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Graco 313540G User's Manual

1. AS The inlet strainer at each proportioning pump filters out solid matter that can plug the inlet check valves Inspect the screens daily as part of the startup routine and clean as required Isocyanate can crystallize from moisture contamination or from freezing If the chemicals used are clean and proper storage transfer and operating procedures are followed there should be minimal contamination of the A side screen 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 material supply valve at the pump inlet to prevent material from being pumped while the strainer plug C is removed 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
2. 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 Fic 12 Fluid Temperature Sensor and Heated Hoses ti9581c 40 313540G Repair Transformer Primary Check 3 To verify transformer voltage turn on hose zone Measure voltage from 18CB 2 to POD HOSE P15 2 see Reactor Electrical Dia 1 Turn main power OFF grams manual 312064 2 Locate the two smaller 10 AWG wires coming out Model Secondary Voltage of transformer Trace these wires back to contactor 310 ft 90 Vac and circuit breaker 811 Use an ohmmeter to test for continuity between two wires there should be 410 ft 120 Vac continuity For 230 Vac line voltage Transformer Secondary Check Replace Transformer i t f i 1 Turn main power OFF NOTE Use this procedure to replace transformer 2 Locate the two larger 6 AWG wires coming out of transformer Trace these wires back to large green connector under hose control module and circuit 1 Turn main power OFF Disconnect power breaker 809 Use an ohmmeter to test for
3. r 256886 313539 6 180 190 Fic 3 Remove Guard 313540G Repair 8 Disconnect all fluid hoses connected to pumps 9 Remove pump base pin 183 and top pin 255 on both pumps See page 57 184 r 256886 313539 7 FIG 4 Remove Pump Pins 10 Remove pump assemblies and take to a workbench 11 See manual 313485 for pump repair instructions 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 29 Repair Circuit Breaker Module Table 3 Circuit Breakers see FIG 5 Ref Size Component 1 Turn main power OFF Disconnect power 809 50A Hose Transformer supply Turn circuit breakers on to test Secondary Side 811 40A Transformer Primary 812A 50A Heater A 812B 50A Heater B 2 Relieve pressure page 27 813 20A Motor Pumps 3 Using an ohmmeter check for continuity across cir cuit breaker top to bottom If no continuity trip breaker reset and retest If still no continuity replace breaker as follows a Refer to electrical diagrams and to TABLE 3 Dis connect wires and remove bad breaker b Install new breaker and reconnect wires NOTE To reference cables and con 812B nectors see the electrical diagrams and 813 the parts drawings on p
4. Slow E24 Errors Slow E24 errors occur gradually The pressures are bal anced when you begin spraying but slowly become imbalanced until an E24 occurs NOTE If spraying at a ratio other than 1 1 an E24 may occur Size hoses and mix chamber appropri ately 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 e drum is not vented E27 High motor temperature Causes of E27 Errors e Motor temperature is too high Reduce pressure gun tip size or move Reactor to a cooler location Allow 1 hour for cooling e Make sure there is no obstruction to fan airflow Ensure that the motor fan shroud is installed e Check that the motor overtemperature wire assem bly is plugged into J9 on the motor control board page 33 e Ifthe preceding checks do not correct the problem perform the following tests 1 Turn main power OFF Ui 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 the motor thermal switch or the wire harness is bad Check wiring measure thermal switch continuity at motor and replace failed part 3 Unplug
5. D front and rear mounting holes F side mounting holes G mounting post inner diameter in mm 32 5 825 5 30 4 771 6 0 44 11 2 A r 256886 313539 1 r 256886 313539 4 313540G Technical Data Technical Data Category Data Maximum Fluid Working Pressure 3500 psi 24 1 MPa 241 bar Fluid Inlets 3 4 npsm union in 1 in npt f ball valve Fluid Outlets Component A ISO 8 1 2 in JIC with 5 5 16 in JIC adapter Component B RES 10 5 8 in JIC with 6 3 8 in JIC adapter Fluid Circulation Ports 1 4 npsm m with plastic tubing 250 psi 1 75 MPa 17 5 bar maximum Maximum Fluid Temperature 190 F 88 C Maximum Output 10 weight oil at ambient temperature 3 0 gpm 11 4 liter min 60 Hz 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 A and B heaters total no hose See Models page 3 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 1 m from equipment 84 0 dB A Weight 955 Ib 433 kg Wetted Parts Aluminum stainless steel zinc plated carbon steel brass carbide chrome fluoroelastomer PTFE ultra high molecular weight pol
6. Fluid leaking from pump outlet rup ture 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 Ratio Lock Handle B Pump Arm B Resin Proportioning Pump Hydraulic Cylinder FIG 1 Pump Line when viewed from rear of machine Change Over Box TRE an Troubleshooting A Pump Arm Ratio Adjustment Wheel A ISO BEN O o Proportioning Reversing Switches Switch Disk r 256886 313540 4 Table 2 Directional Valve Indicator Status Left Pump Directional Indicator Lighted Right Pump Directional Indicator Lighted B side pump piston valve dirty or damaged B side pump inlet valve dirty or damaged A side pump inlet valve dirty or damaged A side pump piston valve dirty or damaged 313540G 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 exampl
7. NOTE If spraying at a ratio other than 1 1 an E24 may occur Size hoses and mix chamber appropri ately 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 Fast E24 Errors Fast E24 errors occur e within 10 seconds of turning the pumps on or e 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 N is set to PRESSURE RELIEF CIRCULATION 94 Checks for Fast E24 Errors NOTE If a fast E24 error occurs first check the readings of the analog gauges e If the gauge readings are very close 1 Clear the error page 12 and try running the unit again 2 If E24 recurs and the gauge readings are still very close a pressure transducer has failed 313540G one PRESSURE RELIEF SPRAY valve is leaking or Motor Control Diagnostic Codes The digital display always shows the higher of the two pressures As soon as the higher analog pres sure drops below the lower analog pressure the dis play 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 For testing purposes only set DIP switch 2 on the motor control board
8. 1 1 16 npt m x 1 2 in 13 50X 308212 PAD pamphlet safety 1 mm tube 51 15B775 COVER wire access 1 52 247846 COVER heater 2 53 SCREW machine pan hd 3 8 32 x 3 8 544A 15G280 LABEL warning 1 55 113505 NUT KEPS hex hd 4 56 112776 WASHER plain 2 57 113802 SCREW hex hd flanged 8 58 STRAP tie wire 20 313540G 55 Parts Ref 118 119 120 122 125 126 127 129 130 131 132 133 134 135 137 139 142 143 144 146 147 148k 150 151 153 160 161 161a 161b 161c 161d 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 180 1814 1824 183 184 185 186 56 Part 247856 15H512 15H204 117560 247793 255029 121320 255036 117792 117773 15G782 15G784 116915 247792 116793 107156 112586 110996 C19862 247836 255048 255039 261821 104373 255653 257543 100060 101044 100018 100321 15W350 122400 117502 122398 122401 111856 155677 15X244 15X710 15W800 15W349 15X743 GC2108 Description PULLEY fan LABEL control KNOB pressure SCREW set socket hd HOSE inlet coupled GAUGE pressure fluid panel mount ELBOW ELBOW male GUN grease GREASE lubricant HOSE coupled HOSE coupled DIPSTICK with breather cap FILTER oil 18 23 psi bypass FITTING SCREW cap socket head SCREW cap hex hd NUT hex flange hd 5 16 18 NUT lock hex COVER access NUT strain relief M40 thread CONNECTOR heater SCREW set 1
9. 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 9 Install new heater element 407 holding mixer 409 so it does not block thermocouple port P 10 Reinstall thermocouple page 38 11 Reconnect heater element leadwires to heater wire connector 12 Replace heater shroud Line Voltage The primary heaters output their rated wattage at 230 Vac Low line voltage will reduce power available and the heaters will not perform at full capability 37 Repair 8 Thermocouple 1 Turn main power OFF Un Disconnect power supply 2 Relieve pressure page 27 A 3 Wait for heaters to cool 4 Remove heater shroud 5 Disconnect thermocouple wires from B on tempera ture control module See TABLE 6 page 35 and FIG 9 page 35 10 6 Feed thermocouple wires out of cabinet Note path 11 as wires must be replaced in the same way 7 See FIG 10 Loosen ferrule nut N Remove ther mocouple 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 409 Fic 10 Thermocouple 38 401 Replace thermocouple FIG
10. 821 820 805 806 S gt gt 803 804 NG fa _ 808 802 810 ee 801 Eled 818 ER 819 il S 313540G 64 Circuit Breaker Modules Parts List Breaker Modules Ref Description 230V hae 400V EYES Qty 801 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 7 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 313540G Parts 65 Dimensions Dimensions Dimension in mm A height 57 3 1455 4 B width 37 9 961 6 C depth 33 0 838 2 Top View Front of Machine a D ma A C _ Y F lo lo lt D aag B Bo Rear of Machine 66 Dimension
11. AAU RAS 313 314 309 Ref 340 341 342 343 344 345 346 347 344 346 r 256886 313540 6 Part Description Qty 255037 ELBOW 3 4 nptf 255038 CONNECTOR 15H184 WIRE bi directional cable assy 15H253 HOSE gauge hydraulic 3000 psi 121309 CONNETOR 3 4 SAE x 1 2 JIC 15W003 BLOCK port 15X237 BRACKET shroud 111800 SCREW cap hex hd D DD 59 Parts 7 65 kW Single Zone Heater Two Per Machine Part 247813 Ref 401 403 404 405 406 407 408 409 60 Part 121309 15H304 15H306 120336 15B138 15B137 15B135 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 407 r 247813 312063 A Apply 110009 thermal heatsink compound Qty 1 2 OO Ww 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 413 Qty U ond 313540G Display Ref 501 501a 501b 501c 502 502a 502b 502c 503 504 507 506 Part 245978 246130 246478 112324 245977 246130 246479 112324 15B293 15B292 313540G 506 Description DISPLAY pressure includes 501a 501c BOARD circuit SWITCH membrane SCREW DISPLAY temperature includes 502a 502c BOARD circ
12. Allow equipment to cool Try the recommended solutions in the order given for each problem to avoid unnecessary repairs Also determine that all circuit breakers switches and con trols are properly set and wiring is correct before assum ing there is a problem PROBLEM CAUSE SOLUTION Hose heats but heats slower than usual or it does not reach tempera ture Ambient temperature is too cold FTS failed or not installed correctly Use auxiliary hose heat system 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 Hose does not maintain temperature while spraying 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 Low supply voltage Wait for hose to heat to correct tem perature before spraying Verify line voltage Low line voltage significantly reduces power available to hose heat system affecting longer hose lengths Hose temperature exceeds setpoint A and or B heaters are overheating material Check primary heaters for either a thermocouple problem or a failed ele men
13. anti foaming oxidation stability corrosion protection and water separation 46 313540G Parts Parts 84 60 ER LR See page 52 See page 52 mag 100 60 See page 50 See page 60 ti9831a 313540G 47 Parts 185 186 187 181 182 180 170 174 177 174 146 ER 160 See page 49 168 j 177 161 See page 54 Ca 164 104 105 106 163 r 256886 313540 2 48 313540G Pump Assembly Overview 189 See page 57 191 Parts 188 182 190 ae el I bkd pa See page kia NO lal YEA lal See page 58 192 193 KI 313540G 195 196 197 r 256886 313540 4 49 Parts Detail of Cabinet Area See page 51 54A TI9834a 50 313540G Parts Left Side of Cabinet G Pst 1S hate hip L TI9835a 103 Ref TI9836a 313540G Parts Detail Fluid Manifold Area 111 Ref sy 39 151 TI9838a 111 Ref See page 59 52 313540G Parts Detail Electric Motor Area F 118 Ref Detail Hydraulic Reservoir Area 111 Ref ti7709a 122 j 119 120 H PU 111 Ref 111 Ref 132 114 1j 142 143 150 1 Ref TI9832b 313540G 53 Parts Ref 161 Fluid Inlet Kit 161d 161a 161b 161d 161c r 256886 313540 7 Ref 110 Hydraulic Reservoir 11
14. any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 All 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
15. at no cost Model 256887 only v Available with fluid hose kit 257791 Available with pin and bearing kit 257794 Not shown 313540G Parts Sub Assemblies Pump Assembly Pump Detail A Side Pump Shown 223 see manual 313485 280 274 275 or 276 A Apply blue Loctite and torque to 250 ft lbs 337 5 Nem r 256886 313540 5 AN Apply blue Loctite and torque to 15 ft Ibs 20 3 Nem 313540G 57 Parts 250 249 253 A Apply blue Loctite and torque to 250 ft lbs 337 5 Nem Ref 204 205 208 211 212 213 214 215 216 217 218 220 222 223 224 225 226 227 228 229 238 241 246 247 249 58 Part GC2041 GC2112 159239 GC0518 GC0527 GC0419 GC0519 GC0521 GC0420 GC0520 GC1195 GC0524 GC0421 GC0526 GC0532 GC0536 GC0912 GC0535 157191 GC1147 15X709 GC1132 GC2107 Description WASHER flat std 1 2 in WASHER lock spring 1 2 in NIPPLE pipe YOKE guide rod WASHER flat PIN clevis 1 2 in WASHER flat LINK drive pump BRACKET pivot PIN clevis 1 2 in WASHER flat ADAPTER pump FITTING lube 1 4 28 SCREW adjustment 1 2 20 WASHER flat SHAFT locking WHEEL hand aluminum STUD 5 8 11 x 3 in SPACER 1 5 16 in diameter 9 16 in HANDLE FITTING adapter 1 2 npt x 3 4 npt PUMP assy fluid PLATE change over bottom EXTENSION stndoff change over WASHER lock spring 8 O
16. 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 11 Motor Control Diagnostic Codes Motor Control Diagnostic Codes Motor control diagnostic codes E21 through E27 appear on pressure display There are two types of motor control codes alarms and warnings Alarms take priority over warnings Alarms Alarms turn off Reactor Turn main power OFF then ON to clear NOTE Alarms can also be cleared except for code 23 by pressing o Warnings Reactor will continue to run Press to clear A warning will not recur for a aa amount of time varies for different warnings or until main power is turned OFF a then ON 11 Code Code Name Alarm A or Corrective Warning W Action page 99 Loss of communication A 15 Code Code Name Alarm A or Corrective Warning W Action page 21 No transducer compo A 12 nent A 22 No transducer compo A 12 nent B 23 High fluid pressure A 12 24 Pressure imbalance A W to 13 select see page 32 27 High motor temperature A 14 30 Momentary loss of com A 15 munication 31 Pump
17. continu supply ity between two wires there should be continuity i If you are not sure which wire in green plug under hose module connects to transformer test both wires One wire should have continuity with the other transformer wire in breaker 809 and the other wire should not 2 Open Reactor cabinet 3 Remove bolts holding transformer to cabinet floor Slide transformer forward 4 Disconnect the transformer wires see Reactor Elec trical Diagrams manual 312064 5 Remove transformer from cabinet 6 Install new transformer in reverse order Fic 13 Circuit Breaker Module 313540G 41 Repair Display Module Temperature and Pressure Displays 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 Um Disconnect power supply Red Stop Button 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 UA 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 cor ner of display module see FIG 14 6 Remove screws 509 510 and cover 504 see FIG 14 If replacing both displays la
18. eeeeee OR iz MOVING PARTS HAZARD Moving parts can pinch or amputate fingers and other body parts e Keep clear of moving parts e Do not operate equipment with protective guards or covers removed e Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure in this manual Disconnect power or air supply ARA BURN HAZARD Equipment surfaces and fluid that s heated can become very hot during operation To avoid severe burns e Do not touch hot fluid or equipment e Wait until equipment fluid has cooled completely 313540G Isocyanate Conditions gt mo ttt AA Spraying materials containing isocyanates creates potentially harmful mists vapors and atomized partic ulates 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 ventila tion 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 per sonal protective equipment including chemically impermeable gloves boots aprons and goggles is also required for everyone in the work area Material Self ignition Some mater
19. 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 recon nected 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 E31 may also occur if the system is modified to produce a higher flow rate 313540G Motor Control Diagnostic Codes E99 Loss of communication If communication is lost between the motor control dis play and the motor control board or the temperature control display and the temperature control module the affected display will show E99 1 Check all wiring between the display and the motor control board and the temperature control module Pay close attention to the wire crimping at J13 on the motor control b
20. page 39 b 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 313540G E04 Fluid Temperature Sensor FTS or thermocouple disconnected 1 Check temperature sensor connections to long green connector B on temperature control module page 34 Unplug and re plug sensor wires Test fluid temperature sensor continuity with ohm meter page 9 If an error occurred for the hose zone check FTS connections at each section of hose If an error occurred for the hose zone test FTS by plugging directly into machine ti9878a To verify heater control module is not causing the problem use a wire to short circuit the two pins cor responding to the FTS red and yellow for A or B zone red and purple for hose The display will show the control heater module temperature If an error occurred for the hose zone temporarily use the current control mode Refer to Reactor H VR Operation manual 313539 313540G Temperature Control Diagnostic Codes 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 that fan above electrical cabinet is operating 2 Check that electrical cabinet door is properly installed 3 Check for obstructions
21. present while in SPRAY fm mode Spraying at a ratio other than 1 1 can Size hoses and mix chamber appro cause pressure imbalance priately 313540G 23 Troubleshooting PROBLEM CAUSE SOLUTION Pumps do not reverse direction or pumps do not move Damaged reversing switch assembly See Pumps Do Not Reverse Direc tion page 26 Faulty directional valve See Pumps Do Not Reverse Direc tion page 26 Erratic pump movement 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 mate rial supplier for recommended fluid temperature to maintain a viscosity of 250 to 1500 centipoise Faulty reversing switch connection See Pumps Do Not Reverse Direc tion page 26 Faulty directional valve Replace directional valve see Pumps Do Not Reverse Direction page 26 Pump output low Fluid leak at pump rod seal 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 Worn throat seals Replace See pump manual 313485 No pressure on one side
22. temperature verify voltage between connectors at each section of hose 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 5 ANO Z 3 Allow equipment to cool Before performing any troubleshooting procedures 1 Relieve pressure page 27 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 PROBLEM CAUSE SOLUTION Electric motor will not start or stops Loose connections Check connections at motor control during operation 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 313540G 21 Troubleshooting PROBLEM CAUSE SOLUTION Hydraulic pump does not develop pressure Low or zero pressure with screeching noise 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 Con
23. the equipment clean 6 Proceed with operation 44 Sa re IN a FiG 15 Y Strainer Components Fluid filter screen within 161c replacements Part Description 180199 20 mesh standard 1 pack 255082 80 mesh optional 2 pack 255083 80 mesh optional 10 pack 187758 Replacement gasket Change Hydraulic Fluid and Filter NN VN N ARA 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 which ever comes first Table 8 Frequency of Oil Changes Ambient Recommended Temperature Frequency 0 to 90 F 1000 hours or 12 months 17 to 32 C 90 F and above 32 C and above whichever comes first 500 hours or 6 months which ever comes first 1 Relieve pressure page 27 2 Allow hydraulic fluid to cool 313540G 3 Place a pan under reservoir drain plug 110k to catch oil ti9888a 110k FIG 16 Change Hydraulic Fluid and Filter 4 Remove drain plug 110k 313540G 9 Repair 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 Reinstall drain plug 110k Replace filter 135 a Coat filter seal with fresh oil b Screw filter on snug then an addit
24. to OFF See page 32 This will allow the Reactor to continue to run with a pressure imbalance c Run the unit until pressure is 1000 1500 psi 7 10 5 MPa 70 105 bar Shut down the unit clear the alarm and power back up but do not depressurize the unit d Check the analog gauges to see which pressure is higher and check if the display matches If the higher gauge and display match that transducer is communicating with the motor control board Continue with step e If the higher gauge and display do not match that transducer is not communicating with the motor control board Check wire con nections and replace transducer page 34 e Turn pumps off Reduce pressure of higher com ponent by slightly turning PRESSURE RELIEF SPRAY valve for that component toward NN PRESSURE RELIEF CIRCULATION Oy while watching the display and the analog gauges As soon as the higher analog pressure drops below the lower analog pressure the dis play should change to the new higher reading Continue reducing the original higher pressure an additional 200 psi 1 4 MPa 14 bar digital display should stop dropping f Repeat for the other side to check the other transducer A Turn valve slightly to reduce pressure of AC component ti9877a 4 To test if the failure is with the transducer or the socket on the motor control board 13 Motor Control Diagnostic Codes a Reverse connections at J3 and J8 on the motor
25. 0 CONDUIT assembly motor power 104 100560 SCREW cap hex hd 3 8 16 105 100133 WASHER lock 3 8 in 106 100731 WASHER 3 8 in 107 119253 SUPPRESSOR ferrite 151 ohm 110 247826 RESERVOIR hydraulic includes 110b 110m see page 54 110b 247778 HOUSING inlet 110c 247771 GASKET inlet 110d 247777 TUBE inlet 110f 247770 TUBE return 110 116919 FILTER inlet 110k 255032 PLUG 110m 255021 FITTING straight 111 247822 BRACKET motor mount 20 15B383 CABLE display 21k 261669 KIT fluid temp sensor coupler 23 103181 WASHER lock ext 24 15B360 GASKET fan 25 255047 STRAIN RELIEF M40 thread 26 MODULE breaker see page 64 27 116149 SPACER 29 117666 TERMINAL ground 30 C19843 SCREW CAP socket hd 31 247841 SWITCH disconnect 32 247842 KNOB operator disconnect 33 117723 SCREW mach slotted hd 34 C20487 NIPPLE hex 35 247502 COVER heater wire 36 247843 BRACKET heater 37 167002 INSULATOR heat 38 117623 NUT cap 3 8 16 39 113796 SCREW flanged hex hd 40 115942 NUT hex flange head 42 15K817 LABEL fault codes RER PS SAAN mu M Cor 44 RIVET pop 3 16 in 5 mm x 0 4 112 247819 BRACKET mounting pump in 10 mm 113 255019 PUMP hydraulic 454 189930 LABEL caution o 114 247821 BRACKET reservoir hydraulic 47 247845 PULLEY drive 1 115 247820 BRACKET support pumpmount 48 803889 BELT 1 116 247829 COOLER hydraulic 49k 15B593 SHIELD membrane switch 1 117 255020 ELBOW
26. 0f Bakal Wa 116k 110j ti9840a 54 313540G Parts Parts Ref Part Description Qty Ref Part Description Qty 2 247813 HEATER 2 60 111800 SCREW cap hex hd 35 3 247785 MOTOR 1 62 247782 SPACER 4 4 245974 DISPLAY see page 61 1 63 247850 COVER front 1 5 CONTROL temperature see page 1 67 117284 GRILL fan guard 1 62 68t 117553 SWITCH added pole 1 6 247835 BOARD circuit motor control 1 74k 206995 THROAT SEAL LIQUID 1 quart 1 7 247823 MANIFOLD fluid see page 63 1 76 115836 GUARD finger 1 8 247786 TRANSFORMER 1 77 186494 CLIP spring 5 9 247832 COVER motor 1 78 205447 COUPLING hose 2 10 246976 COVER main cabinet 1 79 054826 TUBE PTFE 1 4 in 6mm ID 8ft 8 11 PUMP proportioning see page 59 1 2 4 m 13 115834 FAN cooling 1 82 15H207 BRACKET tensioner 1 14 15X243 TUBE inlet component A 1 844 189285 LABEL caution 2 15 15R645 TUBE outlet component A 1 85 114269 GROMMET rubber 2 16 15X241 TUBE inlet component B 1 88 247851 FITTING reducer 5 x 8 JIC 1 17 15R644 TUBE outlet component B 1 89 247852 FITTING reducer 6 x 10 JIC 1 18k 247787 CABLE harness heater overtemp 1 90 111802 SCREW cap hex hd 1 2 13x3 4 2 includes 12 pin connector in 19 mm 19 15B380 CABLE hose control see manual 1 93 151895 HOSE supply 312064 94 247784 TUBE return 96 247853 ADJUSTER belt tensioner 97 15G816 COVER plate wire way 99 112125 PLUG tube 100 247780 LABEL 102 15H189 BOOT wire feed through 103 24779
27. 10 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 405 c Pushin thermocouple 410 so tip T contacts heater element 407 d Holding thermocouple T against heater ele ment tighten ferrule nut N 1 4 turn past tight Route wires S into cabinet and thread into bundle as before Reconnect wires to board Replace heater shroud Turn on heaters A and B simultaneously to test Temperatures should rise at same rate If one heater is low loosen ferrule nut N and tighten ther mocouple housing H to ensure thermocouple tip T contacts element 407 A Apply PTFE tape and thread sealant A Apply 110009 thermal heatsink compound 407 A 408 ti7924a 313540G Overtemperature Switch 1 Turn main power OFF Un Disconnect power supply 2 Relieve pressure page 27 A hul 7 3 Wait for heaters to cool 4 Remove heater shroud 5 Disconnect one leadwire from overtemperature switch 408 FiG 10 Test across switch with ohm meter Resistance must be approximately O 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 401 and secure with screws 411 Reconnect wires NOTE If wires need replacement disconnect from temperature control board See TABLE 6 pa
28. 4 x 1 2 13 mm CONNECTOR wire 6 AWG pair WASHER thrust PUMP assy see page 57 KIT fluid inlet each kit includes 161a 161d VALVE ball 3 4 in NIPPLE hex Y STRAINER FITTING union swivel 3 4 in KIT skid KIT caster includes 4 casters SCREW cap hex hd WASHER plain WASHER lock spring NUT BRACKET ELBOW bulkhead 8 JIC REDUCER 5 x 8 JIC HOSE moisture lock assy A 3 ft REDUCER 6 x 8 JIC HOSE moisture lock assy B 3 ft ADAPTER bulkhead 8 JIC 6 nptf ELBOW street 3 8 18 npt ADAPTER union 90 deg 3 8 nptf x 3 8 npsm HOSE coupled 5600 psi GUARD LABEL warning LABEL caution pinch point PIN base fluid pump PIN hitch HANDLE round WASHER lock spring 10 Qty mob mob cb smb smb Din mm HAH NNwW AH AH AH AH BH a aa st Din HYPO SARAH ER P mmk _ 8 D DO 2 D 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 SCREW socket hd LABEL calibration right LABEL calibration left KNOB clamping FITTING lube 1 8 npt SHAFT guard EXTENSION standoff hex 1 in x 2in SHAFT cylinder hydraulic WASHER lock spring 1 4 in SCREW cap hex hd WASHER flat fender 1 4 in FRAME WIRE switch cable A Replacement Danger and Warning labels tags and cards are available
29. AUGE pressure fluid 2 P 704 162453 FITTING 1 4 npsm x 1 4 npt 2 a Replacement Warning labels signs tags and cards 705 24K999 TRANSDUCER pressure control 2 are available at no cost 706 247788 HANDLE red l t Included in the following complete valve kits 707 247789 HANDLE blue ISO Valve Kit left red handle 255149 7081 112309 NUT hex jam 2 Resin Valve Kit right blue handle 255150 712 117556 NIPPLE 8 JIC x 1 2 npt 1 Valve Set Kit both handles and grease gun 255148 713 117557 NIPPLE 10 JIC x 1 2 npt 1 313540G 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 dia 810 rams manual 312064 supplied See page 65 for parts BP pag j 820 805 806 811 821 803 804 3 808 802 _ o Pi ojo o Oo g sika 801 816 74 o Q ol 178CB 187CB 19708 172CB o o o IO O ojo o i J 813 812 B19 809 807 822 NG B 400V 3 Phase Circuit Breaker Modules For wiring and cable connections refer to electrical dia 817 grams manual 312064 supplied See page 65 for parts 810
30. NE pnk ee WR HUE a ae ER nG 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 ANAN GRABA ANG 15 E99 Loss of communication 15 Troubleshooting 16 Reactor Electronics 16 Primary Heaters AandB 18 Hose Heat System 19 Hydraulic Drive System 21 Proportioning System 23 Repaint a Bana AA re lod ka 27 Pressure Relief Procedure 27 FIUSING ae a a BA INIP a ae bed 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 AA AT KNANG 47 Su
31. 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 o MINNEAPOLIS MN 55440 1441 USA Copyright 2009 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com Revised 01 2012
32. Repair Parts G g KQEAC Tor H VR 3135406 Hydraulic Variable Ratio Heated Plural Component Proportioner For spraying polyurethane foam and polyurea coatings Not for use in explosive atmospheres B 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 C 4 ED 9902471 Conforms to ANSI UL Std 499 Certified to PROVEN QUALITY LEADING TECHNOLOGY Contents Models 22 24 20 Fee Ree F 3 Supplied Manuals 4 Related Manuals 4 Warnings 222800 Anetta de eee ae 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 Lu
33. age 64 ti9884a FIG 5 Circuit Breaker Module 30 313540G Electric Motor Removal 1 Turn main power OFF Disconnect power supply WA 2 Relieve pressure page 27 3 Remove motor shroud 4 Disconnect motor cables as follows a Refer to electrical diagrams in the Reactor Elec trical 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 junc tion box cover The motor must operate counter clockwise when looking at the output shaft Motor is heavy Two people may be required to lift 5 Remove screws holding motor to bracket Lift motor off unit 313540G Repair Installation 1 Place motor on unit 2 Fasten motor with screws 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 counter clockwise when viewed from shaft end If rotation is incorrect reverse power leads L1 and L2 See Reac tor H VR Operation manual 313539 Connect Electri cal Cord 4 Return to service 31 Repair Motor Control Board NOTE Motor control board has one r
34. ation Order Part 15M334 for a compact disk of Reactor manu als Related Manuals The following manuals are for accessories used with the Reactor Feed Pump Kits Reactor Hydraulic Proportioner Part Description 313539 Reactor H VR Proportioner Operation Manual English Reactor Electrical Diagrams Part Description 309815 Instruction Parts Manual English Air Supply Kit Part Description 309827 Instruction Parts Manual English for Feed Pump Air Supply Kit Circulation and Return Tube Kits Part Description Part Description 312064 Reactor Hydraulic Proportioner 309852 Instruction Parts Manual English Electrical Diagrams English Heated Hose Fluid Pump Part Description Part Description 309572 Instruction Parts Manual English 313485 Pump Instructions Parts Manual Circulation Kit English Et 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 Part Description 309969 Instruction Parts Manual English 4 313540G Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion point symbol alerts you to a general warning and the hazard sy
35. b Assemblies 57 Pump Assembly 57 Hydraulic Directional Valve Assembly 59 7 65 kW Single Zone Heater 60 Display aaa REA NA 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 Full Load Max Flow Approximate Peak Primary Rate Output per Hydraulic Maximum Fluid Part Amps Per Voltage System Heater Ib min Cycle A B Pressure Working Pressure Series Phase phase Wattst Watts kg min gal liter Ratio psi MPa bar 256886 71 230V 3 26 600 15 300 30 13 6 Variable Variable 3500 24 1 241 256887 41 400V 3 26 600 15 300 30 13 6 Variable Variable 3500 24 1 241 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 Supplied Manuals Supplied Manuals The following manuals are used with the Reactor HV R Proportioner Refer to these manuals for detailed equipment inform
36. bel 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 dis play 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 Fic 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 1 Turn main power OFF Disconnect power supply 2 Relieve pressure page 27 3 Refer to electrical diagrams 4 Put on static conductive wrist strap 5 Remove screws 509 510 and cover 504 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 313540G Repair A Apply medium strength thread sealant 507 506 ti2574a Detail of Membrane Switches and Display Boards Temperature Display AN 502c Pressure Display 502a ti3172a FIG 14 Display Module 313540G 43 Repair Inlet Fluid Strainer Screen
37. cable connections page 42 Temperature display does not illuminate 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 Pressure display does not illuminate 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 dis play illuminates motor control board is causing problem Otherwise dis play cable or display is failing Erratic display display turns on and off 16 Low voltage Ensure input voltage is within specifi cations page 42 Poor display connection Check cable connections page 42 Replace damaged cable Display cable damaged or corroded Display cable not grounded Clean connections replace cable if is damaged Ground cable page 42 Display extension cable too long Must not exceed 100 ft 30 5 m 313540G Troubleshooting PROBLEM CAUSE SOLUTION Hose display reads OA at sta
38. cing new fluid e Use the lowest possible pressure when flushing e 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 5 RELIEF CIRCULATION 7 Flush through bleed lines N SA NN ti9880a e To flush entire system circulate through gun fluid manifold with manifold removed from gun e To prevent moisture from reacting with isocyanate always leave the system dry or filled with a mois ture free plasticizer or oil Do not use water 28 NOTE See manual 313485 for pump repair instruc tions 1 Shut off EN B and heat zones 2 Flush page 28 M Tri 3 If pumps are not parked press Q Trigger gun until pumps stop 4 Turn main power OFF um Disconnect power supply 5 Shut off both feed pumps Close both fluid inlet ball valves B ti10971a 313540G 6 Turn both PRESSURE RELIEF SPRAY valves SA NN SB to PRESSURE RELIEF CIRCULATION Oy Route fluid to waste containers or supply tanks Ensure gauges drop to 0 ti9879a NOTE Use a drop cloth or rags to protect Reactor H VR and surrounding area from spills 7 Remove guard Loosen all four clamping knobs 190 and remove guard 180 To avoid injury never remove guard unless all pres sure is relieved and all power is shut off
39. control board b Run the unit until pressure is 1000 1500 psi 7 10 5 MPa 70 105 bar c Ifthe problem stays on the same side as before replace the motor control board If the problem appears to move to the other side replace the transducer e Ifthe 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 A RELIEF CIRCULATION Oy until gauges show balanced pressures AN Turn valve slightly to reduce pressure of gt N he component ti9877a NOTE Turn PRESSURE RELIEF SPRAY valve only enough to balance pressure If you turn it com pletely all pressure will bleed off 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 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 b Check and clean the gun mix chamber impinge ment ports and center port See gun manual NOTE Some mix chambers have counter bored impingement ports requiring two drill sizes to clean completely
40. cross contamination of the equipment s wetted parts never interchange component A isocy anate 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 Changing Materials e When changing materials flush the equipment mul tiple times to ensure it is thoroughly clean e Always clean the fluid inlet strainers after flushing e Check with your material manufacturer for chemical compatibility e Most materials use ISO on the A side but some use ISO on the B side e Epoxies often have amines on the B 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 tem perature display These alarms turn off heat E99 clears automatically when communication is regained Codes E03 through E06 can be cleared by pressing O For other codes turn main power OFF then ON E01 High fluid temperature Causes of E01 Errors e Thermocouple A or B 310 senses a fluid tempera ture above 230 F 110 C e Fluid temperature sensor FTS senses a fluid tem perature above 230 F 110 C e Overtemperature switch A or B 408 senses a fluid temperature above 230 F 110 C and open
41. ctor B is firmly plugged into tem perature control module see FIG 9 page 35 2 Clean and re plug connections 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 depend ing on which zone is displaying E01 See TABLE 6 page 35 Ensure that all wires are securely con nected to connector B Temperature Control Diagnostic Codes 4 Remove connector B from temperature control mod ule and check continuity of overtemperature switches A and B thermocouples A and B or FTS by measuring resistance across the pins on the plug end see TABLE 1 NOTE Before doing the following checks note which zone A B FTS or all has high fluid tempera ture Table 1 Sensor Connector Continuity Checks Pins Description Reading 1 amp 2 OT switch A nearly 0 ohms 3 amp 4 OT switch B nearly 0 ohms 5 amp 6 Thermocouple A 4 6 ohms 8 amp 9 Thermocouple B 4 6 ohms 11812 FTS approximately 35 ohms per 50 ft 15 2 m of hose plus approximately 10 ohms for FTS 10812 FTS open 5 Verify fluid temperature using an external tempera ture sensing device e If temperature is too high sensor reading is 229 F 109 C or above 6 Check if thermocouples A and B are damaged or not contacting the heater element page 38 7 To test that temperature control module turns o
42. e if component B is under proportioned focus on the B side pressure gauge If the B gauge reads considerably higher than the A gauge the prob lem is at the gun If the B gauge reads considerably lower than the A gauge the problem is at the pump 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 cor rectly and that none of the components are dam aged See Fic 1 page 25 and Parts page 58 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 illumi nate when each switch is activated r 256886 313540 1 Directional Valve Fic 2 Hydraulic Directional Valve Assembly There are two possible problems with the directional valve a IfD19 and D20 do not alternately illuminate the possible causes include e faulty reversing switch wiring e faulty reversing switch or e faulty motor board To resolve this problem e verify that the reversing switch cable is con nected at the bulkhead bracket and that it is plugged into the J5 connector on the motor board 26 e verify reversing switches Unplug the J5 reversing switch connector Verify that when the switc
43. ed LED D11 Power must be on to check See Fic 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 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 um Disconnect power supply Table 4 DIP Switch SW2 Settings DIP Switch ON up OFF down Switch 1 Motor soft start ON Not applicable to factory default 3 phase motors Switch 2 ON for pressure OFF for pressure imbalance alarm imbalance warn factory default ing Switch 3 Standby ON Standby OFF factory default Switch 4 N A OFF 9 Install new board in reverse order Apply thermal heatsink compound to mating surfaces of board and heatsink NOTE Order Part 110009 Thermal Compound Table 5 Motor Control Board Connectors UA 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 7 Remove screws and take board
44. ff when equipment reaches temperature setpoint a Set temperature setpoints far below displayed temperature b Turn zone on If temperature rises steadily power board is failing c Verify by swapping with another power module See Replacing Temperature Control Assem bly Modules page 36 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 37 10 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 disap pears replace faulty module a For hose zone lf 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 disap pears replace faulty module 4 If E03 occurs for all zones the contactor may not be closing Verify wiring from heater control to contac tor coil a Hose zone test hose continuity
45. ftware bootloader POWER RELAY G Circuit board power input and contactor control output Table 7 Temperature Power Module Connections Connector Description H COMMUNICATION Communication to control board POWER J Power to heater 313540G Repair ti9875a ti9843a1 Right Side of Control Heater Module ti9843a4 Bottom of Power Modules FIG 9 Temperature Control Module Connections 35 Repair Test SCR Circuit 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 ambi ent hose temperature d Turn on heat zone by pressing O e Hold down D to view electrical current Hose current should ramp up to 45A If there is no hose current see E03 No zone current page 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 2 Test the SCR circuit in the off position a Make sure everything is connected including the hose b Turn main power ON c Adjust the hose heat setpoint below the ambi ent hose temperature d Turn on heat zone by pressing O e Using a voltmeter carefully measure the voltage at the hose connector You should not get a volt age reading If you do the SCR on the tempera ture control board is bad Rep
46. ge 35 and FIG 9 page 35 Heated Hose NOTE Refer to the heated hose manual 309572 for hose replacement parts Check Hose Connectors 1 Turn main power OFF Ui 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 termi nals of the connector D There should be continu ity 313540G Repair 5 If hose fails test retest at each length of hose including whip hose until failure is isolated Check FTS Cables 1 Turn main power OFF Um Disconnect power supply 2 Relieve pressure page 27 3 Disconnect FTS cable F at Reactor FIG 11 ti9878a FiG 11 Heated Hose 4 Test with ohmmeter between pins of cable connec tor Pins Result 1 to2 approximately 35 ohms per 50 ft 15 2 m of hose plus approximately 10 ohms for FTS 1to3 infinity 5 If cable fails test retest at FTS page 39 39 Repair Fluid Temperature Sensor FTS Test Removal 1 Turn main power OFF a Disconnect power supply 2 Relieve pressure page 27 3 Remove tape and protective covering from FTS 21 Fic 11 Disconnect hose cable F Test with ohmmeter between pins of cable connector fitting ISO Pins Result 1to2 approximately 10 ohms 1to3 infinity 3toFTS groundscrew Oohms 1 to FTS component A infinity
47. hes are not triggered there is conti nuity between 1150 NC and 1160 T COM and between 1150 NC and 1170 B COM Toggle reversing switches Ensure that con tinuity between 1150 NC and 1160 T COM and between 1150 NC and 1170 B COM is lost Refer to the Electrical Diagrams man ual 312064 Detailed Schematic Motor Controls 3 Phase Motor If these four conditions are not verified replace revers ing switches e if the reversing switch and wiring are not the cause and D19 and D20 will not alternately illuminate replace the motor board b IfD19 and D20 do illuminate but the direction indication lights do not the possible causes include e faulty motor board e faulty directional valve wiring or e faulty directional valve To resolve this problem e verify the motor board output voltages at the J18 directional valve connector When the reversing switch is toggled one 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 e verify continuity of each directional valve wire and verify wiring connections see Electrical Diagrams manual 312064 e if motor board and wiring are not the cause replace the directional valve NOTE For diagnostic purposes it is possible to manually override the directional valve by using a small screwdriver to dep
48. ials may become self igniting if applied too thickly Read material manufacturer s warnings and material MSDS 313540G Isocyanate Conditions 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 e Always use a sealed container with a desiccant dryer in the vent or a nitrogen atmosphere Never store ISO in an open container e Use moisture proof hoses specifically designed for ISO such as those supplied with your system e Never use reclaimed solvents which may contain moisture Always keep solvent containers closed when not in use e Never use solvent on one side if it has been contam inated from the other side e Always park pumps when you shutdown e Always lubricate threaded parts except for GC1128 GC0697 and GC2150 with Part 217374 ISO pump oil or grease when reassembling Keep Components A and B Separate Keep Components A and B Separate To prevent
49. ional 1 4 turn Refill reservoir with approved hydraulic fluid See Table 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 require ments Qil Type kaaa ne be ee ce OL lee IN Anti Wear AW Hydraulic ISO Grade insistent baat 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
50. lace the temperature control assembly 36 Replacing Temperature Control Assembly Modules Before handling assembly put on a static conductive wrist strap to protect against static discharge which can damage assembly Follow instructions provided with wrist strap 1 Turn main power OFF supply aA 2 Relieve pressure page 27 Disconnect power 3 Refer to electrical diagrams see Electrical Dia grams manual 312064 Temperature control assem bly is on left side inside cabinet 4 Remove bolts that secure transformer assembly and slide assembly to side in cabinet 5 Put on static conductive wrist strap 6 Disconnect all cables and connectors from assem bly see 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 313540G Primary Heaters Heater Element Shit 7 SANS 1 Turn main power OFF Disconnect power supply 2 Relieve pressure page 27 3 Wait for heaters to cool 4 Remove heater shroud 5 See page 60 for parts Disconnect heater element wires from heater wire connector Test with ohmme ter Total Heater Wattage Element Ohms 7 650 2550 18 21 313540G Repair 6 To remove heater element first remove thermocou ple 410 to avoid damage see step 7 page 38 7 Remove heater element
51. line reversing switch A 15 failure high cycle rate 12 E21 No component A transducer 1 Check transducer A connection at J3 on motor con trol board page 33 and clean contacts 2 Reverse A and B transducer connections If error moves to transducer B E22 replace transducer A page 12 If error does not move replace motor con trol board page 32 E22 No component B transducer 1 Check transducer B connection at J8 on motor con trol board page 33 and clean contacts 2 Reverse A and B transducer connections If error moves to transducer A E21 replace transducer B page 12 If error does not move replace motor con trol board page 32 E23 High fluid pressure 1 Relieve pressure Verify low pressure with analog gauges Turn main power OFF then ON 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 3 Ensure at least one pump is in the number 1 posi tion See Setup section of Reactor H VR Operation manual 313539 4 If error still persists reduce hydraulic pressure 313540G 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 compo nents A and B exceeds 500 psi 3 5 MPa 35 bar an E24 will occur This default value is adjustable see the operation manual
52. lt D D ND B D ON BND BND B ND O0 OX N N OB N Ref 250 251 252 253 254 255 256 258 265 271 272 273 274 275 276 278 279 280 Part Air Motor Detail Description GC2194 SCREW shdc SST 0 164 32 x 0 0750 SST GC2118 SCREW rdhd CS 0 164 32 x 0 750 zp 15X708 GUARD change over box GC2052 WASHER flat std 8 15W983 DISK switch PIN 2 75 in base fluid pump GC1137 SHAFT cylinder hydraulic 15W340 BRACKET limit switch 15X711 111856 155677 108126 248187 117832 122406 192348 100081 PLATE change over top ELBOW street ADAPTER union 90 deg FITTING tee street HOUSING rupture disc ADAPTER 9 16 18 JIC x 3 8 npt ADAPTER 1 2 20 JIC x 3 8 npt NUT head PIN clevis 1 2 in BUSHING pipe Available with pin and bearing kit 257794 r 256886 313540 8 Qty 10 Oo ND ND BH HD N ON 313540G Parts Hydraulic Directional Valve Assembly 308 Proporione Assembly Ref 304 305 306 307 308 309 313 314 321 322 326 327 345 347 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 O lt Maas ARA
53. mbol 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 ELECTRIC SHOCK HAZARD AN This equipment must be grounded Improper grounding setup or usage of the system can cause electric shock e Turn off and disconnect power cord before servicing equipment Use only grounded electrical outlets Use only 3 wire extension cords Ensure ground prongs are intact on power and extension cords Do not expose to rain Store indoors D TOXIC FLUID OR FUMES HAZARD AA Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swal lowed e Read MSDS s to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines e Always wear impervious gloves when spraying or cleaning equipment e If this equipment is used with isocyanate material see additional information on isocyanates in Isocy anate Conditions Section of this manual ai PERSONAL PROTECTIVE EQUIPMENT 2 You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you from serious injury including eye injury inhalation of toxic fumes burns and hearing loss This equipment includes but is not limited to e Protective eyewear e Clothing and respirator as rec
54. n 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
55. nect Electrical Cord in Reactor H VR Operation manual 313539 Check dipstick to ensure that hydrau lic 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 fil ter Screeching noise is characteristic of cavitation and is normal at initial startup for a maximum of 30 sec onds If noise continues longer than 30 sec onds press motor O key to shut off the motor Check that the inlet fit tings are tight and that the pump has not lost its prime 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 clock wise from pully end Drive belt loose or broken Check drive belt condition Replace if broken 22 313540G Proportioning System Troubleshooting WA Z 2 Turn main power OFF Ui 3 Allow eq
56. oard 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 e 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 lf error no longer occurs the board or module was at fault Switch connections back to ensure connec tor was not poorly connected 15 Troubleshooting Troubleshooting Reactor Electronics BAe lt Before performing any troubleshooting procedures 1 Relieve pressure page 27 2 Turn main power OFF iam 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 con trols are properly set and wiring is correct before assum ing there is a problem PROBLEM CAUSE SOLUTION Both sides of display do not illuminate Plug in power cord No power Turn disconnect ON Low voltage Ensure input voltage is within specifi cations page 42 Loose wire Check connections page 42 Display disconnected Check
57. off heatsink 8 Set DIP switch SW2 on new board See TABLE 4 for factory settings See FIG 6 for location on board 32 Connector Pin Description J1 n a Main power J3 n a Transducer A J4 n a Not used J7 n a Not used J8 n a Transducer B J9 n a Motor thermostat NC J10 n a Not used J12 n a Data reporting J13 n a To display board J14 n a Motor power J18 Directional valve A Directional valve A Directional valve B GND 1 2 3 4 Directional valve B 5 1 J5 Pumpline reversing switch 1150 NC 2 Pumpline reversing switch 1160 T COM 3 Pumpline reversing switch 1170 B COM 313540G Repair Motor Control ON 123 4 ti3178c 4 SW2 A Apply 110009 thermal heatsink compound to mating surfaces ti7724a Fic 6 Motor Control Board 313540G 33 Repair Transducers 1 Turn main power OFF Ui Disconnect power supply UA 2 Relieve pressure page 27 3 Refer to electrical diagrams Motor control board is on right side inside cabinet 4 Disconnect transducer cables at board see FIG 6 page 33 Reverse A and B connections and check if 706 A Side 701 FIG 7 Transducers diagnostic code follows see E21 No component A transducer page 12 5 If transducer fails test thread cable through top of cabinet Note path as cable must be replaced in same way 6 Ins
58. ommended by the fluid and solvent manufacturer e Gloves e Hearing protection SKIN INJECTION HAZARD High pressure fluid from gun hose leaks or ruptured components will pierce skin This may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment a 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 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 e Use equipment only in well ventilated area e Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc e 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 o
59. peration immediately Do not use equipment until you identify and correct the problem e 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 e Do not operate the unit when fatigued or under the influence of drugs or alcohol e Do not exceed the maximum working pressure or temperature rating of the lowest rated system com ponent 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 e Check equipment daily Repair or replace worn or damaged parts immediately with genuine manu facturer s replacement parts only Do not alter or modify equipment 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
60. re control alarm Press A or B zone keys Check temperature display for diag nostic code page 9 Signal failure from thermocouple See E04 Fluid Temperature Sen sor FTS or thermocouple discon nected page 11 Control of primary heat is abnormal high temperature overshoots or E01 error occurs intermittently Dirty thermocouple connections Examine connection of thermocou ples 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 Failed heater element Loosen ferrule nut N push in ther mocouple 410 so tip T contacts heater element 407 Holding ther mocouple tip T against heater ele ment tighten ferrule nut N 1 4 turn past tight See page 38 for illustra tion See Primary Heaters page 18 Signal failure from thermocouple See E04 Fluid Temperature Sen sor FTS or thermocouple discon nected page 11 Thermocouple wired incorrectly See E04 Fluid Temperature Sen sor FTS or thermocouple discon nected page 11 Power up zones one at a time and verify that tempera ture for each zone rises 18 313540G Hose Heat System WA Z Before performing any troubleshooting procedures 1 Relieve pressure page 27 Problems Troubleshooting 2 Turn main power OFF 3
61. ress the button in the cen ter of either directional valve end cap 313540G Repair WA 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 elec trician 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 Ae 1 Relieve pressure in gun and perform gun shutdown procedure See gun manual 2 Close gun fluid manifold valves A and B ti2421a 3 Shut off feed pumps and agitator if used 313540G Repair Turn PRESSURE RELIEF SPRAY valves SA SB A to PRESSURE RELIEF CIRCULATION Oy Route fluid to waste containers or supply tanks Ensure gauges drop to 0 ti2409a It Disconnect gun air line and remove gun fluid mani fold ti2554a 27 Repair Flushing Flush equipment only in a well ventilated area Do not spray flammable fluids Do not turn on heaters while flushing with flammable solvents Proportioning Pumps To avoid injury and damage to pump arms and ratio adjustment screws relieve all pressure and shut off all power before repairing proportioning pumps e Flush out old fluid with new fluid or flush out old fluid with a compatible solvent before introdu
62. rtup FTS disconnected or not installed Verify proper installation of FTS see H VR Operation manual 313539 or adjust FTS to desired current setting Display does not respond properly to button pushes 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 disconnected or broken Connect cable page 42 or replace Broken display button Replace page 42 Red stop button does not work Broken button fused contact Replace page 42 Loose wire Check connections page 42 Fan not working Blown fuse Verify with ohmmeter replace if nec essary page 42 Loose wire Check fan wire Defective fan Replace page 42 313540G 17 Troubleshooting Primary Heaters A and B 77 mt anO Before performing any troubleshooting procedures 1 Relieve pressure page 27 2 Turn main power OFF HU 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 con trols are properly set and wiring is correct before assum ing there is a problem PROBLEM CAUSE SOLUTION Primary heater s does not heat Heat turned off Temperatu
63. s At 190 F 87 C the switch closes again e 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 e Overtemperature switch A or B 408 fails in the open position e The temperature control board fails to turn off any heat zone e Zone power wires or thermocouples are switched from one zone to another e Failed heater element where thermocouple is installed e Loose wire 313540G to clear Code Code Name Alarm Corrective Zone Action page 01 High fluid temperature Individual 9 02 High zone current Individual 10 03 No zone current with Individual 10 hose heater on 04 FTS not connected Individual 11 05 Board overtemperature Individual 11 06 Communication cable Individual 11 unplugged from module 99 Loss of communication A 15 NOTE For hose zone only if FTS is disconnected at startup display will show hose current 0A Checks aA Troubleshooting this equipment requires access to parts that may cause electric shock or other serious injury if work is not performed properly Have a quali fied electrician perform all electrical troubleshooting Be sure to shut off all power to the equipment and relieve all pressure see Pressure Relief Procedure page 27 before repairing Check which zone is displaying the E01 error 1 Check that conne
64. t 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 ther mocouples 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 con trol board 313540G 19 Troubleshooting PROBLEM CAUSE SOLUTION Erratic hose temperature Faulty thermocouple connections Verify that all FTS connections are snug and that pins of connectors are clean Examine connection of ther mocouples 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 Hose does not heat 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 diag nostic code page 39 Hoses near Reactor are warm but hoses downstream are cold Shorted connection or failed hose heating element With hose heat on and temperature setpoint above displayed hose zone
65. tall 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 8 Route cable into cabinet and thread into bundle as before 9 Connect transducer cable at board see FIG 6 page 33 706 B Side 720 ti9885a Electric Fan 1 Turn main power OFF ri Disconnect power supply UA 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 5 Remove fan 6 Install fan in reverse order ti9884a 1 Fic 8 Fan Fuses 313540G Temperature Control Module Table 6 Temperature Control Module Connections Connector Description DATA A Data reporting PIN 12 HOSE T C P FTS purple 11 HOSE T C R FTS red 10 HOSE T C S FTS silver unshielded bare wire HEATER T C B Y Thermocouple yellow SENSOR B HEATER T C B R Thermocouple red Not used HEATER T C A Y Thermocouple yellow HEATER T C A R Thermocouple red OVERTEMPERATURE B Overtemperature switch B OVERTEMPERATURE A Overtemperature switch A DISPLAY C Display COMMUNICATION D Communication to power boards PROGRAM E Software programming BOOT F So
66. uipment to cool Before performing any troubleshooting procedures 1 Relieve pressure page 27 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 PROBLEM CAUSE SOLUTION Proportioning pump does not hold pressure when stalled k Observe gauges to determine which pump is losing pressure Pump piston or intake valve leaking 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 man ual 313485 Material imbalance See Pres sure Material Imbalance page 25 Restriction at the gun Clean the gun see Pumps Do Not Reverse Direction page 26 Inadequate flow from pump cavita Increase fluid supply to proportioning tion pump e Use 2 1 supply pump e Use minimum 3 4 in 19 mm ID supply hose as short as practical Fluid is too thick Consult your mate rial supplier for the recommended fluid temperature to maintain a vis cosity of 250 to 1500 centipoise 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
67. uit SWITCH membrane SCREW GASKET COVER hp a A Ref 505 506 507 508 510 511 512 Part 15B291 246287 117499 117523 15B386 195853 501b Description PLATE HARNESS wire red stop button HANDLE NUT cap 10 24 SCREW machine pan hd M5 x 0 8 16 mm CABLE display SCREW machine M2 5 x 6 Parts ti2574a ti3172a Qty DON i 61 Parts Temperature Control 605 ToB Heater 606 Module ToA Heater Module 601 To Hose Heater Module TI9843a 603 Ref Part Description Qty 601 247772 PANEL module mounting 1 602 247827 HOUSING control module 1 603 247828 HOUSING heater module 3 604 115942 NUT hex 4 605 247801 CABLE communication 1 606 247825 KIT cover connector with screws 1 62 313540G Fluid Manifold A Torque to 355 395 in Ib 40 1 44 6 Nem A Apply sealant 113500 to threads A Valve must be closed with handle position as shown on drawing Apply PTFE tape or thread sealant to tapered threads A708 gt O lt _ 706 A Ba 718 A Parts 705 TI9839b as Ref Part Description Qty Her ek Dep Qty 714 121312 ELBOW 90 degrees 2 701 247837 MANIFOLD fluid 1 715 100840 ELBOW street 1 4 npsm x 1 4npt 2 702t 247824 VALVE drain cartridge 2 2 702at 158674 O RING 1 716 111457 O RING PTFE 717 189285 LABEL caution 1 ODA SEAL seal YANG 718t 150829 SPRING compression 2 703 102814 G
68. yethylene 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 retur

Graco 313540G User's Manual

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