Contents

Proportioner Models . . . . . . . . . . . . . . . . . . . . . . . . 3

Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Important Two-Component Material Information . 7

Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 7 Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 7 Keep Components A and B Separate . . . . . . . . . 7 Moisture Sensitivity of Isocyanates . . . . . . . . . . . 7 Foam Resins with 245 fa Blowing Agents . . . . . . 7 Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 8 DataTrak Diagnostic Codes . . . . . . . . . . . . . . . . . 9 Temperature Control Diagnostic Codes . . . . . . . 9 E01: High fluid temperature . . . . . . . . . . . . . . . 10 E02: High zone current . . . . . . . . . . . . . . . . . . . 11 E03: No zone current . . . . . . . . . . . . . . . . . . . . 11 E04: Fluid Temperature Sensor (FTS) or

thermocouple disconnected . . . . . . . . . . . . 11 E05: Control board over temperature . . . . . . . . 12 E06: Communication cable unplugged . . . . . . . 12 Communication Diagnostic Codes . . . . . . . . . . 12 E30: Momentary loss of communication . . . . . . 12 E99: Loss of communication . . . . . . . . . . . . . . . 12

Before Beginning Repair . . . . . . . . . . . . . . . . . . . 13

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 13

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Park . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Pumps and Pressures . . . . . . . . . . . . . . . . . . . . 15

Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Hose Heat System . . . . . . . . . . . . . . . . . . . . . . 20

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Disconnect Pump . . . . . . . . . . . . . . . . . . . . . . . 22 Connect Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Remove Air Motor . . . . . . . . . . . . . . . . . . . . . . . 24 Install Air Motor . . . . . . . . . . . . . . . . . . . . . . . . . 24 Recirculation / Over Pressure Relief Block . . . . 25 Air Inlet Filter / Water Separator (Auto Drain) . . 25 Temperature Control Module . . . . . . . . . . . . . . . 26 Primary Heater . . . . . . . . . . . . . . . . . . . . . . . . . 28 Heated Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Fluid Temperature Sensor (FTS) . . . . . . . . . . . . 32 Pump Lubrication System . . . . . . . . . . . . . . . . . 35 Fluid Inlet Strainer Screen . . . . . . . . . . . . . . . . . 36 Temperature Display . . . . . . . . . . . . . . . . . . . . . 36 Replace DataTrak Battery or Fuse . . . . . . . . . . 38

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Recommended Spare Parts . . . . . . . . . . . . . . . . . 39

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Control Panel, 262575 . . . . . . . . . . . . . . . . . . . . 44 Temperature Control . . . . . . . . . . . . . . . . . . . . . 45 Wheel Kit, 262695 . . . . . . . . . . . . . . . . . . . . . . . 45 Fluid Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Fluid Inlet Kit, 262695 . . . . . . . . . . . . . . . . . . . . 46 6 kw Dual Zone Heater, 24J788 . . . . . . . . . . . . 47 A-25 Air Motor Pump Assembly, 262573 . . . . . . 48 Air Tubing Connections . . . . . . . . . . . . . . . . . . . 49 Breaker Module, 262576 . . . . . . . . . . . . . . . . . . 50

Reactor A-25 Wiring Schematic . . . . . . . . . . . . . . 51

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 56

Related Manuals

Manuals are available at www.graco.com.

Component manuals in English:

Isocyanate Conditions

Spraying or dispensing 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.

Material Self-ignition

Some materials may become self-igniting if applied too thickly. Read material manufacturer???s warnings and material MSDS.

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 crystal- lization varies depending on the blend of ISO, the humidity, and the temperature.

To prevent exposing ISO to moisture:

???Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container.

???Keep the ISO lube pump reservoir (if installed) filled with Graco Throat Seal Liquid (TSL), Part 206995. The lubricant creates a barrier between the ISO and the atmosphere.

???Use moisture-proof hoses specifically designed for ISO, such as those supplied with your system.

???Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.

???Always lubricate threaded parts with ISO pump oil or grease when reassembling.

Keep Components A and B

Separate

Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination of the equipment???s wetted parts, never interchange component A (isocyanate) and component B (resin) parts.

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.

DataTrak Diagnostic Codes

DataTrak can diagnose several problems with the pump. When the monitor detects a problem, the LED will flash and a diagnostic code will appear on the display.

To acknowledge the diagnosis and return to the normal operating screen, press once to wake up the display, and once more to clear the diagnostic code screen.

Temperature control diagnostic codes appear on tem- perature display.

These alarms turn off heat. E99 clears automatically when communication is regained. Codes E03 through

E06 can be cleared by pressing . For other codes,

E01: High fluid temperature

Causes of E01 Errors

???Thermocouple A or B (361) senses a fluid tempera- ture above 230??F (110??C).

???Fluid temperature sensor (FTS) senses a fluid tem- perature above 230??F (110??C).

???Overtemperature switch (359) senses a fluid tem- perature above 230??F (110??C) and opens. At 190??F (87??C) the switch closes again.

???Thermocouple A or B (361) fails, is damaged, is not touching the heater element (358), or has a poor connection to the temperature control module.

???Overtemperature switch (359) fails in the open posi- tion.

???The temperature control module fails to turn off any heat zone.

???Zone power wires or thermocouples are switched from one zone to another.

???Failed heater element where thermocouple is installed.

???Loose wire

???Jumper wire covered in heat shrink in the wiring har- ness near the single over temperature switch con- nectors on the heater, is loose or incorrectly wired

Checks

Troubleshooting this equipment requires access to parts that may cause electric shock or other serious injury if work is not performed properly. Have a qualified electrician perform all electrical troubleshooting. Be sure to shut off all power to the equipment before repairing.

Check which zone is displaying the E01 error.

1.Check that connector B is firmly plugged into tem- perature control module (see FIG. 6, page 26).

2.Clean and re-plug connections.

3.Check connections between the temperature control module and overtemperature switch (359), and

between temperature control module and thermo- couples A and B (361) or FTS (21) [depending on which zone is displaying E01]. See Table 2, page 26. Ensure that all wires are securely connected to connector B.

4.Remove connector B from temperature control mod- ule, and check continuity of overtemperature switch, thermocouples A and B, or FTS by measuring resis- tance across the pins on the plug end; see Table 1.

Table 1: Sensor Connector Continuity Checks

NOTE: Before doing the following checks, note which zone (A, B, FTS, or all) has high fluid temperature.

5.Verify fluid temperature, using an external tempera- ture sensing device.

???If temperature is too high (sensor reading is 229??F [109??C] or above):

6.Check if thermocouples A and B are damaged, or not contacting the heater element, page 30.

7.To test that temperature control module turns off when equipment reaches temperature setpoint:

a.Set temperature setpoints far below displayed temperature.

b.Turn zone on. If temperature rises steadily, power module is failing.

c.Verify by swapping with another power module. See Replacing Temperature Control Assem- bly Modules, page 27.

d.If the swapped module does not fix the problem, the power module is not the cause.

8.Verify continuity of heater elements with an ohmme- ter, see page 28.

E02: High zone current

2. Relieve pressure, page 13.

NOTE: Disconnect whip hose.

3.Disconnect hose connector (D) at Reactor.

4.Using an ohmmeter, check between the two termi- nals of the connector (D). There should be no conti- nuity.

5.Exchange zone module with another one. Turn zone on and check for error (see page 27). If error disap- pears, replace faulty module.

For hose zone: If error still occurs, perform Transformer Primary Check and Transformer Secondary Check, starting on page 33.

NOTE: When there is a high current error, the LED on that zone???s module will turn red while the error is dis- played.

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 27). If error disap- pears, replace faulty module.

4.If E03 occurs for all zones, the 238CR contactor may not be closing. Verify wiring from heater control to contactor coil.

a. Hose zone: test hose continuity, page 31.

Important Two-Component Material Information

b.Perform Transformer Primary Check and Transformer Secondary Check, starting on page 33.

NOTE: When a no current error occurs, the LED on this specific zone???s module turns red when the error is dis- played.

E04: Fluid Temperature Sensor (FTS) or thermocouple disconnected

1.Check temperature sensor connections to long green connector (B) on temperature control module, page 26. Unplug and re-plug sensor wires.

2.Test fluid temperature sensor continuity with ohm- meter, page 10.

3.If an error occurred for the hose zone, check FTS connections at each section of hose.

4.If an error occurred for the hose zone, test FTS by plugging directly into machine.

F

D

ti17788a

5.To verify heater control module is not causing the problem, use a wire to short-circuit the two pins cor- responding to the FTS (red and yellow for A or B zone, red and purple for hose). The display will show the control heater module temperature.

6.If an error occurred for the hose zone, temporarily use the current control mode. Refer to Reactor Operation manual.

E05: Control board over temperature

NOTE: Each module has an on-board temperature sen- sor. Heat is turned off if module temperature exceeds 185??F (85??C) within the heater module.

1.Check that fan above electrical cabinet is operating.

2.Check that electrical cabinet door is properly installed.

3.Check for obstructions blocking cooling holes in bot- tom of electrical cabinet.

4.Clean heatsink fins behind heater control modules.

5.Ambient temperature may be too high. Allow Reac- tor to cool by moving to a cooler location.

E06: Communication cable unplugged

1.Unplug and re-plug cable that connects heater con- trol module to heater module.

2.Replace communication cable if problem persists.

Communication Diagnostic

Codes

E30: Momentary loss of communication

Communications between the display and the motor control board or the temperature control module have been momentarily lost. Normally, when communication is lost, the corresponding display will show E99. The corresponding control board will register E30 (The red LED will flash 30 times). If communications are recon- nected, the display can show the E30 for a small time (no more than about two seconds). It should not be pos- sible for E30 to be shown continuously, unless there is a loose connection causing the display and the board to continuously loose and regain communication.

Check all wiring between the display and the control board.

E99: Loss of communication

Communications between the display and the tempera- ture control module has been lost. When communication is lost, the display will show E99.

1.Check all wiring between the display and the tem- perature control module. Pay close attention to the wire crimping on plug J13 for temperature display and connector for control module.

Step 2 measures line voltage and should be done by a qualified electrician. If work is not performed properly it may cause electric shock or other serious injury.

2.Measure the incoming voltage to the module (it should be ~ 230Vac).

3.If it was only receiving 1 leg of the 230Vac the board may light up, and still not function properly. Correct the incoming voltage problem.

Before Beginning Repair

Repairing this equipment requires access to parts that may cause electric shock or other serious injury if work is not performed properly. Electrical troubleshooting must be done by a qualified electrician. Be sure to shut off all power to equipment and lock out power at the source before repairing.

1. Flush if necessary. See Flushing, page 14.

5. Close gun fluid inlet valves A and B.

ti2421a

6. Close pump inlet supply valves.

The Fusion AP gun is shown.

1.Turn off feed pumps and agitator if used.

2.Park component A pump. Follow Park; see page 14.

3.Close the air inlet valve.

4.Engage gun piston safety lock.

ti2409a

2.Follow Park.

3.Check and fill wet-cups (AK, Z).

AK

Park the pumps at the end of the day to cycle compo- nent A pump to home position, submerging displace- ment rod.

1. Open the park valve.

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, such as toluene, naptha, or mineral spirits before introducing new fluid.

???Use lowest possible pressure when flushing.

???To flush feed hoses, pumps, and the heater sepa- rately from the heated hoses, set PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION. Flush through bleed lines

(N).

2.Trigger the gun until pumps stops at the bottom and relieves pressure.

3.Close the air motor shutoff valve.

4.Close the park valve.

N

SA

SB

N

Troubleshooting

Before performing any troubleshooting procedures: 1. Relieve pressure, page 13.

Troubleshooting

Problems

Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Also, determine that all circuit breakers, switches, and con- trols are properly set and wiring is correct before assum- ing there is a problem.

Repair

Repair

Unless otherwise noted, all repair procedures must be completed with incoming power switched OFF and locked out at the source. Any electrical repair or troubleshooting required beyond the scope of this manual must be performed by a qualified electrician. Shut off air inlet ball valve and shut off all air supply pressure.

Disconnect Pump

Air motor shaft, yoke, pump rod and connecting rod move during operation. Moving parts can cause serious injury such as pinching or amputation. Keep hands and fingers away from connecting rod during operation.

NOTE: See manual 309577 for pump repair instructions.

2.Follow Flushing, page 14.

3.Follow Pressure Relief Procedure, page 13.

4.Follow Park instructions, page 14.

5.Shut off both feed pumps and close both inlet supply valves (F).

6.Shut off inlet air ball valve (G)

7.Remove screws (13, 15) and pump covers (63).

13

63

13

ti17989a

15

8.Disconnect A side (21) and B side (23) steel outlet tubes from adapters (312).

318

324

9.Remove adapter (312) from fluid outlet (M).

10.For A Side pump, disconnect barb fitting (318), elbow fitting (317), and two pipe plugs (324).

NOTE: It is not necessary to cut tubes connected to barb fittings.

11.Push retaining wire clip (307) up. Push retaining pin (306) out.

307

306

301

302

304

12.Loosen lock nut (302) by hitting firmly with a non-sparking hammer.

13.Unscrew pump out of pump mounting plate (301).

14.See pump manual for repair procedures and replacement parts.

Connect Pump

1.Ensure locknut (302) is screwed on pump with flat side up. Grease pump mounting threads in plate and pump cylinders (303, 304) with lithium grease. Screw pump into pump mounting plate (301) until top of pump thread is above mounting plate 1/2 to 1 1/2 threads above flush.

NOTE: Pump rod connecting links (302) should be posi- tioned so that pins (306) are in line with each other.

2.Align pump rod hole with link hole. Push retaining pin (306) in. Pull retaining wire clip (307) down to cover pin ends.

3.Tighten locknut (302) by hitting firmly with a non-sparking hammer.

4.Install adapter (312) in fluid outlet. Connect A side (21) and B side (23) steel outlet tubes.

5.For Iso A pump only:

a.Install two pipe plugs (324).

b.Reconnect two tubing lines (N) from ISO Pump Lube reservoir. Flush and refill reservoir with TSL 206995.

6.Refill Resin B pump wet cup with TSL 206995.

Repair

Remove Air Motor

1.Press in tube fitting ferrules and pull out tubing (65) to disconnect air line.

2.Disconnect DataTrak communication cable, if installed.

3.Place wrench on adapter (315) and a another wrench on lock nut (313). Remove lock nut (313).

315 313

ti17992a

FIG. 1

4. Remove four nuts (310) from tie rods (309).

5.Loosen two screws (314) behind air motor bracket. Carefully lift air motor and tie rods away from the proportioner frame and plate (301).

6.Lay air motor on a clean flat work space. Place a wrench on the tie rod flats (309) and hold one of other tie rods with your hand to keep the air motor (308) in place. Remove the tie rods from the air

motor.

309

308

ti17994a

FIG. 3

7.Use a wrench to hold the piston rod in place and remove the adapter (315) with another wrench. See FIG. 1.

8.See air motor manual for repair instructions.

Install Air Motor

1.Apply medium blue thread lock on adapter (315). Use a wrench to hold the piston rod in place and install the adapter (315) with another wrench.

Torque to 32-38 ft-lbs (43-51 N???m). See FIG. 1.

2.Install tie rods (309) in the bottom of the air motor

(308). See FIG. 3.

3.Install tie rods through plate (301). Ensure screws

(314)fit in the bracket slots (311). Install screws

(314). See FIG. 2.

4.Tighten nut (313) to 32-38 ft-lbs (43-51 N???m).

5.Evenly torque four tie rod nuts (310) in small incre- ments to 27-32 ft-lbs (37-43N???m). See FIG. 2.

Recirculation / Over Pressure

Relief Block

Valves can be serviced with the block on the machine (see page 46 for parts view). For thorough cleaning, remove the block assembly as follows.

1.Disconnect two fluid tubes connected to back of recirculation block (3).

2.Loosen and remove two screws (10) in back of recir- culation block.

10

3

ti17995a

FIG. 4

3.See Fluid Manifold, page 46. Clean and inspect all parts for damage. Ensure that the seat (8a) and gasket (8b) are positioned inside each valve car- tridge (8).

4.Apply PTFE pipe sealant to all tapered pipe threads before reassembling.

5.Reassemble in reverse order, following all notes on page 46.

Repair

Air Inlet Filter / Water Separator

(Auto Drain)

Air Filter Element Removal

1.Close air inlet valve (302) on filter (301).

2.Hold in metal spring clip and twist black cover coun- terclockwise to remove.

302 301

ti17996a

FIG. 5

3.Unscrew clear drain cover by hand.

4.Unscrew black filter element retainer to remove ele- ment.

5.Inspect filter element. Clean or replace.

Air Filter Element Installation

1.Insert cleaned or replacement filter (114228).

2.Hand-screw filter retainer into place.

3.Hand-screw clear drain cover until tight.

4.Reposition black cover and turn. Make sure it ???snaps??? back into place.

Repair

Temperature Control Module

Table 2: Temperature Control Module Connections

A

B

C

H

ti17997a

D

E

F

G

ti9843a1

Right Side of

Control Heater Module

J

ti9843a4

Bottom of Power Modules

FIG. 6: Temperature Control Module Connections

Test SCR Circuit

1.Test the SCR circuit in the on position:

a.Make sure everything is connected, including the hose.

c.Adjust the hose heat setpoint above the ambi- ent hose temperature.

d.Turn on heat zone by pressing .

e.Hold down to view electrical current. Hose current should ramp up to 45A. If there is no hose current, see E03: No zone current, page 11. If hose current exceeds 45A, see E02: High zone current, page 11. If hose current stays several amps below 45A, hose is too long or voltage is too low.

2.Test the SCR circuit in the off position:

a.Make sure everything is connected, including the hose.

c.Adjust the hose heat setpoint below the ambi- ent hose temperature.

d.Turn on heat zone by pressing .

Using a voltmeter, carefully measure the voltage at the hose connector. You should not get a voltage reading. If you do, the SCR on the temperature control module is bad. Replace the temperature control assembly.

Repair

Replacing Temperature Control Assembly

Modules

NOTICE

Before handling assembly, put on static conductive wrist strap to protect against static discharge which can damage assembly. Follow instructions provided with wrist strap.

supply.

2.Relieve pressure, page 13.

3.Refer to electrical diagrams. See Reactor A-25 Wir- ing Schematic, page 51. Temperature control assembly is on left side inside cabinet.

4.Remove bolts that secure transformer assembly and slide assembly to side in cabinet.

5.Put on static conductive wrist strap.

6.Disconnect all cables and connectors from assem- bly. See Temperature Control Module, page 26.

7.Remove nuts and take entire temperature control assembly to workbench.

8.Replace defective module.

9.Install assembly in reverse order.

Repair

Primary Heater

Read Warnings on page 4. Wait for heater to cool before repairing.

Heater Element

supply.

2.Relieve pressure, page 13.

3.Wait for heaters to cool.

4.Remove heater shroud.

5.See FIG. 7. Disconnect heater element wires from heater wire connector. Test with ohmmeter.

Heater Rod

Element

Wattage Ohms

6.To remove heater element, first remove thermocou- ple (361) to avoid damage, see step 7, page 30.

7.Remove heater element (358) from housing (351). Be careful not to spill any fluid left in housing.

8.Inspect element. It should be relatively smooth and shiny. If there is a crusted, burnt, ash-like material adhered to element or sheath shows pitting marks, replace element.

9.Install new heater element (358), holding mixer (360) so it does not block thermocouple port (P).

10.Reinstall thermocouple, page 30.

11.Reconnect heater element leadwires to heater wire connector.

12.Replace heater shroud.

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.

353 1 6

5 361

2 5 355

351

1Torque to 120 ft-lbs (163 N???m).

2Torque to 23 ft-lbs (31 N???m).

3Torque to 40 ft-lbs (54 N???m).

4Apply 110009 thermal heatsink compound.

5Apply sealant and PTFE tape to all non swiveling and threads without o-rings.

356

357 6

362

359

354 3 6 7

352

6 360

Repair

Thermocouple

Read Warnings on page 4. Wait for heater to cool before repairing.

supply.

2.Relieve pressure, page 13.

3.Wait for heaters to cool.

4.Remove heater shroud.

5.Disconnect thermocouple wires from B on tempera- ture control module. See Table 2, page 26 and FIG. 6, page 26.

6.Feed thermocouple wires out of cabinet. Note path as wires must be replaced in the same way.

7.See FIG. 8. Loosen ferrule nut (N). Remove thermo- couple (361) from heater housing (351), then remove thermocouple housing (H). Do not remove the thermocouple adapter (356) unless necessary. If adapter must be removed, ensure that mixer (360) is out of the way when replacing the adapter.

T

360

FIG. 8. Thermocouple

8.Replace thermocouple, FIG. 8.

a.Remove protective tape from thermocouple tip

(T).

b.Apply PTFE tape and thread sealant to male threads and tighten thermocouple housing (H) into adapter (356).

c.Push in thermocouple (361) so tip (T) contacts heater element (358).

d.Holding thermocouple (T) against heater ele- ment, tighten ferrule nut (N) 1/4 turn past tight.

9.Route wires (S) into cabinet and thread into bundle as before. Reconnect wires to board.

10.Replace heater shroud.

11.Turn on heaters A and B simultaneously to test. Temperatures should rise at same rate. If one heater is low, loosen ferrule nut (N) and tighten ther- mocouple housing (H) to ensure thermocouple tip

(T) contacts element (358).

1Apply PTFE tape and thread sealant.

2Apply 110009 thermal heatsink compound.

ti7924a

Overtemperature Switch

Read Warnings on page 4. Wait for heater to cool before repairing.

supply.

2.Relieve pressure, page 13.

3.Wait for heaters to cool.

4.Remove heater shroud.

5.Disconnect one leadwire from overtemperature switch (359), FIG. 8. Test across switch with ohmme- ter. Resistance must be approximately 0 ohms.

6.If switch fails test, remove wires and screws. Dis- card failed switch. Apply thermal compound 110009, install new switch in same location on housing (351), and secure with screws (311). Reconnect wires.

NOTE: If wires need replacement, disconnect tempera- ture control module. See Table 2, page 26 and FIG. 6, page 26

Heated Hose

Refer to the heated hose manual for hose replacement parts.

Check Hose Connectors

supply.

2. Relieve pressure, page 13.

NOTE: Whip hose must be connected.

3.Disconnect hose connector (D) at Reactor, FIG. 9.

4.Using an ohmmeter, check between the two termi- nals of the connector (D). There should be continu- ity.

5.If hose fails test, retest at each length of hose, including whip hose, until failure is isolated.

Check FTS Cables

supply.

2.Relieve pressure, page 13.

3.Disconnect FTS cable (F) at Reactor, FIG. 9.

F

D

ti17788a

FIG. 9. Heated Hose

4.Test with ohmmeter between pins of cable connec- tor.

1 to 2 approximately 35 ohms per 50 ft (15.2 m) of hose, plus approximately 10 ohms for FTS

5. If cable fails test, retest at FTS, page 32.

Fluid Temperature Sensor (FTS)

Test/Removal

supply.

2.Relieve pressure, page 13.

3.Remove tape and protective covering from FTS. Disconnect hose cable (F). Test with ohmmeter between pins of cable connector.

F

B

A

4.If FTS fails any test, replace FTS.

5.Disconnect air hoses (C, L), and electrical connec- tors (D).

6.Disconnect FTS from whip hose (W) and fluid hoses (A, B).

7.Remove ground wire (K) from ground screw on underside of FTS.

8.Remove FTS probe (H) from component A (ISO) side of hose.

Installation

The Fluid Temperature Sensor (FTS) is supplied. Install FTS between main hose and whip hose. See Heated Hose manual 309572 for instructions.

D B

K

W

A

ISO

L

H

C

Transformer Primary Check

2.Locate the two smaller (10 AWG) wires coming out of transformer. Trace these wires back to contactor and circuit breaker (911). Use an ohmmeter to test for continuity between two wires; there should be continuity.

Repair

3.To verify transformer voltage, turn on hose zone. Measure voltage from 178CB-2 to HPOD-1; see

Reactor A-25 Wiring Schematic, page 51.

* For 230 Vac line voltage.

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 (909). Use an ohmmeter to test for continu- ity 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 (909) and the other wire should not.

909

911

ti17999a

FIG. 11: Circuit Breaker Module

supply.

2.Open Reactor cabinet.

3.Remove bolts holding transformer to cabinet floor. Slide transformer forward.

4.Disconnect the transformer wires; see Reactor A-25 Wiring Schematic, page 51.

5.Remove transformer from cabinet.

6.Install new transformer in reverse order.

Pump Lubrication System

Check the condition of the ISO pump lubricant daily. Change the lubricant if it becomes a gel, its color dark- ens, or it becomes diluted with isocyanate.

Gel formation is due to moisture absorption by the pump lubricant. The interval between changes depends on the environment in which the equipment is operating. The pump lubrication system minimizes exposure to mois- ture, but some contamination is still possible.

Lubricant discoloration is due to continual seepage of small amounts of isocyanate past the pump packings during operation. If the packings are operating properly, lubricant replacement due to discoloration should not be necessary more often than every 3 or 4 weeks.

To change pump lubricant:

1.Relieve pressure, page 13.

2.Lift the lubricant reservoir (LR) out of the bracket (RB) and remove the container from the cap. Hold- ing the cap over a suitable container, remove the check valve and allow the lubricant to drain. Reat- tach the check valve to the inlet hose (ST). See FIG. 13.

3.Drain the reservoir and flush it with clean lubricant.

4.When the reservoir is flushed clean, fill with fresh lubricant.

5.Thread the reservoir onto the cap assembly and place it in the bracket.

6.The lubrication system is ready for operation. No priming is required.

Repair

ST

RT

LR

FIG. 13. Pump Lubrication System

Repair

Fluid Inlet Strainer Screen

The inlet strainers filter out particles that can plug the pump inlet check valves. Inspect the screens daily as part of the startup routine, and clean as required.

Isocyanate can crystallize from moisture contamination or from freezing. If the chemicals used are clean and proper storage, transfer, and operating procedures are followed, there should be minimal contamination of the A-side screen.

NOTE: Clean the A-side screen only during daily startup. This minimizes moisture contamination by immediately flushing out any isocyanate residue at the start of dispensing operations.

1.Close the fluid inlet valve at the pump inlet and shut off the appropriate feed pump. This prevents mate- rial from being pumped while cleaning the screen.

2.Place a container under the strainer base to catch drain off when removing the strainer plug (C).

3.Remove the screen (A) from the strainer manifold. Thoroughly flush the screen with compatible solvent and shake it dry. Inspect the screen. No more than 25% of the mesh should be restricted. If more than 25% of the mesh is blocked, replace the screen. Inspect the gasket (B) and replace as required.

4.Ensure the pipe plug (D) is screwed into the strainer plug (C). Install the strainer plug with the screen (A) and gasket (B) in place and tighten. Do not over- tighten. Let the gasket make the seal.

5.Open the fluid inlet valve, ensure that there are no leaks, and wipe the equipment clean. Proceed with operation.

A

B

C

Temperature Display

NOTICE

Before handling board, put on static conductive wrist strap to protect against static discharge which can damage assembly. Follow instructions provided with wrist strap.

supply.

2.Relieve pressure, page 13.

3.Refer to Reactor A-25 Wiring Schematic, page 51.

4.Put on static conductive wrist strap.

5.Disconnect main display cable (106) at lower left corner of display module; see FIG. 15.

6.Remove screws (116) and cover (105); see FIG. 15.

7.Disconnect cable connector from back of tempera- ture display (102). See FIG. 15.

8.Disconnect ribbon cable(s) (R) from back of display; see FIG. 15.

9.Remove nuts (103) and plate (101).

10.Disassemble display, see detail in FIG. 15.

11.Replace board (102a) or membrane switch (102b) as necessary.

12.Reassemble in reverse order, see FIG. 15. Apply medium strength thread sealant where shown. Be sure display cable ground wire (G) is secured between cable bushing and cover (105) with screws (107).

D

FIG. 14. Fluid Inlet Strainer

Ti10974a

Temperature Display

102b

102a

102c 1

Replace DataTrak Battery or Fuse

The battery and fuse must be replaced in a non-hazardous location.

Use only the following approved replacement batter- ies. Use of an unapproved battery will void Graco???s warranty and FM and Ex approvals.

???Ultralife lithium # U9VL

???Duracell alkaline # MN1604

???Energizer alkaline # 522

???Varta alkaline # 4922

Use only a Graco-approved replacement fuse. Order Part 24C580.

Replace Battery

1.Unscrew cable from the back of the reed switch assembly. See FIG. 16.

2.Remove the cable from the two cable clips.

ti11992a

FIG. 16. Disconnect DataTrak

3.Remove DataTrak module from bracket. See FIG. 17. Take module and attached cable to a non-haz- ardous location.

ti18004a

FIG. 17. Remove DataTrak

4.Remove two screws on back of module to access battery.

5.Disconnect the used battery and replace with an approved battery. See FIG. 18.

Replace Fuse

1.Remove the screw, metal strap, and plastic holder.

2.Pull the fuse away from the board.

3.Replace with a new fuse.

Solenoid Cable

Connection

Fuse

Sensor Cable

Connection

Battery

ti11994a

FIG. 18. DataTrak Battery and Fuse Location

Accessories

Feed Pump Kits

Pumps, hoses, and mounting hardware to supply fluids to Reactor. Includes 246483 Air Supply Kit. See 309815.

P2 Spray Gun

Probler P2 Gun available in round or flat pattern. See 313213.

246483 Air Supply Kit

Hoses and fittings to supply air to feed pumps, agitator, and gun air hose. Included in feed pump kits. See 309827.

246978 Circulation Kit

Return hoses and fittings to make circulation system. Includes two 246477 Return Tube Kits. See 309852.

246477 Return Tube Kit

Desiccant dryer, return tube, and fittings for one drum. Two included in 246978 Circulation Kit. See 309852.

TSL (Throat Seal Liquid)

206995 1 qt (1 liter) bottle

206996 1 gal. (3.8 liter) container

24A592 DataTrak with Cycle Count Only Kit

DataTrack and reed switch for NXT Air Motor. See man- ual 313541.

Heated Hoses

50 ft (15.2 m) and 25 ft (7.6 m) lengths, 1/4 in. (6 mm), 3/8 in. (10 mm), or 1/2 in. (13 mm) diameter, 2000 psi (14 MPa, 140 bar) or 3500 psi (24 MPa, 241 bar). See 309572.

Heated Whip Hoses

10 ft (3 m) whip hose, 1/4 in. (6 mm) or 3/8 in. (10 mm) diameter, 2000 psi (14 MPa, 140 bar) or 3500 psi (24 MPa, 241 bar). See 309572.

Fusion Spray Gun

Air Purge Gun available in round or flat pattern. See 309550. Mechanical Purge Gun available in round or flat pattern. See manual 309856. Clear Shot Gun available in round or flat patter. See manual 312666.

Y-Strainer Screen

Replacement strainer screen for fluid Y-strainer; 20 mesh.

Part Description

180199 20 mesh; as shipped

255082 80 mesh (2 pack)

255083 80 mesh (10 pack)

114228 Air Filter Element

Replacement air filter element; 5 micron.

262695 Wheel Kit

All hardware and wheels to convert model 262572.

Recommended Spare

Parts

Keep the following spare parts on hand to reduce down- time.

Parts

262572, Bare Reactor A-25

262614, Reactor A-25 with DataTrak and Wheels

66

11 (x6)

62

52

59

9 (x4)

8

7

1

58

18

16

56 (x4)

38

35

100 (x4)

88

17

85 26

13

91, 92

13 (x2)

7

2

68

69

15 63

61

23

22

3

Parts

98

33

60

49

34

13 (x4)

37

ti18025a

83

29 28

80 ti18007a

Parts

???Replacement Danger and Warning labels, tags, and cards are available at no cost.

??? Only used with 262614.

??? Only used with 262572.

??? Included in Reed Switch Kit 24B659.

??? Not shown.

1 108

113

115

3

4

113 118 1

Temperature Control

Parts

Wheel Kit, 262695

195

???Only used with 262614. Available as add on wheel kit 262695.

Parts

Fluid Manifold

1Apply sealant and torque to 250 in-lbs (28 N???m).

2Use blue thread lock on valve cartridge threads into manifold.

3Part of item 208.

4Apply lubricant to mating surfaces.

5Apply pipe sealant to all NPT threads.

???Replacement Danger and Warning labels, tags, and cards are available at no cost.

Fluid Inlet Kit, 262695

255

1 254

253

ti18027a

252

251

1Assemble ball valves in orientation shown.

2Apply anaerobic polyacrylate pipe sealant to all NPT connections.

6 kw Dual Zone Heater, 24J788

353 1 6

5 361

2 5 355

351

1Torque to 120 ft-lbs (163 N???m).

2Torque to 23 ft-lbs (31 N???m).

3Torque to 40 ft-lbs (54 N???m).

4Apply 110009 thermal heatsink compound.

5Apply sealant and PTFE tape to all non swiveling and threads without o-rings.

356

357 6

362

359

354 3 6 7

352

6 360

314

308

1Apply PTFE tape and sealant to non-swiveling pipe threads.

2Torque to 88.5-124 in.-lbs (10-14 N???m).

3Torque to 32-38 ft-lbs (43-51 N???m). Torque nut (313) after assembly of item pin (306) and spring (307).

4Install adapters so that pins (306) will be in-line with each other.

5Lubricate threads of pump cylinders (303, 304) and plate (301) with lubricant prior to assembly into mounting plate. Assemble pump cylinder 1/2 thread above flush to one and one half thread above flush of mounting pate surface.

6Torque to 27-32 ft-lbs (37-43 N???m).

7Use blue thread lock (medium).

3A1570A

170

171

172

173

174

175

176

177

178

179

179-1

179-2

179-3

179-4

179-5

51

380V

WYE

3 PHASE

DSC 1-4

PE

TB9-2

FUSE1

187

HOSE HEATER

207

FTS

230V DELTA

3 PHASE

DSC 1-4

L2 L3

PE

TB13-19

BRIDGE BRIDGE

212

TB10-1

NN1

L

F 1

238CR L1 T1

PP1

212

TB9-1

195

196

50A 183CB

1 2

230V

1 PHASE

DSC 1-4

L1 L2

PE

BRIDGE BRIDGE

TB13-19

124T1

62V230V

Schematic Wiring 25-A Reactor

Schematic Wiring 25-A Reactor

52

NN1

L

F 2

SCR CIRCUIT

HEATER

POWER

MODULE

ZONE A

Schematic Wiring 25-A Reactor

193

194

195

196

TB16

N N1

12

L

25A 197CB F

2

209

BPOD-2

BPOD-1 B-POD

179-2

179-1

HPOD-2

197

198

199

SCR CIRCUIT

HPOD-1 H-POD

200

201

202

203

OPTIONAL

204CONNECTION

DATA

205REPORTING 246122

206

HEATER

POWER

MODULE

ZONE B

SCR CIRCUIT

HOSE

POWER

MODULE

ZONE HOSE

TB4-2

TB5-2

3A1570A

INCOMING POWER

(DISREGARD TERMINATION

ID'S SHOWN ON DISCONNECT)

DSC-1

TB1-TB8

JUMPER PLACEMENT

(INCOMING POWER)

1 1 1 1 1 1 1

2 2 2 2 2 2 2

TB13-TB19

380V 3-PHASE

1 1 1 1 1 1 1

2 2 2 2 2 2 2

TB13-TB19

230V 3-PHASE

1 1 1 1 1 1 1

2 2 2 2 2 2 2

TB13-TB19

230V 1-PHASE

L3

L2

L1

N

G

P

O

W

E

R

NL1

S

230V 1-PHASE

54

Simplified Schematic, Heater Controls

Schematic Wiring 25-A Reactor

TO OPTIONAL

DATA

REPORTINGCONTROL HEATER MODULE

TO FTS

TO THERMOCOUPLE B

TO THERMOCOUPLE A

3KW HEATER

JUMPER PLACEMENT

1

1 1 1 1 1 1 1 1

F

U

S

E 1

2 2 2 2 2 2 2 2 2

6KW HEATER

JUMPER PLACEMENT

CR

OI

NM

DA