 6. If an error occurred for the hose zone, temporarily use the current control mode. Refer to Reactor H-VR Operation manual 313539. 313540G 11 Motor Control Diagnostic Codes Motor Control Diagnostic Codes Motor control diagnostic codes E21 through E27 appear on pressure display. Code There are two types of motor control codes: alarms and warnings. Alarms take priority over warnings. 99 Code Name Loss of communication Alarm (A) or Corrective Warning (W) Action page 15 A Alarms E21: No component A transducer Alarms turn off Reactor. Turn main power OFF 1. Check transducer A connection at J3 on motor control board, page 33, and clean contacts. then ON 2. Reverse A and B transducer connections. If error moves to transducer B (E22), replace transducer A, page 12. If error does not move, replace motor control board, page 32. to clear. NOTE: Alarms can also be cleared, except for code 23, by pressing . 1. Check transducer B connection at J8 on motor control board, page 33, and clean contacts. Warnings Reactor will continue to run. Press to clear. A warning will not recur for a predetermined amount of time (varies for different warnings), or until main power is turned OFF E22: No component B transducer then ON 2. Reverse A and B transducer connections. If error moves to transducer A (E21), replace transducer B, page 12. If error does not move, replace motor control board, page 32. E23: High fluid pressure . 1. Relieve pressure. Verify low pressure with analog Code Code Name Alarm (A) or Corrective Warning (W) Action page 21 No transducer (component A) A 12 22 No transducer (component B) A 12 23 High fluid pressure A 12 24 Pressure imbalance A/W (to select, see page 32) 13 gauges. Turn main power OFF then ON . 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. 27 High motor temperature A 14 3. Ensure at least one pump is in the number 1 position. See Setup section of Reactor H-VR Operation manual 313539. 30 Momentary loss of communication A 15 4. If error still persists, reduce hydraulic pressure. 31 Pumpline reversing switch A failure/high cycle rate 15 12 313540G Motor Control Diagnostic Codes E24: Pressure imbalance NOTE: Upon initial start-up this diagnostic code will not cause an alarm for 2 minutes. NOTE: 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. The digital display always shows the higher of the two pressures. As soon as the higher analog pressure drops below the lower analog pressure, the display changes to the new higher reading. Knowing this, the following checks will show which transducer has failed, or if the motor control board has failed. 3. 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. NOTE: If spraying at a ratio other than 1:1, an E24 may occur. Size hoses and mix chamber appropriately to avoid pressure imbalance. NOTE: 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. 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. Continue with step e. Fast E24 Errors Fast E24 errors occur: • • If the higher gauge and display do not match, that transducer is not communicating with the motor control board. Check wire connections and replace transducer, page 34. within 10 seconds of turning the pumps on, or as soon as you trigger the gun. Causes of Fast E24 Errors • • • • • • • • 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 e. Turn pumps off. Reduce pressure of higher component by slightly turning PRESSURE RELIEF/SPRAY valve for that component toward PRESSURE RELIEF/CIRCULATION , while watching the display and the analog gauges. As soon as the higher analog pressure drops below the lower analog pressure, the display 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. . Checks for Fast E24 Errors NOTE: If a fast E24 error occurs, first check the readings of the analog gauges. • If the gauge readings are very close: 1. Clear the error (page 12) and try running the unit again. 2. If E24 recurs and the gauge readings are still very close, a pressure transducer has failed. f. Repeat for the other side, to check the other transducer. 1 Turn valve slightly to reduce pressure of higher component. 1 ti9877a 4. To test if the failure is with the transducer or the socket on the motor control board: 313540G 13 Motor Control Diagnostic Codes b. a. Reverse connections at J3 and J8 on the motor control board. • b. Run the unit until pressure is 1000-1500 psi (7-10.5 MPa, 70-105 bar). c. If the 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: 1. 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 PRESSURE RELIEF/SPRAY valve for that component toward PRESSURE RELIEF/CIRCULATION balanced pressures. , until gauges show 1 Turn valve slightly to reduce pressure of higher component. 1 Check and clean the gun mix chamber impingement ports and center port. See gun manual. NOTE: Some mix chambers have counter bored impingement ports, requiring two drill sizes to clean completely. Slow E24 Errors Slow E24 errors occur gradually. The pressures are balanced when you begin spraying, but slowly become imbalanced until an E24 occurs. NOTE: If spraying at a ratio other than 1:1, an E24 may occur. Size hoses and mix chamber appropriately to avoid pressure imbalance. 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 hose is not heating properly. kinked supply hose. bottom of drum is damaged, causing blockage of feed pump inlet. drum is not vented. ti9877a E27: High motor temperature NOTE: Turn PRESSURE RELIEF/SPRAY valve only enough to balance pressure. If you turn it completely, all pressure will bleed off. Causes of E27 Errors • Motor temperature is too high. Reduce pressure, gun tip size, or move Reactor to a cooler location. Allow 1 hour for cooling. • Make sure there is no obstruction to fan airflow. Ensure that the motor/fan shroud is installed. • Check that the motor overtemperature wire assembly is plugged into J9 on the motor control board, page 33. • If the preceding checks do not correct the problem, perform the following tests: 2. 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. 3. If you are able to balance pressures, try running the unit. 1. Turn main power OFF 4. If a fast E24 error occurs again, and the gauges readings are not very close: a. Check and clean the gun inlet screens. 14 . 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, 313540G Motor Control Diagnostic Codes 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. If the 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 reconnected, the display may show E30 briefly (no more than 2 seconds). 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. E99: Loss of communication If communication is lost between the motor control display 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. 2. Incoming voltage should be 230 Vac. Check the temperature control module voltage at terminal block (805) on the circuit breaker module (see page 64). 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: 3. Swap display connection on temperature control module (C) with display connection on motor control board (J13). 4. If error no longer occurs, the board or module was at fault. Switch connections back to ensure connector was not poorly connected. E31 may also occur if the system is modified to produce a higher flow rate. 313540G 15 Troubleshooting Troubleshooting Reactor Electronics 2. Turn main power OFF . 3. Allow equipment to cool. Before performing any troubleshooting procedures: 1. Relieve pressure, page 27. PROBLEM Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Also, determine that all circuit breakers, switches, and controls are properly set and wiring is correct before assuming there is a problem. CAUSE SOLUTION Plug in power cord. No power. Both sides of display do not illuminate. Temperature display does not illuminate. Pressure display does not illuminate. Erratic display; display turns on and off. 16 Turn disconnect ON . Low voltage. Ensure input voltage is within specifications, page 42. Loose wire. Check connections, page 42. Display disconnected. Check cable connections, page 42. 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 display illuminates, heater control board is causing problem. Otherwise, display cable or display is failing. 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 pressure display illuminates, motor control board is causing problem. Otherwise, display cable or display is failing. Low voltage. Ensure input voltage is within specifications, page 42. Poor display connection. Check cable connections, page 42. Replace damaged cable. 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) 313540G Troubleshooting PROBLEM Hose display reads OA at startup. Display does not respond properly to button pushes. CAUSE FTS disconnected or not installed. Verify proper installation of FTS (see H-VR Operation manual 313539), 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 damaged. Ribbon cable on display circuit board Connect cable (page 42) or replace. disconnected or broken. Broken display button. Red stop button does not work. Fan not working. 313540G SOLUTION Replace, page 42. Broken button (fused contact). Replace, page 42. Loose wire. Check connections, page 42. Blown fuse. Verify with ohmmeter; replace if necessary (page 42). Loose wire. Check fan wire. Defective fan. Replace, page 42. 17 Troubleshooting Primary Heaters (A and B) 2. Turn main power OFF . 3. Allow equipment to cool. Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Also, determine that all circuit breakers, switches, and controls are properly set and wiring is correct before assuming there is a problem. Before performing any troubleshooting procedures: 1. Relieve pressure, page 27. PROBLEM CAUSE SOLUTION Heat turned off. Press Primary heater(s) does not heat. Control of primary heat is abnormal; high temperature overshoots or E01 error occurs intermittently. 18 A or B zone keys. Temperature control alarm. Check temperature display for diagnostic code, page 9. Signal failure from thermocouple. See E04: Fluid Temperature Sensor (FTS) or thermocouple disconnected, page 11. Dirty thermocouple connections. Examine connection of thermocouples to long green plug on heater control board. Unplug and re-plug thermocouple wires, cleaning off any debris. Unplug and re-plug long green connector. Thermocouple not contacting heater element. Loosen ferrule nut (N), push in thermocouple (410) so tip (T) contacts heater element (407). Holding thermocouple tip (T) against heater element, tighten ferrule nut (N) 1/4 turn past tight. See page 38 for illustration. Failed heater element. See Primary Heaters, page 18. Signal failure from thermocouple. See E04: Fluid Temperature Sensor (FTS) or thermocouple disconnected, page 11. Thermocouple wired incorrectly. See E04: Fluid Temperature Sensor (FTS) or thermocouple disconnected, page 11. Power up zones one at a time and verify that temperature for each zone rises. 313540G Troubleshooting Hose Heat System 2. Turn main power OFF . 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 controls are properly set and wiring is correct before assuming there is a problem. 1. Relieve pressure, page 27. PROBLEM Hose heats but heats slower than usual or it does not reach temperature. Hose does not maintain temperature while spraying. Hose temperature exceeds setpoint. 313540G CAUSE SOLUTION Ambient temperature is too cold. Use auxiliary hose heat system. FTS failed or not installed correctly. Check FTS, page 11. Low supply voltage. Verify line voltage. Low line voltage significantly reduces power available to hose heat system, affecting longer hose lengths. A and B setpoints too low. Increase A and B setpoints. Hose is designed to maintain temperature, not to increase it. Ambient temperature is too cold. Increase A and B setpoints to increase fluid temperature and keep it steady. Flow too high. Use smaller mix chamber. Decrease pressure. Hose was not fully preheated. Wait for hose to heat to correct temperature before spraying. Low supply voltage. Verify line voltage. Low line voltage significantly reduces power available to hose heat system, affecting longer hose lengths. A and/or B heaters are overheating material. Check primary heaters for either a thermocouple problem or a failed element attached to thermocouple, page 11. Faulty thermocouple connections. Verify that all FTS connections are snug and that pins of connectors are clean. Examine connection of thermocouples to long green plug on heater control board. Unplug and re-plug thermocouple wires, cleaning off any debris. Unplug and re-plug long green connector on heater control board. 19 Troubleshooting PROBLEM CAUSE Faulty thermocouple connections. Verify that all FTS connections are snug and that pins of connectors are clean. Examine connection of thermocouples to long green plug on heater control board. Unplug and re-plug thermocouple wires, cleaning off any debris. Unplug and re-plug long green connector. FTS not installed correctly. FTS should be installed close to end of hose in same environment as gun. Verify FTS installation, page 39. FTS failed or is not contacting correctly. Check FTS, page 39. FTS not installed correctly. FTS should be installed close to end of hose in same environment as gun. Verify FTS installation, page 39. Temperature control alarm. Check temperature display or diagnostic code, page 39. Shorted connection or failed hose heating element. With hose heat on and temperature setpoint above displayed hose zone temperature, verify voltage between connectors at each section of hose. Erratic hose temperature. Hose does not heat. Hoses near Reactor are warm, but hoses downstream are cold. SOLUTION Voltage should drop incrementally for each section of hose further from Reactor. Use safety precautions when hose heat is turned on. 20 313540G Troubleshooting Hydraulic Drive System 2. Turn main power OFF . 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 controls are properly set and wiring is correct before assuming there is a problem. 1. Relieve pressure, page 27. PROBLEM Electric motor will not start or stops during operation. 313540G CAUSE SOLUTION Loose connections. Check connections at motor control board. Circuit breaker tripped. Reset breaker (813); see Circuit Breaker Module, page 30. Check 230 Vac at output of breaker. Damaged motor control board. Replace board. See Motor Control Board, page 32. 21 Troubleshooting PROBLEM Hydraulic pump does not develop pressure. Low or zero pressure with screeching noise. CAUSE SOLUTION Pump is not primed or lost its prime. 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 Connect Electrical Cord in Reactor H-VR Operation manual 313539. Check dipstick to ensure that hydraulic reservoir is properly filled (see H-VR Operation manual 313539). 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 increase 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 filter. 22 Screeching noise is characteristic of cavitation and is normal at initial startup for a maximum of 30 seconds. If noise continues longer than 30 sec- Hydraulic fluid is too hot. Ensure that the reservoir is properly serviced. Improve ventilation to allow more efficient heat dissipation. Electric motor operating in wrong direction for 3 Phase system. Motor must operate counter-clockwise from pully end. Drive belt loose or broken. Check drive belt condition. Replace if broken. onds, press motor key to shut off the motor. Check that the inlet fittings are tight and that the pump has not lost its prime. 313540G Troubleshooting Proportioning System 2. Turn main power OFF . 3. Allow equipment to cool. Before performing any troubleshooting procedures: 1. Relieve pressure, page 27. PROBLEM Proportioning pump does not hold pressure when stalled. Problems Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Also, determine that all circuit breakers, switches, and controls are properly set and wiring is correct before assuming there is a problem. CAUSE Pump piston or intake valve leaking. SOLUTION 1. Observe gauges to determine which pump is losing pressure. 2. Determine in which direction the pump has stalled by observing which directional valve indicator light is on. See Table 2, page 25 to isolate the problem. 3. Repair the valve; see pump manual 313485. Material imbalance. See Pressure/Material Imbalance, page 25. Restriction at the gun. Clean the gun; see Pumps Do Not Reverse Direction, page 26. Inadequate flow from pump; cavitation. Increase fluid supply to proportioning pump: • • Use 2:1 supply pump Use minimum 3/4 in. (19 mm) ID supply hose, as short as practical Fluid is too thick. Consult your material supplier for the recommended fluid temperature to maintain a viscosity of 250 to 1500 centipoise. Worn pump inlet valve ball/seat or gasket. Replace; see pump manual 313485. Pressure relief/circulation valve leak- Remove return line and determine if ing back to supply. flow is present while in SPRAY mode. Spraying at a ratio other than 1:1 can Size hoses and mix chamber approcause pressure imbalance. priately. 313540G 23 Troubleshooting PROBLEM Pumps do not reverse direction or pumps do not move. Erratic pump movement. CAUSE SOLUTION Damaged reversing switch assembly. See Pumps Do Not Reverse Direction, page 26. Faulty directional valve. See Pumps Do Not Reverse Direction, page 26. Pump cavitation. Feed pump pressure is too low. Adjust pressure to maintain 100 psi (0.7 MPa, 7 bar) minimum. Fluid is too thick. Consult your material supplier for recommended fluid temperature to maintain a viscosity of 250 to 1500 centipoise. Pump output low. Faulty reversing switch connection. See Pumps Do Not Reverse Direction, page 26. Faulty directional valve. Replace directional valve; see Pumps Do Not Reverse Direction, page 26. Obstructed fluid hose or gun; fluid hose ID too small. Open, clear; use hose with larger ID. Worn piston valve or intake valve in displacement pump. See pump manual 313485. Inadequate feed pump pressure. Check feed pump pressure and adjust to 100 psi (0.7 MPa, 7 bar) minimum. One pump is not in position “1”. Move pump to position “1”. Fluid leak at pump rod seal. Worn throat seals. Replace. See pump manual 313485. No pressure on one side. Fluid leaking from pump outlet rupture disk (274). Check if heater (2) and PRESSURE RELIEF/SPRAY valve (SA or SB) are plugged. Clear. Replace rupture disk (274) with a new one; do not replace with a pipe plug. Inadequate feed pump pressure. Check feed pump pressure and adjust to 100 psi (0.7 MPa, 7 bar) minimum. 24 313540G Troubleshooting Ratio Lock Handle A Pump Arm B Pump Arm Ratio Adjustment Wheel B (Resin) Proportioning Pump A (ISO) Proportioning Pump Change Over Box Hydraulic Cylinder Reversing Switches 3 2 1 1 2 3 Switch Disk r_256886_313540_4 FIG. 1. Pump Line when viewed from rear of machine Table 2. Directional Valve Indicator Status Left Pump Directional Indicator Lighted B-side pump piston valve dirty or damaged A-side pump inlet valve dirty or damaged Right Pump Directional Indicator Lighted B-side pump inlet valve dirty or damaged A-side pump piston valve dirty or damaged 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 problem is at the gun. If the B gauge reads considerably lower than the A gauge, the problem is at the pump. 313540G 25 Troubleshooting Pumps Do Not Reverse Direction • 1. For the proportioning pumps to reverse direction, the switch disk must contact the reversing switches. Ensure that the change over box is assembled correctly and that none of the components are damaged. See FIG. 1 (page 25) and Parts (page 58). Toggle reversing switches. Ensure that continuity between 1150-NC and 1160-T-COM, and between 1150-NC and 1170-B-COM is lost. Refer to the Electrical Diagrams manual 312064 (Detailed Schematic, Motor Controls (3-Phase Motor)). If these four conditions are not verified, replace reversing switches. r_256886_313540_1 2. Check the function of the directional valve. Direction indication lights should switch on and off based on the position of the reversing switches (199). LEDs D19 and D20 (near J5 reversing switch connector on motor board, see FIG. 6) should alternately illuminate when each switch is activated. • b. Directional Valve verify reversing switches. Unplug the J5 reversing switch connector. Verify that when the switches are not triggered there is continuity between 1150-NC and 1160-T-COM, and between 1150-NC and 1170-B-COM. if the reversing switch and wiring are not the cause, and D19 and D20 will not alternately illuminate, replace the motor board. If D19 and D20 do illuminate but the direction indication lights do not, the possible causes include: • • • faulty motor board, faulty directional valve wiring, or faulty directional valve. FIG. 2: Hydraulic Directional Valve Assembly To resolve this problem: There are two possible problems with the directional valve: • verify the motor board output voltages at the J18 directional valve connector. When the reversing switch is toggled one direction, 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. • verify continuity of each directional valve wire and verify wiring connections (see Electrical Diagrams manual 312064). • if motor board and wiring are not the cause, replace the directional valve. a. If D19 and D20 do not alternately illuminate, the possible causes include: • • • faulty reversing switch wiring, faulty reversing switch, or faulty motor board. To resolve this problem: • verify that the reversing switch cable is connected at the bulkhead bracket and that it is plugged into the J5 connector on the motor board. NOTE: 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. 26 313540G Repair Repair Repairing this equipment requires access to parts that may cause electric shock or other serious injury if work is not performed properly. Have a qualified electrician 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 4. Turn PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION . Route fluid to waste containers or supply tanks. Ensure gauges drop to 0. 1. Relieve pressure in gun and perform gun shutdown procedure. See gun manual. SB 2. Close gun fluid manifold valves A and B. SA ti9879a 5. Engage gun piston safety lock. ti2421a 3. Shut off feed pumps and agitator, if used. ti2409a 6. Disconnect gun air line and remove gun fluid manifold. ti2554a 313540G 27 Repair Flushing Proportioning Pumps Flush equipment only in a well-ventilated area. Do not spray flammable fluids. Do not turn on heaters while flushing with flammable solvents. • Flush out old fluid with 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 RELIEF/CIRCULATION lines (N). To avoid injury and damage to pump arms and ratio adjustment screws, relieve all pressure and shut off all power before repairing proportioning pumps. NOTE: See manual 313485 for pump repair instructions. 1. Shut off A , B , and heat zones. 2. Flush, page 28. 3. If pumps are not parked, press . Trigger gun until pumps stop. . Flush through bleed 4. Turn main power OFF SA . Disconnect power supply. SB 5. Shut off both feed pumps. Close both fluid inlet ball valves (B). N 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 moisture-free plasticizer or oil. Do not use water. 28 B ti10971a 313540G Repair 6. Turn both PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION . Route fluid to waste containers or supply tanks. Ensure gauges drop to 0. 8. Disconnect all fluid hoses connected to pumps. 9. Remove pump base pin (183) and top pin (255) on both pumps. See page 57. SB SA ti9879a 183 NOTE: Use a drop cloth or rags to protect Reactor H-VR and surrounding area from spills. 184 r_256886_313539_7 FIG. 4: Remove Pump Pins 7. Remove guard. Loosen all four clamping knobs (190), and remove guard (180). 10. Remove pump assemblies and take to a workbench. 11. See manual 313485 for pump repair instructions. r_256886_313539_6 To avoid injury, never remove guard unless all pressure is relieved and all power is shut off. 12. Reconnect pump in reverse order NOTE: Insert pump top pin (255) before base pin (183) when reconnecting pump. 13. Replace guard (180) and tighten all four clamping knobs (190). Ensure warning label on guard faces outward on machine. 180 190 190 FIG. 3: Remove Guard 313540G 29 Repair Circuit Breaker Module 1. Turn main power OFF Table 3: Circuit Breakers, see FIG. 5 . Disconnect power Ref. Size Component 809 50A Hose/Transformer Secondary Side 811 40A Transformer Primary 812A 50A Heater A 812B 50A Heater B 813 20A Motor/Pumps supply. Turn circuit breakers on to test. 2. Relieve pressure, page 27. 3. Using an ohmmeter, check for continuity across circuit breaker (top to bottom). If no continuity, trip breaker, reset, and retest. If still no continuity, replace breaker as follows: a. Refer to electrical diagrams and to TABLE 3. Disconnect wires and remove bad breaker. b. Install new breaker and reconnect wires. 809 811 NOTE: To reference cables and connectors, see the electrical diagrams and the parts drawings on page 64. 812A 812B 813 ti9884a FIG. 5. Circuit Breaker Module 30 313540G Repair Electric Motor Installation 1. Place motor on unit. Removal 1. Turn main power OFF 2. Fasten motor with screws. . Disconnect power supply. 2. Relieve pressure, page 27. 3. Remove motor shroud. 3. Connect the wires, using wire nuts. Refer to the 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. NOTE: 3-Phase Motors: motor must rotate counterclockwise when viewed from shaft end. If rotation is incorrect, reverse power leads L1 and L2. See Reactor H-VR Operation manual 313539, Connect Electrical Cord. 4. Disconnect motor cables as follows: a. Refer to electrical diagrams in the Reactor Electrical Diagram manual 312064. Motor control board is on right side inside cabinet, 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 junction box cover. The motor must operate counter- 4. Return to service. clockwise when looking at the output shaft. NOTICE Motor is heavy. Two people may be required to lift. 5. Remove screws holding motor to bracket. Lift motor off unit. 313540G 31 Repair Motor Control Board NOTE: Motor control board has one red LED (D11). Power must be on to check. See FIG. 6 for location. Function 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). NOTICE 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. Table 4: DIP Switch (SW2) Settings DIP Switch ON (up) OFF (down) Switch 3 Motor soft start ON (factory default) ON for pressure imbalance alarm (factory default) Standby ON Switch 4 N/A (Not applicable to 3-phase motors) OFF for pressure imbalance warning Standby OFF (factory default) OFF Switch 1 Switch 2 9. Install new board in reverse order. Apply thermal heatsink compound to mating surfaces of board and heatsink. NOTE: Order Part 110009 Thermal Compound. 1. Turn main power OFF . Disconnect power supply. 2. Relieve pressure, page 27. 3. Refer to electrical diagrams. Motor control board is on right side inside cabinet. 4. Put on static conductive wrist strap. 5. Disconnect all cables and connectors from board. 6. Remove nuts (40) and take entire motor control assembly to workbench. Table 5: Motor Control Board Connectors Connector Pin Description J1 J3 J4 J7 J8 J9 J10 J12 J13 J14 J18 n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a 1 2 3 4 5 1 Main power Transducer A Not used Not used Transducer B Motor thermostat (NC) Not used Data reporting To display board Motor power Directional valve, A+ Directional valve, ADirectional valve, B+ Directional valve, BGND Pumpline reversing switch (1150-NC) Pumpline reversing switch (1160-T-COM) Pumpline reversing switch (1170-B-COM) 7. Remove screws and take board off heatsink. 8. Set DIP switch (SW2) on new board. See TABLE 4 for factory settings. See FIG. 6 for location on board. J5 2 3 32 313540G Repair Motor Control J5 D11 ON 1 D19 D20 1 2 3 4 J3 (A) ti3178c-4 J8 (B) J9 ON J12 OFF SW2 J13 1 Apply 110009 thermal heatsink compound to mating surfaces. J18 J1 J14 J7 J4 ti7724a FIG. 6. Motor Control Board 313540G 33 Repair Transducers diagnostic code follows; see E21: No component A transducer, page 12. 1. Turn main power OFF . Disconnect power supply. 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. 7. 7. Install transducer in manifold. Mark end of cable with tape (red=transducer A, blue=transducer B). 2. Relieve pressure, page 27. 8. Route cable into cabinet and thread into bundle as before. 3. Refer to electrical diagrams. Motor control board is on right side inside cabinet. 9. Connect transducer cable at board; see FIG. 6, page 33. 4. Disconnect transducer cables at board; see FIG. 6, page 33. Reverse A and B connections and check if 706 (A Side) 706 (B Side) 701 720 ti9885a FIG. 7. Transducers Electric Fan 5. Remove fan. 6. Install fan in reverse order. 1. Turn main power OFF . Disconnect power supply. F 2. Relieve pressure, page 27. 3. Check fuses (F) at left of breaker module, FIG. 8. Replace if blown. If good, continue with step 4. 4. Refer to electrical diagrams. Disconnect fan wires from fuses (F). 34 ti9884a-1 FIG. 8. Fan Fuses 313540G Repair Temperature Control Module Table 6: Temperature Control Module Connections Connector A H Description DATA (A) Data reporting PIN 12 11 10 HOSE T/C P; FTS (purple) HOSE T/C R; FTS (red) HOSE T/C S; FTS (silver (unshielded bare wire)) 9 HEATER T/C B, Y; Thermocouple (yellow) SENSOR (B) 8 HEATER T/C B, R; Thermocouple (red) 7 Not used 6 HEATER T/C A, Y; Thermocouple (yellow) 5 HEATER T/C A, R; Thermocouple (red) 4, 3 OVERTEMPERATURE B; Overtemperature switch B 2, 1 OVERTEMPERATURE A; Overtemperature switch A DISPLAY (C) Display COMMUNICATION (D) Communication to power boards PROGRAM (E) Software programming BOOT (F) Software bootloader POWER/RELAY (G) Circuit board power input and contactor control output B C ti9875a D E F G ti9843a1 Right Side of Control Heater Module J Table 7: Temperature Power Module Connections Connector COMMUNICATION (H) POWER (J) Description Communication to control board Power to heater ti9843a4 Bottom of Power Modules FIG. 9: Temperature Control Module Connections 313540G 35 Repair Test SCR Circuit Replacing Temperature Control Assembly Modules 1. Test the SCR circuit in the on position: a. Make sure everything is connected, including the hose. b. Turn main power ON c. Adjust the hose heat setpoint above the ambient hose temperature. d. Turn on e. Hold down NOTICE 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. . heat zone by pressing 1. Turn main power OFF . Disconnect power supply. . 2. Relieve pressure, page 27. to view electrical current. Hose current should ramp up to 45A. If there is no hose current, see E03: No zone current, page 10. If hose current exceeds 45A, see E02: High zone current, page 10. If hose current stays several amps below 45A, hose is too long or voltage is too low. 3. Refer to electrical diagrams; see Electrical Diagrams manual 312064. Temperature control assembly 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. 2. Test the SCR circuit in the off position: a. Make sure everything is connected, including the hose. b. Turn main power ON 6. Disconnect all cables and connectors from assembly; see Temperature Control, page 62. 7. Remove nuts and take entire temperature control assembly to workbench. 8. Replace defective module. . 9. Install assembly in reverse order. c. Adjust the hose heat setpoint below the ambient hose temperature. d. Turn on heat zone by pressing . e. Using a voltmeter, carefully measure the voltage at the hose connector. You should not get a voltage reading. If you do, the SCR on the temperature control board is bad. Replace the temperature control assembly. 36 313540G Repair Primary Heaters 6. To remove heater element, first remove thermocouple (410) to avoid damage, see step 7, page 38. Heater Element 7. Remove heater element (407) from housing (401). 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. 1. Turn main power OFF . Disconnect power supply. 9. Install new heater element (407), holding mixer (409) so it does not block thermocouple port (P). 2. Relieve pressure, page 27. 10. Reinstall thermocouple, page 38. 3. Wait for heaters to cool. 11. Reconnect heater element leadwires to heater wire connector. 4. Remove heater shroud. 12. Replace heater shroud. 5. See page 60 for parts. Disconnect heater element wires from heater wire connector. Test with ohmmeter. Total Heater Wattage Element Ohms 7,650 2550 18-21 313540G 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. Replace thermocouple, FIG. 10. Thermocouple a. Remove protective tape from thermocouple tip (T). 1. Turn main power OFF . Disconnect power supply. b. Apply PTFE tape and thread sealant to male threads and tighten thermocouple housing (H) into adapter (405). c. Push in thermocouple (410) so tip (T) contacts heater element (407). 2. Relieve pressure, page 27. d. Holding thermocouple (T) against heater element, tighten ferrule nut (N) 1/4 turn past tight. 3. Wait for heaters to cool. 4. Remove heater shroud. 5. Disconnect thermocouple wires from B on temperature control module. See TABLE 6, page 35 and FIG. 9, page 35. 6. Feed thermocouple wires out of cabinet. Note path as wires must be replaced in the same way. 7. See FIG. 10. Loosen ferrule nut (N). Remove thermocouple (410) from heater housing (401), then remove thermocouple housing (H). Do not remove the thermocouple adapter (405) unless necessary. If adapter must be removed, ensure that mixer (409) is out of the way when replacing the adapter. 9. Route wires (S) into cabinet and thread into bundle as before. Reconnect wires to board. 10. Replace heater shroud. 11. Turn on heaters A and B simultaneously to test. Temperatures should rise at same rate. If one heater is low, loosen ferrule nut (N) and tighten thermocouple housing (H) to ensure thermocouple tip (T) contacts element (407). 1 Apply PTFE tape and thread sealant. 2 Apply 110009 thermal heatsink compound. 410 S N H 1 401 407 2 408 405 T 409 ti7924a FIG. 10. Thermocouple 38 313540G Repair Overtemperature Switch 1. Turn main power OFF 5. If hose fails test, retest at each length of hose, including whip hose, until failure is isolated. . Disconnect power Check FTS Cables supply. 1. Turn main power OFF 2. Relieve pressure, page 27. . Disconnect power supply. 2. Relieve pressure, page 27. 3. Disconnect FTS cable (F) at Reactor, FIG. 11. 3. Wait for heaters to cool. 4. Remove heater shroud. 5. Disconnect one leadwire from overtemperature switch (408), FIG. 10. Test across switch with ohmmeter. Resistance must be approximately 0 ohms. 6. If switch fails test, remove wires and screws. Discard failed switch. Apply thermal compound 110009, install new switch in same location on housing (401), and secure with screws (411). Reconnect wires. NOTE: If wires need replacement, disconnect from temperature control board. See TABLE 6, page 35 and FIG. 9, page 35. Heated Hose NOTE: Refer to the heated hose manual 309572 for hose replacement parts. F D ti9878a FIG. 11. Heated Hose 4. Test with ohmmeter between pins of cable connector. Pins Result 1 to 2 approximately 35 ohms per 50 ft (15.2 m) of hose, plus approximately 10 ohms for FTS 1 to 3 infinity 5. If cable fails test, retest at FTS, page 39. Check Hose Connectors 1. Turn main power OFF . Disconnect power supply. 2. Relieve pressure, page 27. NOTE: Whip hose must be connected. 3. Disconnect hose connector (D) at Reactor, FIG. 11. 4. Using an ohmmeter, check between the two terminals of the connector (D). There should be continuity. 313540G 39 Repair Fluid Temperature Sensor (FTS) 4. If FTS fails any test, replace FTS. Test/Removal 5. Disconnect air hoses (C, L), and electrical connectors (D). 1. Turn main power OFF 6. Disconnect FTS from whip hose (W) and fluid hoses (A, B). . Disconnect power supply. 7. Remove ground wire (K) from ground screw on underside of FTS. 2. Relieve pressure, page 27. 8. Remove FTS probe (H) from component A (ISO) side of hose. 3. Remove tape and protective covering from FTS (21), FIG. 11. Disconnect hose cable (F). Test with ohmmeter between pins of cable connector. Pins Result 1 to 2 approximately 10 ohms 1 to 3 infinity 3 to FTS groundscrew 0 ohms 1 to FTS component A fitting (ISO) infinity Installation The Fluid Temperature Sensor (FTS) is supplied. Install FTS between main hose and whip hose. See Heated Hose manual 309572 for instructions. B D K W A ISO B A L H C ti9581c FIG. 12: Fluid Temperature Sensor and Heated Hoses 40 313540G Repair Transformer Primary Check 1. Turn main power OFF . 2. Locate the two smaller (10 AWG) wires coming out of transformer. Trace these wires back to contactor and circuit breaker (811). Use an ohmmeter to test for continuity between two wires; there should be continuity. 3. To verify transformer voltage, turn on hose zone. Measure voltage from 18CB-2 to POD-HOSE-P15-2; see Reactor Electrical Diagrams manual 312064. Model Secondary Voltage 310 ft. 90 Vac* 410 ft. 120 Vac* * For 230 Vac line voltage. Transformer Secondary Check Replace Transformer 1. Turn main power OFF . 2. Locate the two larger (6 AWG) wires coming out of transformer. Trace these wires back to large green connector under hose control module and circuit breaker (809). Use an ohmmeter to test for continuity between two wires; there should be continuity. 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. NOTE: Use this procedure to replace transformer. 1. Turn main power OFF . Disconnect power supply. 2. Open Reactor cabinet. 3. Remove bolts holding transformer to cabinet floor. Slide transformer forward. 4. Disconnect the transformer wires; see Reactor Electrical Diagrams manual 312064. 5. Remove transformer from cabinet. 6. Install new transformer in reverse order. 809 811 FIG. 13: Circuit Breaker Module 313540G 41 Repair Display Module Red Stop Button Temperature and Pressure Displays NOTICE 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. NOTICE 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 . Disconnect power supply. 1. Turn main power OFF . Disconnect power 2. Relieve pressure, page 27. supply. 3. Refer to electrical diagrams. 4. Put on static conductive wrist strap. 5. Remove screws (509, 510) and cover (504), FIG. 14. 2. Relieve pressure, page 27. 3. Refer to electrical diagrams. 4. Put on static conductive wrist strap. 5. Disconnect main display cable (20) at lower left corner of display module; see FIG. 14. 6. Remove screws (509, 510) and cover (504); see FIG. 14. 6. Disconnect button cable connectors (506) from back of temperature display (501) and pressure display (502). 7. Remove red stop button (506). 8. Reassemble in reverse order. Be sure display cable ground wire (G) is secured between cable bushing and cover (504) with screws (512). If replacing both displays, label temperature display cables TEMP and pressure display cables PUMP before disconnecting. 7. Disconnect cable connectors (506 and 511) from back of temperature display (501) or pressure display (502); see FIG. 14. 8. Disconnect ribbon cable(s) (R) from back of display; see FIG. 14. 9. Remove nuts (508) and plate (505). 10. Disassemble display, see detail in FIG. 14. 11. Replace board (501a or 502a) or membrane switch (501b or 502b) as necessary. 12. Reassemble in reverse order, see FIG. 14. Apply medium strength thread sealant where shown. Be sure display cable ground wire (G) is secured between cable bushing and cover (504) with screws (512). 42 313540G Repair 1 Apply medium strength thread sealant. G 511 511 503 502 504 510 507 1 506 512 20 1 501 508 505 ti2574a 506 Detail of Membrane Switches and Display Boards Temperature Display 1 502c Pressure Display 502a 502b 501c 1 501a R R 501b ti3172a FIG. 14. Display Module 313540G 43 Repair Inlet Fluid Strainer Screen 161c C 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. A* D B 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. FIG. 15. Y Strainer Components NOTE: Clean the A-side screen only during daily startup. This minimizes moisture contamination by immediately flushing out any isocyanate residue at the start of dispensing operations. Part 180199 255082 255083 187758 1. Close the material supply valve at the pump inlet to prevent material from being pumped while the strainer plug (C) is removed. Change Hydraulic Fluid and Filter * Fluid filter screen (within 161c) replacements: Description 20 mesh (standard); 1 pack 80 mesh (optional); 2 pack 80 mesh (optional); 10 pack Replacement gasket 2. Place a container under the strainer base to catch drain off when removing the strainer plug. 3. Remove the screen (A) from the strainer manifold. Thoroughly flush the screen with gun cleaner and shake it dry. Inspect the screen for blockage. No more than 25% of the mesh should be restricted. If more than 25% is blocked, replace the screen. Inspect the strainer gasket (B) and replace as required. 4. Ensure the pipe plug (D) is securely screwed into the strainer plug (C). Install the strainer plug with the screen (A) and gasket (B) in place and tighten. Do not 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. See Table 8 for recommended frequency of oil changes. NOTE: 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 Temperature Recommended Frequency 0 to 90°F (-17 to 32°C) 1000 hours or 12 months, whichever comes first 90°F and above (32°C and above) 500 hours or 6 months, whichever comes first 1. Relieve pressure, page 27. 2. Allow hydraulic fluid to cool. 44 313540G Repair 3. Place a pan under reservoir drain plug (110k) to catch oil. 135 5. Place a rag around base of oil filter (135) to prevent oil from spilling. Unscrew filter 1/4-3/4 turn to break air lock in filter. Wait five minutes to allow oil in filter to drain back into reservoir. Unscrew filter and remove. 6. Reinstall drain plug (110k). 7. Replace filter (135): a. Coat filter seal with fresh oil. b. Screw filter on snug, then an additional 1/4 turn. 8. Refill reservoir with approved hydraulic fluid. See Table 9. ti9888a 110k FIG. 16: Change Hydraulic Fluid and Filter 4. Remove drain plug (110k). 313540G 9. Proceed with normal operation. NOTE: Upon starting motor, hydraulic pump may make a screeching noise until primed. If this noise continues for more than 30 seconds, switch off motor control. See Hydraulic Drive System, page 21. 45 Repair Table 9: Approved Anti-Wear (AW) Hydraulic Oils Supplier Name Citgo A/W ISO Grade 46 Amsoil AWI ISO Grade 46 (synthetic*) BP Oil International Energol® HLP-HM, ISO Grade 46 Carl Bechem GmbH Staroil HVI 46 Castrol Hyspin AWS 46 Chevron Rykon® AW, ISO 46 Exxon Humble Hydraulic H, ISO Grade 46 Mobil Mobil DTE 25, ISO Grade 46 Shell Shell Tellus, ISO Grade 46 Texaco Texaco AW Hydraulic, 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 requirements: Oil Type: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-Wear (AW) Hydraulic ISO Grade:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Viscosity, cSt at 40°C: . . . . . . . . . . . . . . . . . . . . . 43.0-47.0 Viscosity, cSt at 100°C: . . . . . . . . . . . . . . . . . . . . 6.5-9.0 Viscosity Index: . . . . . . . . . . . . . . . . . . . . . . . . . . 95 or higher Pour Point, ASTM D 97:. . . . . . . . . . . . . . . . . . . . -15°F (-26°C) or lower Other essential properties: . . . . . . . . . . . . . . . . . Formulated for anti-wear, anti-foaming, oxidation stability, corrosion protection, and water separation 46 313540G Parts Parts 42▲ 9 76 60 See page 53 84 38 44 60 30 99 4 52 60 67 44 107 20 37 77 See page 52 37 84 See page 52 100 See page 53 60 63 See page 50 60 52 See page 60 ti9831a 313540G 47 Parts 185, 186, 187 181 182 180 169 175 170 174 177 174 146 160 See page 49 169 172 168 171 173 177 161 See page 54 164 104 105 106 165 162 163 166 167 r_256886_313540_2 48 313540G Parts Pump Assembly Overview See page 57 189 188 191 182 See page 57 190 198 199 See page 58 182 192 183, 184 193 194 195, 196, 197 r_256886_313540_4 313540G 49 Parts Detail of Cabinet Area 23 97 102 35 23 36 102 13 85 24 2 51 97 33 85 53 45 32 25, 147 See page 51 54▲ 10 TI9834a 50 313540G Parts Left Side of Cabinet 40 5 55, 56 62 TI9835a 8 (Ref) 39 Right Side of Cabinet 26 31 103 (Ref) 29 68 27 6 40 8 TI9836a 313540G 51 Parts Detail, Fluid Manifold Area 15 78 7, see page 63 78 79 717 (Ref) 17 88 79 111 (Ref) 89 39 39 151 19 TI9838a Detail, Proportioner Area 111 (Ref) 93 94 343 57 See page 59 52 313540G Parts 103 3 Detail, Electric Motor Area 153 82 90 47 57 48 96 111 (Ref) 118 (Ref) ti7709a Detail, Hydraulic Reservoir Area 111 (Ref) 122 119, 120 116 111 (Ref) 132 60 127 113 134 135 115 60 118 133 125 114 139 126 133 93 117 132 137 60 94 60 129 112 142, 143 150 146 See page 54 See page 50 114 111 1 (Ref) 92 60 TI9832b 313540G 53 Parts Ref. 161, Fluid Inlet Kit 161d 161b 161a 161c 161d r_256886_313540_7 Ref. 110, Hydraulic Reservoir 39 110f 110m 110b 110c 110d 110j 110k ti9840a 54 313540G Parts Parts Ref. 2 3 4 5 Part 247813 247785 245974 6 7 8 9 10 11 13 14 15 16 17 18★ 247835 247823 247786 247832 246976 19 15B380 20 21★ 23 24 25 26 27 29 30 31 32 33 34 35 36 37 38 39 40 42 44 15B383 261669 103181 15B360 255047 45▲ 47 48 49★ 50★ 51 52 53 189930 247845 803889 15B593 308212 15B775 247846 54▲ 55 56 57 58★ 15G280 113505 112776 113802 115834 15X243 15R645 15X241 15R644 247787 116149 117666 C19843 247841 247842 117723 C20487 247502 247843 167002 117623 113796 115942 15K817 313540G Description Qty. HEATER 2 MOTOR 1 DISPLAY; see page 61 1 CONTROL, temperature; see page 1 62 BOARD, circuit, motor control 1 MANIFOLD, fluid; see page 63 1 TRANSFORMER 1 COVER, motor 1 COVER, main cabinet 1 PUMP, proportioning; see page 59 1 FAN, cooling 1 TUBE, inlet, component A 1 TUBE, outlet, component A 1 TUBE, inlet, component B 1 TUBE, outlet, component B 1 CABLE, harness, heater overtemp., 1 includes 12-pin connector CABLE, hose, control; see manual 1 312064 CABLE, display 1 KIT, fluid temp sensor, coupler 1 WASHER, lock ext 1 GASKET, fan 1 STRAIN RELIEF, M40 thread 1 MODULE, breaker; see page 64 1 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 2 BRACKET, heater 2 INSULATOR, heat 4 NUT, cap (3/8-16) 4 SCREW, flanged, hex hd 14 NUT, hex, flange head 9 LABEL, fault codes 1 RIVET, pop; 3/16 in. (5 mm) x 0.4 8 in. (10 mm) LABEL, caution 2 PULLEY, drive 1 BELT 1 SHIELD, membrane switch 1 PAD, pamphlet safety 1 COVER, wire access 1 COVER, heater 2 SCREW, machine, pan hd; 3 8-32 x 3/8 LABEL, warning 1 NUT, KEPS, hex hd 4 WASHER, plain 2 SCREW, hex hd, flanged 8 STRAP, tie, wire 20 Ref. 60 62 63 67 68† 74★ 76 77 78 79 Part 111800 247782 247850 117284 117553 206995 115836 186494 205447 054826 82 84▲ 85 88 89 90 15H207 189285 114269 247851 247852 111802 93 94 96 97 99 100 102 103 104 105 106 107 110 15T895 247784 247853 15G816 112125 247780 15H189 247790 100560 100133 100731 119253 247826 110b 110c 110d 110f 110j 110k 110m 111 112 113 114 115 116 117 247778 247771 247777 247770 116919 255032 255021 247822 247819 255019 247821 247820 247829 255020 Description Qty. SCREW, cap, hex hd 35 SPACER 4 COVER, front 1 GRILL, fan guard 1 SWITCH, added pole 1 THROAT SEAL LIQUID; 1 quart 1 GUARD, finger 1 CLIP, spring 5 COUPLING, hose 2 TUBE, PTFE; 1/4 in. (6 mm) ID; 8 ft 8 (2.4 m) BRACKET, tensioner 1 LABEL, caution 2 GROMMET, rubber 2 FITTING, reducer #5 x #8 JIC 1 FITTING, reducer #6 x #10 JIC 1 SCREW, cap, hex hd; 1/2-13 x 3/4 2 in. (19 mm) HOSE, supply 1 TUBE, return 1 ADJUSTER, belt, tensioner 1 COVER, plate, wire way 1 PLUG, tube 2 LABEL 1 BOOT, wire feed through 1 CONDUIT, assembly, motor power 1 SCREW, cap, hex hd; 3/8-16 4 WASHER, lock; 3/8 in. 4 WASHER; 3/8 in. 4 SUPPRESSOR, ferrite; 151 ohm 1 RESERVOIR, hydraulic; includes 1 110b-110m; see page 54 . HOUSING, inlet 1 . GASKET, inlet 1 . TUBE, inlet 1 . TUBE, return 1 . FILTER, inlet 1 . PLUG 1 . FITTING, straight 1 BRACKET, motor mount 1 BRACKET, mounting, pump 1 PUMP, hydraulic 1 BRACKET, reservoir, hydraulic 2 BRACKET, support, pumpmount 1 COOLER, hydraulic 1 ELBOW; 1-1/16 npt(m) x 1/2 in. (13 1 mm) tube 55 Parts Ref. 118 119 120 122 125 126 Part 247856 15H512 15H204 117560 247793 255029 127 129 130★ 131★ 132 133 134 135 137 139 142 143 144 146 147 148★ 150 151 153 160 161 121320 255036 117792 117773 15G782 15G784 116915 247792 116793 107156 112586 110996 C19862 247836 255048 255039 161a 161b 161c 161d 162 163 164 165 166 167 168 169 170 171✿ 172 173✿ 174 261821 104373 255653 257543 100060 101044 100018 100321 15W350 122400 117502 122398 122401 175 176 111856 155677 177 180 181▲ 182▲ 183✖ 184✖ 185 186 15X244 15X710 15W800 15W349 56 15X743 GC2108 Description Qty. PULLEY, fan 1 LABEL, control 1 KNOB, pressure 1 SCREW, set, socket hd 1 HOSE, inlet, coupled 1 GAUGE, pressure, fluid, panel 1 mount ELBOW 1 ELBOW, male 1 GUN, grease 1 GREASE, lubricant 1 HOSE, coupled 1 HOSE, coupled 1 DIPSTICK with breather cap 1 FILTER, oil,18-23 psi bypass 1 FITTING 1 SCREW, cap socket head 3 SCREW, cap, hex hd 2 NUT, hex, flange hd; 5/16-18 2 NUT, lock, hex 1 COVER, access 1 NUT, strain relief, M40 thread 1 CONNECTOR, heater 1 SCREW, set; 1/4 x 1/2 (13 mm) 2 CONNECTOR, wire, 6 AWG (pair) 1 WASHER, thrust 2 PUMP, assy.; see page 57 1 KIT, fluid inlet; each kit includes 2 161a-161d VALVE, ball; 3/4 in. 1 NIPPLE, hex 1 Y-STRAINER 1 FITTING, union, swivel; 3/4 in. 2 KIT, skid 1 KIT, caster; includes 4 casters 1 SCREW, cap, hex hd 4 WASHER, plain 4 WASHER, lock, spring 4 NUT 4 BRACKET 1 ELBOW, bulkhead; #8 JIC 2 REDUCER; #5 x #8 JIC 1 HOSE, moisture lock, assy., A; 3 ft. 1 REDUCER; #6 x #8 JIC 1 HOSE, moisture lock, assy., B; 3 ft. 1 ADAPTER, bulkhead; #8 JIC - #6 2 nptf ELBOW, street; 3/8-18 npt 1 ADAPTER, union,90 deg.; 1 3/8 nptf x 3/8 npsm HOSE, coupled; 5600 psi 2 GUARD 1 LABEL, warning 1 LABEL, caution, pinch point 16 PIN, base, fluid pump 2 PIN, hitch 14 HANDLE, round 2 WASHER, lock, spring, #10 4 Ref. 187 188 189 190 191 192 193 Part GC2188 GC0530 GC0531 GC0541 GC1196 GC1139 GC1126 194 195 196 197 198 199 GC1137 GC2109 100270 GC2042 15W005 Description Qty. SCREW, socket hd 4 LABEL, calibration, right 2 LABEL, calibration, left 2 KNOB, clamping 4 FITTING, lube; 1/8 npt 1 SHAFT, guard 1 EXTENSION, standoff, hex; 1 in. x 4 2 in. SHAFT, cylinder, hydraulic 1 WASHER, lock, spring; 1/4 in. 4 SCREW, cap, hex hd 4 WASHER, flat, fender; 1/4 in. 4 FRAME 1 WIRE, switch, cable 1 ▲ Replacement Danger and Warning labels, tags, and cards are available at no cost. † Model 256887 only. ✿ Available with fluid hose kit 257791. ✖ Available with pin and bearing kit 257794. ★ Not shown. 313540G Parts Sub Assemblies Pump Assembly 229 Pump Detail 225 218 222 (A Side Pump Shown) 223 228 226 227 214 215 222 184 211 279 222 213 184 224 225 225 212 255 184 217 184 5 216 220 273 3 254 see manual 313485 280 238 3 Apply blue Loctite and torque to 250 ft-lbs (337.5 N•m). 274 275 or 276 r_256886_313540_5 5 Apply blue Loctite and torque to 15 ft-lbs (20.3 N•m). 313540G 57 Parts Air Motor Detail 250 253 251 250 265 3 247 249 278 271 205 252 258 204 249 253 208 272 250 246 3 Apply blue Loctite and torque to 250 ft-lbs (337.5 N•m). Ref. 204 205 208 211 212 213✖ 214 215 216 217✖ 218 220 222 223 224 225 226 227 228 Part GC2041 GC2112 159239 GC0518 GC0527 229 238 GC0535 157191 241 246 247 249 GC1147 15X709 GC1132 GC2107 58 GC0419 GC0519 GC0521 GC0420 GC0520 GC1195 GC0524 GC0421 GC0526 GC0532 GC0536 GC0912 Description Qty. WASHER, flat, std; 1/2 in. 8 WASHER, lock, spring;1/2 in, 8 NIPPLE, pipe 2 YOKE, guide rod 1 WASHER, flat 4 PIN, clevis; 1/2 in. 2 WASHER, flat 4 LINK, drive, pump 2 BRACKET, pivot 2 PIN, clevis; 1/2 in. 2 WASHER, flat 4 ADAPTER, pump 2 FITTING, lube; 1/4-28 6 SCREW, adjustment;1/2-20 2 WASHER, flat 4 SHAFT, locking 10 WHEEL, hand, aluminum 2 STUD; 5/8-11 x 3 in. 2 SPACER; 1 5/16 in. diameter, 2 9/16 in. HANDLE 2 FITTING, adapter (1/2 npt x 3/4 2 npt) PUMP, assy., fluid 2 PLATE, change over, bottom 1 EXTENSION, stndoff, change over 4 WASHER, lock, spring; #8 10 r_256886_313540_8 Ref. 250 Part Description GC2194 SCREW, shdc; SST, 0.164-32 x 0.0750 SST 251 GC2118 SCREW, rdhd; CS,0.164-32 x 0.750 zp 252 15X708 GUARD, change over box 253 GC2052 WASHER, flat, std; #8 254 15W983 DISK, switch 255✖ PIN, 2.75 in. base, fluid pump 256 GC1137 SHAFT, cylinder, hydraulic 258 15W340 BRACKET, limit switch 265 15X711 PLATE, change over, top 271 111856 ELBOW, street 272 155677 ADAPTER, union, 90 deg 273 108126 FITTING, tee, street 274 248187 HOUSING, rupture, disc 275 117832 ADAPTER; 9/16-18 JIC x 3/8 npt 276 122406 ADAPTER; 1/2-20 JIC x 3/8 npt 278 192348 NUT, head 279✖ PIN, clevis; 1/2 in. 280 100081 BUSHING, pipe Qty. 10 6 2 8 1 2 1 1 1 1 1 2 2 1 1 4 2 2 ✖ Available with pin and bearing kit 257794. 313540G Parts Hydraulic Directional Valve Assembly 308 342 343 307 306 313 322 314 321 327 341 340 326 345 305 304 309 344 347 346 r_256886_313540_6 Proportioner Assembly Ref. 304 305 306 307 308 309 313 314 321 322 326 327 Part 106258 298040 113467 120299 C19986 247817 100214 108751 158683 100206 121312 295225 313540G Description O-RING MANIFOLD, hydraulic SCREW, socket head VALVE, directional, hydraulic SCREW, socket head BRACKET, mounting WASHER, lock SCREW, socket head ELBOW, 90 deg. BUSHING, pipe ELBOW; 3/4 SAE x 1/2 JIC PLUG, pipe, flush Qty. 2 1 4 1 4 1 4 4 1 1 1 2 Ref. 340 341 342 343 344 345 346 347 Part 255037 255038 15H184 15H253 121309 15W003 15X237 111800 Description Qty. ELBOW; 3/4 nptf 1 CONNECTOR 1 WIRE, bi-directional cable, assy. 1 HOSE, gauge, hydraulic, 3000 psi 1 CONNETOR; 3/4 SAE x 1/2 JIC 2 BLOCK, port 2 BRACKET, shroud 1 SCREW, cap, hex hd 2 59 Parts 7.65 kW Single Zone Heater (Two Per Machine) Part 247813 401 413 410 411 408 405 403 406 404 1 414 404 409 413 407 r_247813_312063 415 1 Ref. 401 403 Part 404 405 406 407 408 409 15H304 15H306 120336 15B138 15B137 15B135 60 121309 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 Qty 1 2 3 1 1 3 1 3 Apply 110009 thermal heatsink compound. Ref. 410 411 413 414 415 Part 117484 100518 15H305 295607 124132 Description SENSOR SCREW, machine, pan hd PLUG, hollow PLUG, not shown O-RING Qty 1 2 5 1 3 313540G Parts Display 511 502 511 503 504 507 510 506 512 20 (Ref) 508 501 ti2574a 505 506 502a 502c 502b 501c 501a 501b Ref. 501 501a 501b 501c 502 502a 502b 502c 503 504 Part Description 245978 DISPLAY, pressure; includes 501a-501c 246130 .BOARD, circuit 246478 .SWITCH, membrane 112324 .SCREW 245977 DISPLAY, temperature; includes 502a-502c 246130 .BOARD, circuit 246479 .SWITCH, membrane 112324 .SCREW 15B293 GASKET 15B292 COVER 313540G Qty. 1 1 1 4 1 1 1 4 1 1 Ref. 505 506 507 508 510 511 512 Part 15B291 246287 117499 117523 ti3172a Description PLATE HARNESS, wire, red stop button HANDLE NUT, cap; 10-24 SCREW, machine, pan-hd; M5 x 0.8; 16 mm 15B386 CABLE, display 195853 SCREW, machine; M2.5 x 6 Qty. 1 1 2 8 4 1 2 61 Parts Temperature Control 602 605 To B Heater Module 604 606 To A Heater Module 601 To Hose Heater Module 604 604 604 603 603 TI9843a 603 Ref. 601 602 603 604 605 606 62 Part 247772 247827 247828 115942 247801 247825 Description PANEL, module mounting HOUSING, control module HOUSING, heater module NUT, hex CABLE, communication KIT, cover, connector with screws Qty. 1 1 3 4 1 1 313540G Parts Fluid Manifold 1 Torque to 355-395 in-lb (40.1-44.6 N•m). 2 Apply sealant (113500) to threads. 3 Valve must be closed with handle position as shown on drawing. ** Apply PTFE tape or thread sealant to tapered threads. 2 708 706 3 705 1 718 702 3 703 2 714 702a 702b 715 716 704 707 701 712 714 713 Ref. Part 701 247837 702† 247824 702a† 158674 702b† 247779 703 102814 704 162453 705 24K999 706 247788 707 247789 708† 112309 712 117556 713 117557 313540G 3 Description Qty. 1 MANIFOLD, fluid 2 VALVE, drain cartridge 1 . O-RING 1 . SEAL, seat, valve 2 GAUGE, pressure, fluid 2 FITTING, 1/4 npsm x 1/4 npt 2 TRANSDUCER, pressure, control 1 HANDLE, red 1 HANDLE, blue 2 NUT, hex, jam 1 NIPPLE, #8 JIC x 1/2 npt 1 NIPPLE, #10 JIC x 1/2 npt 717 Ref. 714 715 716 717▲ 718† TI9839b Part 121312 100840 111457 189285 150829 Description Qty. 2 ELBOW, 90 degrees 2 ELBOW, street; 1/4 npsm x 1/4 npt 2 O-RING, PTFE 1 LABEL, caution 2 SPRING, compression ▲ Replacement Warning labels, signs, tags, and cards are available at no cost. † 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. * Complete valve kits also include thread sealant. (Purchase kits separately). 63 Parts Circuit Breaker Modules A - 230V, 3 Phase Circuit Breaker Modules For wiring and cable connections, refer to electrical diagrams manual 312064, supplied. See page 65 for parts. 810 820 814 805 806 817 811 821 815 810 803, 804 802 808 816 187CB 178CB 172CB 197CB 801 170CR 238CR 168BR 813 818 812 809 807 819 822 B - 400V, 3 Phase Circuit Breaker Modules For wiring and cable connections, refer to electrical diagrams manual 312064, supplied. See page 65 for parts. 820 817 810 805 806 821 811 803, 804 808 178CB 187CB 197CB 172CB 801 813 818 809 807 64 810 170CR 816 238CR 802 812 819 822 313540G Parts Circuit Breaker Modules Parts List Breaker Modules A 230V, 3 phase B 400V, 3 phase RAIL, mounting 255028 255028 1 802 CLAMP, block, end 255045 255045 1 803 HOLDER, fuse terminal, block 255043 255043 2 804 FUSE 255023 255023 2 805 TERMINAL, block 255042 255042 4 807 BRIDGE, plug in, jumper 255044 255044 2 808 BLOCK, terminal ground 255046 255046 1 809 BREAKER, 1 pole, 50A 255026 255026 1 810 CONTACTOR, relay, 65A 255022 255022 2 811 BREAKER, 2 phase, 40A 247768 247768 1 812 BREAKER, 2 phase, 50A 120579 120579 2 813 BREAKER, 3 pole, 20A 255025 255025 1 814 CONNECTOR, power lug 117679 3 815 BAR, power buss, 3 phase, 3x3 255024 1 816 CABLE, harness lower 247803 247803 1 817 CABLE, harness upper 247808 247807 1 818 CONNECTOR, 2 pin large 255027 255027 3 819 CONNECTOR, 3 pin 120895 120895 1 820 CONNECTOR, 4 pin 255031 255031 1 821 CONNECTOR, 2 pin small 255030 255030 1 822 CABLE, harness, hose wire 247791 247791 1 Ref. Description 801 313540G Qty 65 Dimensions Dimensions Dimension A (height) B (width) C (depth) Dimension D (front and rear mounting holes) F (side mounting holes) G (mounting post inner diameter) in. (mm) 57.3 (1455.4) 37.9 (961.6) 33.0 (838.2) in. (mm) 32.5 (825.5) 30.4 (771.6) 0.44 (11.2) A Top View r_256886_313539_1 Front of Machine G D C F D B r_256886_313539_4 Rear of Machine 66 313540G Technical Data Technical Data Category Maximum Fluid Working Pressure Fluid Inlets Fluid Outlets Data 3500 psi (24.1 MPa, 241 bar) 3/4 npsm union in 1 in. npt(f) ball valve 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 3.0 gpm (11.4 liter/min) (60 Hz) ambient temperature) Line Voltage Requirement 230V 3 phase units: 195-264 Vac, 50/60 Hz 400V 3 phase units: 338-457 Vac, 50/60 Hz Amperage Requirement See Models, page 3. Heater Power See Models, page 3. (A and B heaters total, no hose) Hydraulic reservoir capacity 3.5 gal. (13.6 liters) Recommended hydraulic fluid Citgo A/W Hydraulic Oil, ISO Grade 46 Sound power, per ISO 9614-2 90.9 dB(A) Sound pressure, 84.0 dB(A) 1 m from equipment Weight 955 lb (433 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. 313540G 67 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations. This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco. This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation. THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale. GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties. In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise. FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées. Graco Information For the latest information about Graco products, visit www.graco.com. TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505 All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice. Original instructions. This manual contains English. MM 313540 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA Copyright 2009, Graco Inc. All Graco manufacturing locations are registered to ISO 9001. www.graco.com Revised 01/2012
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