Graco 312066ZAF, Reactor, Electric Proportioners, Repair-Parts Owner's Manual

zone on and check for error (see page 40). If error

NOTE : Disconnect whip hose.

3. Disconnect hose connector (D) at Reactor.

4. Using an ohmmeter, check between the two terminals of the connector (D). There should be no continuity.

5. Exchange zone module with another one. Turn zone on and check for error. If error disappears, replace faulty module.

For hose zone : If error still occurs, perform

Transformer Primary Check

and Transformer

Secondary Check

starting on page 47.

NOTE : When there is a a high current error, the LED on that zone’s module will turn red while the error is displayed.

312066ZAF 11

Temperature Control Diagnostic Codes

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

disappears, replace faulty module.

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

Hose zone:

test hose continuity, page 45.

b. Perform Transformer Primary Check

and

Transformer Secondary Check , starting on

page 47.

NOTE : When a no current error occurs, the LED on the specific zone’s module turns red when the error is displayed.

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

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

Operation manual 312062.

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 blocking cooling holes in bottom of electrical cabinet.

4. Clean heatsink fins behind heater control modules.

5. Ambient temperature may be too high. Allow

Reactor to cool by moving to a cooler location.

E04: Fluid Temperature Sensor

(FTS) or thermocouple disconnected

1. Check temperature sensor connections to long green connector (B) on temperature control module,

page 39. Unplug and re-plug sensor wires.

2. Test fluid temperature sensor continuity with

ohmmeter, 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.

E06: Communication cable unplugged

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

2. Replace communication cable if problem persists.

TI10964a

12 312066ZAF

Motor Control Diagnostic Codes

Motor Control Diagnostic Codes

Motor control diagnostic codes E21 through E29 appear on pressure display.

There are two types of motor control codes: alarms and warnings. Alarms take priority over warnings.

Warnings

Reactor will continue to run. Press to clear. A warning will not recur for a predetermined amount of time (varies for different warnings), or until main power

Alarms

is turned OFF then ON .

Alarms turn off Reactor. Turn main power OFF then ON to clear.

NOTE : Alarms can also be cleared, except for code 23, by pressing .

Code Code Name Alarm (A) or

Warning

(W)

21 No transducer

(component A)

22 No transducer

(component B)

23 High fluid pressure

24 Pressure imbalance A/W (to select, see

page 36)

25 High line voltage A

26 Low line voltage

27 High motor temperature

High current

Brush wear

30 Momentary loss of communication

31 Motor control failure A

32 Motor control overtemperature

99 Loss of communication -

Corrective

Action page

312066ZAF 13

Motor Control Diagnostic Codes

E21: No component A transducer

1. Check transducer A connection at J3 on motor

control board, page 36, and clean contacts.

2. Reverse A and B transducer connections. If error moves to transducer B (E22), replace transducer A,

page 38. If error does not move, replace motor

control board, page 36.

E22: No component B transducer

1. Check transducer B connection at J8 on motor

control board, page 37, and clean contacts.

2. Reverse A and B transducer connections. If error moves to transducer A (E21), replace transducer B,

page 38. If error does not move, replace motor

control board, page 36.

E23: High fluid pressure

1. Perform the

for E30 and E-XP2, pins 7-10, page 36.

Verify low pressure with analog gauges. Turn main power OFF then ON persists, do checks below.

. If error

1. Check the jumpers and the wiring. Check jumper on motor control board J10 for E20 and E-XP1, or J7

2. Remove, clean and re-install the pressure transducer leads

If the jumpers and the wiring are in good working condition and you still have the error, then you will need to replace the “A” and “B” pressure transducers.

3. To determine if it’s the “A” or the “B” transducer, you will need a known good Reactor pressure transducer to use as a “test” transducer. The test is done without removing the existing pressure transducers from the fluid manifold.

a. Unplug the “A” transducer from the Motor

control board socket (page 38) and replace with

“test” transducer.

b. Turn on the Reactor master power.

• If the error is gone, turn off the Reactor main power, remove test transducer, and replace “A” transducer.

• If the error persists, unplug the “test” transducer from the “A” socket, and reinstall the “A” pressure transducer back into the “A” socket.

Repeat this test procedure on the “B” side.

4. If the error persists and no root cause is found through the above testing, replace the motor control

board, page 36.

E24: Pressure Imbalance

NOTE : If the pressure difference between components

A and B exceeds 500 psi (3.5 MPa, 35 bar), an E24 will occur. This default value is adjustable; see the operation manual.

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 36.

Fast E24 Errors

Fast E24 errors occur:

• Within 10 seconds of turning the pumps on.

• As soon as you trigger the gun.

Causes of Fast E24 Errors

• one side of the gun is plugged.

• a pressure transducer has failed.

• damaged pump seals or check valve.

• no feed pressure or empty material drum

• plugged heater.

• plugged hose.

• plugged manifold.

• one PRESSURE RELIEF/SPRAY valve is leaking or is set to PRESSURE RELIEF/CIRCULATION

14 312066ZAF

Motor Control Diagnostic Codes

Checks for Fast E24 Errors

NOTE: If a fast E24 error occurs, first check the readings of the analog gauges.

If gauge pressures are very close:

1. Clear the error and run the unit.

2. Check plug J10 (E20/E-XP1) or J7 (E30/E-XP2) or the jumpers 7 to 10 on the motor control board.

3. Check pressure transducer performance:

NOTE: The digital display on a Reactor always shows the higher of the two pressures. As soon as the higher analog pressure drops below the lower analog pressure the digital display will switch to the new highest reading.

To determine which transducer is performing poorly:

1. For testing purposes only, find the dip switches

labeled SW2 on the motor control board, page 37.

Set dips witch 3 to OFF. This will allow the Reactor to run with a pressure imbalance alarm.

2. Run the unit to build up some pressure (1000 –

1200 psi). Shut down the unit, clear the alarm and power back up. Do not depressurize the unit.

3. Check the analog gauges to see which pressure is higher. Check if the display pressure matches, indicating that the motor control board “sees” that transducer. If not, the motor control board does not

“see” that transducer. Check the wire connections and or replace the transducer.

4. With the pump zone off, use the pressure relief valves to slowly relieve the “high” side pressure, while watching the digital display and the analog gauges. Once the higher analog gauge drops below the lower analog pressure the motor control board should start reading the “new” high side pressure

(because it is now the higher of the two). Continue dropping the original “high” side pressure - the digital display should stop dropping. Repeat the process to check the other pressure transducer.

To determine if the pressure transducer has failed or if the socket on the pressure control board has gone bad:

1. Swap the transducer plug-ins on the motor control board. (J3 and J8 for the E-20 and E-XP1. J3 and

J5 for the E30 and E-XP1).

2. Repeat the transducer performance test above.

3. If the problem stays with the same side as before, then the pressure transducer is bad.

4. If the problem switches to the other transducer, then the problem is in the motor control boards socket.

If the gauge readings are not equal:

1. Clear the error and balance the pressures using the dump valves.

2. If you cannot get the pressures to balance:

• Check for pump failure.

• Check for adequate material.

• Using the feed pump to push fluid out through the gun manifold, check for a plugged fluid path.

• Run the unit.

• Check and clean the gun inlet screens.

• Check and clean the mix chamber “A” and “B” impingement ports a well as the center port.

NOTE : Some mix chambers have counter bored holes, and require two drill sizes to clean impingement ports completely.

Slow E24 Errors

Slow E24 errors occur:

• When spraying, gradual pressure imbalance and eventual E24.

Causes of Slow E24 Errors

• One side of the Gun is partially blocked.

• The “A” or the “B” pump on the Reactor has failed.

• The “A” or the “B” feed pump has failed.

• The “A” or the “B” feed pump pressure is set too high.

• The “A” or the “B” inlet screen is plugged.

• The hose is not heating properly.

• Kinked supply hose.

• Bottom of the drum is damaged causing a blockage to the inlet of the feed pump.

• The drum is not vented properly.

312066ZAF 15

Motor Control Diagnostic Codes

E25: High line voltage

Supply voltage is too high. Check Reactor voltage

requirements, page 75.

E26: Low line voltage

Supply voltage is too low. Check Reactor voltage

requirements, page 75.

E27: High Motor Temperature

1. Motor temperature is too high. Reduce pressure, gun tip size, or move Reactor to a cooler location.

Allow one hour for cooling.

2. Check fan operation.

3. Ensure there is no obstruction around the fan area that would cause lack of airflow; ensure the motor/fan shroud is installed.

4. Ensure the unit is being operated with the front cover on.

5. Ensure the brush wear/over temp switch wire assembly is plugged into J7 (E-20/E-XP1) or J6

(E-30/E-XP2) of the motor control board.

6. With the main power off, unplug the wire harness from J7 (E-20/E-XP1) or J6 (E-30/E-XP2 ) on the motor control board and install a jumper wire on pins 1 and 2. Turn the main power back on.

If E27 is gone:

If the E27 error is gone and the motor is truly not overheated, then the problem can be in the motor/motor wire harness assembly. Measure the resistance between the two yellow wires that go to pins 1 and 2 of the motor connector. If there is an open connection, the thermal overload switch is open or there is a broken wire inside the motor, or a broken wire in the motor harness.

If the E27 error code is still there, double check if pins 1 and 2 are jumpered properly. If jumpered properly, then it would appear that the problem is with in the motor control board.

E28: High current in motor

Check the motor control board:

1. Turn the master power off.

2. Disconnect socket J4 (E-20/E-XP1) J1

(E-30/E-XP2) on the motor control board.

3. Turn the master power back on.

4. If the E28 error did not go away then there is a problem with the motor control board. Replace

board, page 36.

Check the motor:

1. Check to see if the motor rotates freely.

2. Check to see if the brushes are damaged.

3. Check that the voltage going to the motor is good.

4. Check the three wire (yellow, yellow, orange) motor connector to the motor board. A gentle tug on each wire individually at the connector should identify the loose wire. If a wire pulls out, bend the locking tab on the crimp end, insert the wire until it seats and repeat gentle tug.

5. If the above does not resolve the problem, replace

the motor, page 35.

E29: Brush Wear

CAUTION

Prolonged operation of motor after a brush wear warning may result in failure of motor and motor control board.

1. Check for normal brush wear, which causes the brush sensor to come in contact with the motor

commutator. Replace the brushes, page 32.

2. Check spade plug. The spade plug inside the motor housing may be twisted and contacting the commutator side of the brush sensor assembly, causing a false alarm. Follow the orange wire coming from J7 (E-20/E-XP1), or J6 (E-30/E-XP2), up to the spade connector on the motor. Using a flashlight, ensure the spade plug assembly is not making contact with the metal housing of the brush assembly.

16 312066ZAF

Motor Control Diagnostic Codes

3. Check wiring. The orange brush sensor wire coming out of the brush may be routed online with the commutator wiring (thick red wire), causing a false alarm. Reroute the orange wire coming out of the brush, away from the commutator wiring.

4. Check motor control board.

• Remove the plug in J7 (E-20/E-XP1), or J6

(E-30/E-XP2). (This will cause an E27 alarm).

• To remove the E27 alarm, use a jumper wire on the motor control board, across the two pins that the two yellow wires plug into. Then turn the unit on.

• The E27 as well as the E29 alarm should be gone. If the E27 alarm is not gone double-check your jumper.

• If the jumper is installed correctly and the E29 alarm

is still there, replace the motor control board, page

Brush Removal , page 32). Rotate the motor, inspecting the

E31: Motor Control Failure

(E-30 and E-XP2 only)

The E31 error code represents a motor drive error. This indicates that the 24G881 motor control board has malfunctioned and needs to be replaced. A motor control board failure may also be indicated by the motor starting up immediately upon the application of power to the system, without pressing . This is an indication that the output drivers of the motor control have shorted out and are delivering full power to the motor at all times.

The cause of the failure may be one of the following conditions: motor failure, capacitor failure, shorted or frayed wiring, or inadequate power supply. Perform the following procedure before replacing the motor control board.

1. Turn main power OFF supply.

Wait 5 minutes for stored voltage to discharge (E-30 and E-XP2 models only).

2. Perform the

. Disconnect power

Pressure Relief Procedure

3. Perform the following inspections.

, page 25.

Motor failure : Inspect the motor commutator by removing the top brush (see

whole commutator for burns, pocking, or shorts between poles. Continue rotating the motor for a complete pump cycle, up and down, to ensure that there is no mechanical interference or restriction in the pump lower or gear drive system.

Capacitor failure : Inspect and test the motor start capacitor, following the

Capacitor Test instructions on page 34.

Shorted or frayed wiring : Inspect all wiring connected to the motor control board and the motor, for shorts or frayed insulation. Replace any compromised wires with wire of the same gauge, color. and temperature rating.

Inadequate power supply : Verify that the power source is of the correct voltage and current rating for the system, and that all phases are properly connected. Ensure that the power does not dip or surge during operation.

Prior to shutting down the generator, ensure that the motor has stopped and the main disconnect is opened. If the generator is stopped during operation, even due to running out of fuel, the drop in supply voltage may cause a motor drive failure.

312066ZAF 17

Communication Diagnostic Codes

E32: Motor Control

Overtemperature

The E32 error code indicates a high temperature condition within the motor control board (701). This could be caused by an abnormally high ambient temperature in the work location, blockage of cooling vents in the cabinet, or the failure of the cooling fan inside the cabinet.

1. Perform the

Turn circuit breakers ON, page 34.

Verify low pressure with analog gauges.

2. Turn main power OFF then ON

If error still remains, identify cause of the overtemperature condition and remedy.

Communication Diagnostic Codes

E30: Momentary loss of communication

Communications between the display and the motor control board or the temperature control board 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 reconnected, the display can show the E30 for a short time (no more than about two seconds). It should not be possible for E30 to be shown continuously, unless there is a loose connection causing the display and the board to continuously lose and regain communication.

Check all wiring between the display and the corresponding control board.

E99: Loss of communication

Communications between the display and the motor control board or the temperature control board has been lost. When communication is lost, the corresponding display will show E99.

1. Check all wiring between the display and the corresponding control board. Pay close attention to the wire crimping on plug J13 for each board.

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 board (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.

18 312066ZAF

Troubleshooting

Troubleshooting

PROBLEM

Reactor does not operate.

No power.

CAUSE SOLUTION

Plug in power cord.

Turn main power ON .

Motor does not operate.

Fan not working.

Pump output low.

Red stop button circuit open.

Loose connections.

Circuit breaker tripped.

Check button connections. See page

48 and electrical diagrams.

Check connections at motor control board.

Reset breaker (CB5), page 34.

Check 230Vac at output of breaker.

Worn brushes.

Check both sides. Length must be

0.7 in. (17 mm) minimum. To replace,

page 32.

Broken or misaligned brush springs. Realign or replace, page 32.

Brushes or springs binding in brush holder.

Shorted armature.

Check motor commutator for burn spots or other damage.

Damaged motor control board.

Blown fuse.

Loose wire.

Defective fan.

Obstructed fluid hose or gun; fluid hose ID too small.

Worn piston valve or intake valve in displacement pump.

Pressure setpoint too high.

Clean brush holder and align brush leads for free movement.

Replace motor, page 35.

Remove motor. Have motor shop resurface commutator, if possible.

Replace board. See page 36.

Replace, page 38.

Check.

Replace, page 38.

Open, clear; use hose with larger ID.

See pump manual.

Fluid leak in pump packing nut area. Worn throat seals.

No pressure on one side.

Fluid leaking from heater inlet rupture disk (314).

Reduce setpoint and output will increase.

Replace. See pump manual.

Check if heater (2) and PRESSURE

RELIEF/SPRAY valve (SA or SB) are plugged. Clear. Replace rupture disk

(314) with a new one; do not replace with a pipe plug.

312066ZAF 19

Troubleshooting

Reactor Electronics

Before performing any troubleshooting procedures:

1. Perform the

Check connections, page 48.

PROBLEM

Both sides of display do not illuminate.

No power.

CAUSE

2. Turn main power OFF .

3. Allow equipment to cool.

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

SOLUTION

Plug in power cord.

Turn disconnect ON .

Temperature display does not illuminate.

Pressure display does not illuminate.

Erratic display; display turns on and off.

Hose display reads OA at startup.

Low voltage.

Loose wire.

Display disconnected.

Defective circuit board.

Display disconnected.

Ensure input voltage is within

specifications, page 48.

Display disconnected.

Display cable damaged or corroded. Clean connections; replace cable if is damaged.

Swap display connection to motor control board with connection to heater control board. If temperature display illuminates, heater control board is causing problem. Otherwise, display cable or display is failing.

Display cable damaged or corroded. Clean connections; replace cable if is damaged.

Defective circuit board.

Swap display connection to motor control board with connection to heater control board. If pressure display illuminates, motor control board is causing problem. Otherwise, display cable or display is failing.

Low voltage.

Poor display connection.

Ensure input voltage is within

specifications, page 48.

Replace damaged cable.

Display cable damaged or corroded. Clean connections; replace cable if is damaged.

Display cable not grounded.

Ground cable, page 48.

Display extension cable too long.

FTS disconnected or not installed.

Must not exceed 100 ft (30.5 m)

Verify proper installation of FTS (see

Operation manual 312065), or adjust

FTS to desired current setting.

20 312066ZAF

Troubleshooting

PROBLEM CAUSE SOLUTION

Display does not respond properly to button pushes.

Red stop button does not work.

Fan not working.

Poor display connection.

Connect cable (page 48) or replace.

Replace damaged cable.

Display cable damaged or corroded. Clean connections; replace cable if is damaged.

Ribbon cable on display circuit board disconnected or broken.

Broken display button.

Broken button (fused contact).

Loose wire.

Blown fuse.

Replace, page 48.

Check connections, page 48.

Loose wire.

Defective fan.

Verify with ohmmeter; replace if

necessary (page 48).

Check fan wire.

Replace, page 48.

312066ZAF 21

Troubleshooting

Primary Heaters (A and B)

Before performing any troubleshooting procedures:

1. Perform the

diagnostic code, page 10.

2. Turn main power OFF .

3. Allow equipment to cool.

PROBLEM

Primary heater(s) does not heat.

Control of primary heat is abnormal; high temperature overshoots or E01 error occurs intermittently.

CAUSE

Heat turned off.

SOLUTION

Temperature control alarm.

Signal failure from thermocouple.

Dirty thermocouple connections.

Press keys.

zone

Check temperature display for

See

E04: Fluid Temperature

Sensor (FTS) or thermocouple disconnected , page 12.

Examine connection of thermocouples to long green plug on heater control board. Unplug and re-plug thermocouple wires, cleaning off any debris. Unplug and re-plug long green connector.

Thermocouple not contacting heater element.

Failed heater element.

Signal failure from thermocouple.

Thermocouple wired incorrectly.

Loosen ferrule nut (N), push in thermocouple (310) so tip (T) contacts heater element (307).

Holding themocouple tip (T) against heater element, tighten ferrule nut

(N) 1/4 turn past tight. See page 43

for illustration.

See Primary Heaters, page 22.

See

E04: Fluid Temperature

Sensor (FTS) or thermocouple disconnected , page 12.

See

E04: Fluid Temperature

Sensor (FTS) or thermocouple disconnected , page 12. Power up

zones one at a time and verify that temperature for each zone rises.

22 312066ZAF

Troubleshooting

Hose Heat System

Before performing any troubleshooting procedures:

1. Perform the Pressure Relief Procedure , page 25.

3. Allow equipment to cool.

Problems

2. Turn main power OFF .

PROBLEM

Hose heats but heats slower than usual or it does not reach temperature.

Hose does not maintain temperature while spraying.

Hose temperature exceeds setpoint.

CAUSE SOLUTION

Ambient temperature is too cold.

Use auxiliary hose heat system.

FTS failed or not installed correctly.

Check FTS, page 12.

Low supply voltage.

A and B setpoints too low.

Ambient temperature is too cold.

Flow too high.

Hose was not fully preheated.

Low supply voltage.

Verify line voltage. Low line voltage significantly reduces power available to hose heat system, affecting longer hose lengths.

Increase A and B setpoints. Hose is designed to maintain temperature, not to increase it.

Increase A and B setpoints to increase fluid temperature and keep it steady.

Use smaller mix chamber. Decrease pressure.

Wait for hose to heat to correct temperature before spraying.

Verify line voltage. Low line voltage significantly reduces power available to hose heat system, affecting longer hose lengths.

A and/or B heaters are overheating material.

Faulty thermocouple connections.

Check primary heaters for either a thermocouple problem or a failed element

attached to thermocouple, page 12.

Verify that all FTS connections are snug and that pins of connectors are clean.

Examine connection of thermocouples to long green plug on heater control board.

Unplug and re-plug thermocouple wires, cleaning off any debris. Unplug and re-plug long green connector on heater control board.

Missing/damaged insulation around

FTS, causing the hose heat to be ON constantly.

Ensure hose bundle has adequate insulation evenly covering the entire length and connection joints.

312066ZAF 23

Troubleshooting

PROBLEM

Erratic hose temperature.

Hose does not heat.

Hoses near Reactor are warm, but hoses downstream are cold.

No hose heat.

CAUSE

Faulty thermocouple connections.

FTS not installed correctly.

SOLUTION

Verify that all FTS connections are snug and that pins of connectors are clean.

Examine connection of thermocouples to long green plug on heater control board.

Unplug and re-plug thermocouple wires, cleaning off any debris. Unplug and re-plug long green connector.

FTS should be installed close to end of hose in same environment as gun. Verify

FTS installation, page 46.

Missing/damaged insulation around

FTS, causing the hose heat to be ON constantly.

Ensure hose bundle has adequate insulation evenly covering the entire length and connection joints.

Check FTS, page 46.

FTS failed or is not contacting correctly.

FTS not installed correctly.

Temperature control alarm.

FTS should be installed close to end of hose in same environment as gun. Verify

FTS installation, page 46.

Check temperature display or diagnostic

code, page 46.

Shorted connection or failed hose heating element.

With hose heat on and temperature setpoint above displayed hose zone temperature, verify voltage between connectors at each section of hose.

Voltage should drop incrementally for each section of hose further from Reactor.

Use safety precautions when hose heat is turned on.

Loose hose electrical connections.

Check connections. Repair as necessary.

Circuit breakers tripped.

Reset breakers (CB1 or CB2), page 34.

Hose zone not turned on.

Press zone key.

Low hose heat.

A and B temperature setpoints too low.

Check. Increase if necessary.

Failed temperature control board.

A and B temperature setpoints too low.

Open cabinet. Check if board LED is blinking. If not, check power wiring connections to ensure board has power. If board has power and LED is not blinking,

replace board, page 39.

Increase A and B setpoints. Hose designed to maintain temperature, not increase temperature.

Hose temperature setpoint too low.

Check. Increase if necessary to maintain heat.

Flow too high.

Use smaller mix chamber. Decrease pressure.

Low current; FTS not installed.

Hose heat zone not turned on long enough.

Install FTS, see operation manual.

Allow hose to heat up, or preheat fluid.

Loose hose electrical connections.

Check connections. Repair as necessary.

24 312066ZAF

Repair

Pressure Relief Procedure

Repair

Repairing this equipment requires access to parts that may cause electric shock or other serious injury if work is not performed properly. Have a qualified electrician connect power and ground to main power switch terminals, see operation manual. Be sure to shut off all power to the equipment before repairing.

Before Beginning Repair

1. Flush if necessary; see Flushing , page 26.

2. Park component A pump.

1. Relieve pressure in gun and perform gun shutdown procedure. See your gun manual.

2. Engage gun piston safety lock.

3. Close gun fluid manifold valves A and B.

ti2409a a. Press .

b. Trigger gun until pump A stops. After fluid pressure drops below 700 psi (7.9 MPa, 79 bar), motor will run until component A pump is at bottom of its stroke, then shut off.

c. Check ISO reservoir for component A pump. Fill wet cup on component B pump. Refer to your

Reactor system manual.

4. Shut off feed pumps and agitator, if used.

5. Turn PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION .

Route fluid to waste containers or supply tanks.

Ensure gauges drop to 0.

3. Turn main power OFF .

4. Perform the Pressure Relief Procedure .

6. Disconnect gun air line and remove gun fluid manifold.

312066ZAF 25

Repair

Flushing Pump Removal

Flush equipment only in a well-ventilated area. Do not spray flammable fluids. Do not turn on heaters while flushing with flammable solvents.

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.

• Flush out old fluid with new fluid, or flush out old fluid with a compatible solvent before introducing new fluid.

• Use the lowest possible pressure when flushing.

• All fluid components are compatible with common solvents. Use only moisture-free solvents.

• To flush feed hoses, pumps, and heaters separately from heated hoses, set PRESSURE

RELIEF/SPRAY valves (SA, SB) to PRESSURE

NOTE : See your displacement pump manual for repair instructions.

1. Shut off

, and

2. Flush pump.

3. If pumps are not parked, press until pumps stop.

heat zones.

. Trigger gun

RELIEF/CIRCULATION lines (N).

. Flush through bleed

4. Turn main power off supply.

. Disconnect power

5. Shut off both feed pumps. Close both fluid inlet ball valves (B).

TI10954a

• To flush entire system, circulate through gun fluid manifold (with manifold removed from gun).

• To prevent moisture from reacting with isocyanate, always leave the system dry or filled with a moisture-free plasticizer or oil. Do not use water.

ti4147a

6. Turn both PRESSURE RELIEF/SPRAY valves (SA,

SB) to PRESSURE RELIEF. Route fluid to waste containers or supply tanks. Ensure gauges drop to 0.

WLD

NOTE : Use drop cloth or rags to protect Reactor and surrounding areas from spills

312066ZAF

Repair

NOTE : Steps 7-9 apply to pump A. To disconnect pump

B, go to steps 10 and 11.

7. Disconnect fittings at fluid inlet (C) and outlet (D, out of view). Also disconnect steel outlet tube from heater inlet.

8. Disconnect tubes (T). Remove tube fittings (U) from wet-cup.

9. Loosen locknut (G) by hitting firmly with a non-sparking hammer. Unscrew pump far enough to separate and push up finger guard (P), to expose rod retaining pin. Push retaining wire clip up. Push pin out. Continue unscrewing pump.

NOTE : Steps 10 and 11 apply to pump B.

10. Disconnect fluid inlet (C) and outlet (D). Also disconnect steel outlet tube from heater inlet.

11. Push retaining wire clip (E) up. Push pin (F) out.

Loosen locknut (G) by hitting firmly with a non-sparking hammer. Unscrew pump.

E F

TI3765a-2

TI3765a-1

312066ZAF 27

Repair

Pump Installation

Install Pump B

NOTE : Steps 1-5 supply to pump B. To reconnect pump

A, proceed to step 6.

1. Ensure locknut (G) is screwed on pump with flat side up. Screw pump into bearing housing (M) until pin holes align. Push pin (F) in. Pull retaining wire clip (E) down.

2. Continue screwing pump into housing until fluid outlet (D) is aligned with steel tube and top threads are +/- 1/16 in. (2 mm) of bearing face (N).

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

4. Reconnect fluid inlet (C) and outlet (D).

5. To install pump A, see

Install Pump A , .

6. If only one pump is installed, purge air and prime the system. See Reactor operation manual.

1 2

1 Flat side faces up.

Lubricate threads with ISO oil or grease.

Pump top threads must be nearly flush with bearing face

(N).

TI3765a-1

28 312066ZAF

Repair

Install Pump A

1. Ensure star-shaped locknut (G) is screwed on pump with flat side up. Carefully twist and extend displacement rod 2 in. (51 mm) above wet-cup.

2. Start threading pump into bearing housing (M).

Place finger guard (P) over rod when it is accessible through window of bearing housing. When pin holes align, insert pin. Pull retaining wire clip down.

NOTE : Finger guard is not used on Model E-30.

3. Seat finger guard (P) on wet-cup. Continue threading pump into bearing housing (M) until top threads are +/- 1/16 in. (2 mm) of bearing face (N).

Ensure that barbed fittings at wet-cup flush ports are accessible.

1 Flat side faces up.

Lubricate threads with ISO oil or grease.

Pump top threads must be nearly flush with bearing face (N).

4 Finger guard (P) not used on

Model E-30.

4. Connect component A outlet tube loosely at pump and at heater. Line up tube, then tighten fittings securely.

5. Tighten star-shaped locknut (G) by hitting firmly with a non-sparking hammer.

6. Apply thin film of TSL to barbed fittings. Using two hands, support tubes (T) while pushing straight onto barbed fittings. Do not let tubes kink or buckle.

Secure each tube with a wire tie between two barbs.

7. Reconnect fluid inlet (C).

8. Purge air and prime the system. See Reactor operation manual.

TI3765a-2

312066ZAF 29

Repair

Drive Housing

Removal

1. Turn main power OFF supply.

. Disconnect power

2. Perform the

3. Remove screws (38) and motor shield (9), page 52.

4. Remove screws (209) and front cover (217).

NOTE: Examine bearing housing (203) and connecting rod (205). If these parts need replacing, first remove the pump (206), page 28.

5. Disconnect pump inlet and outlet lines. Remove screws (213), washers (215), and bearing housing

(203).

CAUTION

Do not drop gear cluster (204) when removing drive housing (202). Gear cluster may stay engaged in motor front end bell (R) or drive housing.

6. Remove screws (212, 219) and washers (214) and pull drive housing (202) off motor (201).

NOTE : The A side drive housing includes cycle counter switch (221). If replacing this housing, remove pins (P) and switch. Reinstall pins and switch on new drive housing. Switch wires connect to J10 pins 5 and 6 on

motor control board, page 36.

Installation

1. Apply grease liberally to washers (207, 208, 218), all gears, and inside drive housing (202).

2. Install one bronze washer (208) in drive housing, then install steel washers (207, 218) as shown.

3. Install second bronze washer (208) on gear cluster

(204) and insert gear cluster in drive housing.

NOTE : Drive housing crankshaft (S) must be in line with crankshaft at other end of motor.

4. Push drive housing (202) onto motor (201). Install screws (212, 219) and washers (214).

NOTE : If bearing housing (203), connecting rod (205), or pump (206) were removed, reassemble rod in

housing and install pump, page 28.

5. Install bearing housing (203), screws (213), and washers (215). Pumps must be in phase (both at same position in stroke).

6. Install front cover (217) and screws (209).

7. Install motor shield (9) and screws (38).

221

TI3250

30 312066ZAF

Repair

209

217

203

205

212

214

202

201

219

214

218

213

215

206B

1 Crankshaft must be in line with crankshaft at other end of motor.

208 204 207 208

206A

TI3152

312066ZAF 31

Repair

Motor Brushes

Brush Removal

NOTE: Replace brushes worn to less than 1/2 in. (13 mm). Brushes wear differently on each side of motor; check both sides. Brush Repair Kit 234037 is available.

5. Loosen terminal screw (R). Pull away brush lead

(L), being careful motor lead terminal (T) remains in place. Remove and discard brush (B).

1. Turn main power OFF supply.

. Disconnect power

Wait 5 min for stored voltage to discharge (E-30 and

E-XP2 models only).

2. Perform the

3. Remove motor cover, screw, and washers. Remove inspection covers, screws, and gaskets from each end of motor.

4. Push in spring clip (C) to release hooks (H) from brush holder. Pull out clip and spring (S).

T R L

01227-4

6. Inspect commutator for excessive pitting, burning, or gouging. Black color on commutator is normal.

Have commutator resurfaced by qualified motor repair shop if brushes wear too quickly.

7. Repeat for other side.

01227-2

NOTE : One brush has a wire on top for brush wear signal. Note which side of motor it is on. Unplug at spade connector provided.

32 312066ZAF

Repair

Brush Installation

CAUTION

When installing brushes, follow steps carefully.

Improper installation damages parts beyond use.

NOTE : Install brush with wires on same side of motor as before. Plug spade terminal into connector.

1. Install new brush (B) so lead (L) is in long slot (D) of holder.

4. Install spring clip (C) and push in until hooks (H) catch slots in housing. Incorrect installation may jam clip.

01227-2 01227-6

01227-5

2. Slide terminal (L) under terminal screw (R). Make sure motor lead terminal (T) is still connected at screw. Tighten screw.

Do not touch brushes, leads, springs, or brush holders while equipment is plugged in, to reduce the risk of electric shock and serious injury.

T L

R 01227-4

3. Install spring (S) so it will uncoil onto brush (B), as shown. Spring will be damaged if installed backwards.

1 Note direction of spring coil.

CAUTION

Do not run pumps dry for more than 30 sec while checking brushes, to avoid damaging pumps.

5. Reinstall brush inspection covers, gaskets, and screws. Reinstall motor cover, screws, washers, and drive housing/pump assemblies.

6. Test brushes with both pump pins (F) disconnected,

page 32.

Select J 1 (jog mode). Press motor to start motor. Slowly increase jog setting to J 6. Inspect brush and commutator contact area for excessive arcing. Arcs should not “trail” or circle around commutator surface.

Run motor for 20-30 min at J 6 to seat brushes.

312066ZAF

1 01227

Repair

Capacitor Test Circuit Breaker Module

1. Turn main power OFF supply.

. Disconnect power

2. Perform the

3. Locate the large, blue capacitor in the upper right corner of the lower cabinet.

4. With a DC voltmeter, measure the voltage across the capacitor terminals to verify that the voltage has discharged to below 10 volts.

5. With an insulated handle screw driver, short across the two contacts on the end of the capacitor to complete discharging it. Hold for two seconds.

NOTE : A small spark may issue from the contact point.

6. Inspect the capacitor for irregularities such as cracks, leakage, burn marks, or irregular shape.

7. Set an Ohmmeter to a range of at least 1K ˖ and connect the meter leads to the capacitor with the red lead to the positive (+) terminal and the black lead to the negative (-) terminal.

8. Observe the meter reading. It should start near 0 ˖ and climb up to 10K ˖ , 20K ˖ , etc., as the meter battery charges the capacitor. This indicates a good capacitor.

9. A reading of 0 ˖ (shorted) or O.L (open) indicates a bad capacitor. In this case, replace the capacitor. with the exact replacement part, item 76 on pages

57 and 58.

1. Turn main power OFF . Disconnect power supply. Turn circuit breakers on to test.

2. Perform the

and the parts drawings on pages 69-70.

3. Using an ohmmeter, check for continuity across circuit breaker (top to bottom). If no continuity, trip breaker, reset, and retest. If still no continuity, replace breaker as follows: a. Refer to electrical diagrams and to T ABLE 2.

Disconnect wires and remove bad breaker. b. Install new breaker and reconnect wires.

Table 2: Circuit Breakers, see F IG . 1

Ref. Size

909 50A

911

912A

912B

913

40A

25A, 40A*

20A

Component

Hose/Transformer

Secondary Side

Transformer

Primary

Heater A

Heater B

Motor/Pumps

* Depending on model.

NOTE: To reference cables and connectors, see the electrical diagrams

909

911

912A

912B

913

F IG . 1. Circuit Breaker Module

34 ti9884a

312066ZAF

Repair

Electric Motor

Removal

1. Turn main power OFF supply.

. Disconnect power

2. Perform the Pressure Relief Procedure , page 25.

3. Remove drive housing/pump assemblies, page 30.

4. Disconnect motor cables as follows: a. Refer to electrical diagrams. Motor control board is on right side inside cabinet, see page

on board. See F IG . 2, page 37.

b. Unplug motor power harness from connector J4

c. Unplug 3-pin connector J7 from board.

d. Thread cables through top of cabinet to free motor.

CAUTION

Motor is heavy. Two people may be required to lift.

Installation

1. Place motor on unit. Thread motor cables into cabinet and into bundles as before. See electrical diagrams.

2. Fasten motor with screws.

3. Plug 3-pin connector J7 to board.

4. Plug motor power harness to connector J4 on board.

5. Install drive housing/pump assemblies, page 30.

6. Return to service.

5. Remove screws holding motor to bracket. Lift motor off unit.

312066ZAF 35

Repair

Motor Control Board

NOTE: Motor control board has one red LED (D11).

Power must be on to check. See F IG . 2 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).

CAUTION

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

1. Turn main power OFF supply.

. Disconnect power

Wait 5 minutes for stored voltage to discharge (E-30 and E-XP2 models only).

2. Perform the

for factory settings. See F IG . 2 for location on board.

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 off heatsink.

8. Set DIP switch (SW2) on new board. See T ABLE 3

Table 3: DIP Switch (SW2) Settings

DIP

Switch Switch Position

Switch 1

Switch 2 ON for E-20 and

E-30 models

Switch 3 ON to enable not used pressure imbalance alarm

OFF for E-XP1 and

E-XP2

OFF to enable pressure imbalance warning

Switch 4 not used

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 4: Motor Control Board Connectors

Model

E-20 and

E-XP1

Model

E-30 and

E-XP2 Pin Description

J10

J12

J13

N, L

J12

J13 n/a Main motor power n/a Transducer B n/a Motor output

1, 2 Motor thermal overload signal

3 Brush wear signal n/a Transducer A

1-4 Not used

5, 6 Cycle switch signal

7-10 Jumper 15C866 (available in repair kit 246961) n/a Data reporting n/a To display board

36 312066ZAF

Repair

24G879 Motor Control, for E-20 and E-XP1

DIP Switch (SW2) Settings

Model E-20

ON (UP)

Model E-XP1

ON (UP)

TI3178b-3

TI3178b-4

24G881 Motor Control, for E-30 and E-XP2

DIP Switch (SW2) Settings

Model E-30

J13

J10

J12 SW2

J13

SW2

TI3153A-1

J3 (A)

J8 (B)

D11

J12

ON (Down)

Model E-XP2

TI3178b-2

ON (Down)

TI3178b-1

1 Apply 110009 thermal heatsink compound to mating surfaces.

F IG . 2. Motor Control Board

J5 (A)

J3 (B)

TI2576A-1

312066ZAF 37

Repair

Transducers

1. Turn main power OFF supply.

Electric Fan

. Disconnect power 1. Turn main power OFF supply.

. Disconnect power

2. Perform the

4. Disconnect transducer cables at board; see F IG . 2, page 37. Reverse A and B connections and check if

3. Refer to electrical diagrams. Motor control board is on right side inside cabinet.

diagnostic code follows; see

E21: No component A transducer , page 14.

5. If transducer fails test, thread cable through top of cabinet. Note path as cable must be replaced in same way.

6. Install o-ring (820) on new transducer (806), F IG . 3.

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 F IG . 2, page

37.

806

(A Side)

2. Perform the

E03: No zone current , page 12. If hose current exceeds 45A, see

3. Check fuses (F) at left of breaker module, F IG . 4.

Replace if blown. If good, continue with step 4.

4. Refer to electrical diagrams. Disconnect fan wires from fuses (F).

5. Remove fan.

6. Install fan in reverse order.

F IG . 4. Fan Fuses ti9884a-1

801

F IG . 3. Transducers

806

(B Side)

820

TI10957a

38 312066ZAF

Repair

Temperature Control Module

Table 5: Temperature Control Module Connections

Connector Description

DATA (A)

SENSOR (B)

Data reporting

HOSE T/C P; FTS (purple)

11 HOSE T/C R; FTS (red)

10 HOSE T/C S; FTS (silver

(unshielded bare wire))

9 HEATER T/C B, Y;

Thermocouple (yellow)

HEATER T/C B, R;

Thermocouple (red)

Not used

HEATER T/C A, Y;

Thermocouple (yellow)

HEATER T/C A, R;

Thermocouple (red)

DISPLAY (C)

4, 3 OVERTEMPERATURE B;

Overtemperature switch B

2, 1 OVERTEMPERATURE A;

Overtemperature switch A

Display

COMMUNICATION (D) Communication to power boards

PROGRAM (E)

BOOT (F)

Software programming

Software bootloader

POWER/RELAY (G) Circuit board power input and contactor control output

Table 6: Temperature Power Module Connections

Connector Description

COMMUNICATION (H) Communication to control board

POWER (J) Power to heater

Right Side of

Control Heater Module

H ti9875a ti9843a1

Bottom of Power Modules ti9843a4

F IG . 5: Temperature Control Module Connections

312066ZAF 39

Repair

Test SCR Circuit

1. Test the SCR circuit in the on position: a. Make sure everything is connected, including the hose.

Replacing Temperature Control Assembly

Modules

CAUTION

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

b. Turn main power ON .

c. Adjust the hose heat setpoint above the ambient hose temperature.

d. Turn on heat zone by pressing .

1. Turn main power OFF supply.

. Disconnect power e. Hold down to view electrical current.

Hose current should ramp up to 45A. If there is no hose current, 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.

b. Turn main power ON .

c. Adjust the hose heat setpoint below the ambient hose temperature.

2. Perform the

assembly; see Temperature Control , page 66.

3. Refer to electrical diagrams; see Electrical

Diagrams manual 312067. 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

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

8. Replace defective module.

9. Install assembly in reverse order.

d. Turn on heat zone by pressing .

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

40 312066ZAF

Primary Heaters

Heater Element

1. Turn main power OFF supply.

. Disconnect power

2. Perform the Pressure Relief Procedure , page 25.

3. Wait for heaters to cool.

4. Remove heater shroud.

5. See F IG . 6, page 42. Disconnect heater element wires from heater wire connector. Test with ohmmeter.

Total Heater

Wattage

6,000

7,650

10,200

Element

1500

2550

Ohms

30-35

18-21

6. To remove heater element, first remove thermocouple (310) to avoid damage, see step

Thermocouple , page 43.

7. Remove heater element (307) from housing (301).

Be careful not to spill any fluid left in housing.

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

9. Install new heater element (307), holding mixer

(309) so it does not block thermocouple port (P).

10. Reinstall thermocouple. See page

Thermocouple ,

page 43.

11. Reconnect heater element leadwires to heater wire connector.

12. Replace heater shroud.

312066ZAF

Repair

Line Voltage

The primary heaters output their rated wattage at 230

Vac. Low line voltage will reduce power available and the heaters will not perform at full capability.

Repair

304

303

305

306

310

311

308

301

313

304

309

313

1 Apply 110009 thermal heatsink compound.

F IG . 6. Heater (7.5 kW Single Zone Heater Shown)

315

307 r_247813_312066

42 312066ZAF

Repair

Thermocouple

1. Turn main power OFF supply.

. Disconnect power

2. Perform the Pressure Relief Procedure , page 25.

3. Wait for heaters to cool.

4. Remove heater shroud.

5. Disconnect thermocouple wires from B on

temperature control module. See T ABLE 5, page 39 and F IG . 5, page 39.

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

7. See F IG . 7. Loosen ferrule nut (N). Remove thermocouple (310) from heater housing (301), then remove thermocouple housing (H). Do not remove the thermocouple adapter (305) unless necessary. If adapter must be removed, ensure that mixer (309) is out of the way when replacing the adapter.

8. Replace thermocouple, F IG . 7. a. Remove protective tape from thermocouple tip

(T).

b. Apply PTFE tape and thread sealant to male threads and tighten thermocouple housing (H) into adapter (305).

c. Push in thermocouple (310) so tip (T) contacts heater element (307).

d. Holding thermocouple (T) against heater element, 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 thermocouple housing (H) to ensure thermocouple tip (T) contacts element (307).

310

301

1 Apply PTFE tape and thread sealant.

2 Apply 110009 thermal heatsink compound.

307

308

309 ti7924a

F IG . 7. Thermocouple

312066ZAF 43

Repair

Overtemperature Switch

1. Turn main power OFF supply.

. Disconnect power

2. Perform the

temperature control board. See T ABLE 5, page 39 and

3. Wait for heaters to cool.

4. Remove heater shroud.

5. Disconnect one leadwire from overtemperature switch (308), F IG . 7, page 43. Test across switch with ohmmeter. Resistance must be approximately

0 ohms.

6. If switch fails test, remove wires and screws.

Discard failed switch. Apply thermal compound

110009, install new switch in same location on housing (301), and secure with screws (311).

Reconnect wires.

NOTE : If wires need replacement, disconnect from

F IG . 5, page 39.

44 312066ZAF

Repair

Heated Hose

NOTE : Refer to the heated hose manual 309572 for hose replacement parts.

Check Hose Power Connectors

7. Use an ohmmeter to check for continuity between the two connectors (12) at (z).

8. If the hose fails the test, re-test at each length of hose, including whip hose, until the failure is identified.

Check FTS Cables

1. Turn main power OFF supply.

. Disconnect power

2. Perform the Pressure Relief Procedure , page 25.

NOTE : Whip hose must be connected.

NOTE : For proportioners with a termination box (TB), follow steps 3 - 5. For proportioners with electrical splice connectors (12), follow steps 6 - 8.

3. Disconnect power wire harness from terminal block

(TB).

1. Turn main power OFF supply.

. Disconnect power

2. Perform the

5. If cable fails test, retest at FTS, page 46.

3. Disconnect FTS cable (F) at Reactor, F IG . 8.

WLD

(

4. Use an ohmmeter to check for continuity between the two terminals (C, E) on the terminal block.

5. If the hose fails the test, re-test at each length of hose, including whip hose, until the failure is identified.

6. Disconnect power wires from power splice connectors (12).

TI10964a

F IG . 8. Heated Hose

4. Test with ohmmeter between pins of cable connector.

Pins Result

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

1 to 3 infinity

12 z

312066ZAF

WLD

Repair

Fluid Temperature Sensor (FTS)

Test/Removal

1. Turn main power OFF supply.

. Disconnect power

2. Perform the

Reactor Electrical Diagrams manual. See Related

3. Remove tape and protective covering from FTS

(21), F IG . 8., page 45. Disconnect hose cable (F).

Test with ohmmeter between pins of cable connector.

Pins

1 to 2

1 to 3

3 to FTS groundscrew

1 to FTS component A fitting (ISO)

Result approximately 10 ohms infinity

0 ohms infinity

4. If FTS fails any test, replace FTS.

5. Disconnect air hoses (C, L), and electrical connectors (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 your heated hose manual for instructions.

F IG . 9: Fluid Temperature Sensor and Heated Hoses

ISO

WLE

312066ZAF

Repair

Transformer Primary Check Replace Transformer

NOTE : Use this procedure to replace transformer.

1. Turn main power OFF .

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

Transformer Secondary Check

1. Turn main power OFF supply.

. Disconnect power

1. Turn main power OFF .

2. Locate the two larger (6 AWG) wires coming out of transformer. Trace these wires back to large green connector under hose control module and circuit breaker (909). Use an ohmmeter to test for continuity between two wires; there should be continuity.

If you are not sure which wire in green plug under hose module connects to transformer, test both wires. One wire should have continuity with the other transformer wire in breaker (909) 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; refer to your

Manuals , page 4.

5. Remove transformer from cabinet.

6. Install new transformer in reverse order.

909

911

F IG . 10: Circuit Breaker Module ti9884a

3. To verify transformer voltage, turn on hose zone.

Measure voltage from 18CB-2 to

POD-HOSE-P15-2; refer to your Reactor Electrical

Diagrams manual. See Related Manuals , page 4.

Model

310 ft.

210 ft.

Secondary Voltage

90 Vac*

62 Vac*

* For 230 Vac line voltage.

312066ZAF 47

Repair

Display Module

Temperature and Pressure Displays

CAUTION

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

Red Stop Button

CAUTION

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

1. Turn main power OFF supply.

. Disconnect power

2. Perform the

3. Refer to electrical diagrams.

4. Put on static conductive wrist strap.

5. Disconnect main display cable (20) at lower left corner of display module; see F IG . 11.

6. Remove screws (509, 510) and cover (504); see

F IG . 11.

NOTE : If replacing both displays, label temperature display cables TEMP and pressure display cables

PUMP before disconnecting.

7. Disconnect cable connectors (506 and 511) from back of temperature display (501) or pressure display (502); see F IG . 11.

8. Disconnect ribbon cable(s) (R) from back of display; see F IG . 11.

9. Remove nuts (508) and plate (505).

10. Disassemble display, see detail in F IG . 11.

11. Replace board (501a or 502a) or membrane switch

(501b or 502b) as necessary.

12. Reassemble in reverse order, see F IG . 11. 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).

1. Turn main power OFF supply.

. Disconnect power

2. Perform the

1. Perform the Pressure Relief Procedure , page 25.

3. Refer to electrical diagrams.

4. Put on static conductive wrist strap.

5. Remove screws (509, 510) and cover (504), F IG .

11.

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).

48 312066ZAF

Repair

1 Apply medium strength thread sealant.

511

502

503

511

504

510

507

506

512

508

505

506

501 ti2574a

Temperature Display

Detail of Membrane Switches and Display Boards

502c

502a

Pressure Display

502b

501c

501a

501b ti3172a

F IG . 11. Display Module

312066ZAF 49

Repair

Inlet Fluid Strainer Screen

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 the equipment clean.

6. Proceed with operation.

F IG

. 12. Y Strainer Components

* Fluid filter screen (59g) replacements:

Part Description

26A349 KIT, filter, replacement; 2 pack

26A350 KIT, filter, replacement; 10 pack

TI10974a

50 312066ZAF

Repair

Pump Lubrication System

Check the condition of the ISO pump lubricant daily.

Change the lubricant if it becomes a gel, its color darkens, 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 moisture, 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:

2. Lift the lubricant reservoir (LR) out of the bracket

(RB) and remove the container from the cap.

Holding the cap over a suitable container, remove the inlet check valve and allow the lubricant to drain.

Reattach the inlet check valve to the inlet hose. See

F IG . 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 into the bracket.

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

F IG . 13. Pump Lubrication System

TI10970a

TI10969a

312066ZAF 51

Parts

Parts

Reactor Assembly (Model E-XP1 Shown)

121

120

110

109,

111,

112

115

65f

65e

65d

TI10961a

WLE

41, 102

113, 119

65a

65b, 65c

WLD

122

TI10977a

Slotted U-Channel

Style Support Rail

Strut Channel

Style Support

Rail

122 TI18608a

312066ZAF

Left Side of Cabinet

123

61, 62

39, 52, 71, 73

Right Side of Cabinet

TI9835a

31, 42

36 (400V models only)

29, 42

Parts

TI10968a

312066ZAF 53

Parts

Detail, Cabinet Area

WLE

41 mounting base (from motor)

TI10978a

312066ZAF

Parts

Parts Used on All Models

See pages 56 through 58 for parts that vary by model.

Ref. Part

11†

18†

19†

Description

----

FRAME; page 64

HEATER; pages 62 and 63

----

MODULE, proportioner; page 59

245974 DISPLAY; page 65

----

CONTROL, temperature; page 66

CONTROL, motor; page 67

247823 MANIFOLD, fluid; page 68

----

TRANSFORMER; pages 56-58

SHIELD; page pages 56-58

246976 DOOR, cabinet

261669 SENSOR, fluid temperature

15B456 GASKET, manifold

19Y415 FAN, assembly

----

TUBE, heater component A; pages

TUBE, pump, component A; pages

TUBE, heater component B; pages

TUBE, pump, component B; pages

CONNECTOR, tube; pages 56-58

247787 CABLE, overtemperature; see electrical diagrams

15B380 CABLE, hose control; see electrical diagrams

15B383 CABLE, display

116773 CONNECTOR, plug

C38163 WASHER, lock, external tooth

Qty.

65b 101078 Y-STRAINER

65c† 26A349 KIT, filter, replacement (2 pack)

65d

65e

113505 NUT, hex, keps; 10-24

112776 WASHER, plain; no. 10

----

KIT, fluid inlet

FITTING, swivel, elbow

26A350 KIT, filter, replacement (10 pack)

C20487 NIPPLE, 3/4 npt

109077 VALVE, ball; 3/4 npt (fbe)

Ref. Part Description Qty.

65f

66a†

118459 FITTING, union, swivel; 3/4-14 npt(m) x

3/4-14 npt(f)

101078 Y-STRAINER; includes 66a

26A349 KIT, filter, replacement (2 pack)

26A350 KIT, filter, replacement (10 pack)

109077 VALVE, ball; 3/4 npt (fbe)

C20487 NIPPLE; 3/4 npt 2

157785 UNION, swivel; 3/4 npt(m) x 3/4 npsm(f) 2



106

107

109

----

SCREW, machine; pages 56-58

BRACKET. heater; pages 56-58

WASHER, lock; pages 56-58

CAPACITOR; pages 56-58

BRACKET; pages 56-58

CABLE, overtemperature, jumper;

pages 56-58

15B807 SHIELD, fan

186494 CLIP, spring

205447 COUPLING, hose

15M338 TUBE, low pressure; 1/4 in. (6 mm) ID;

3/8 in. (16 mm) OD; 4 ft (1.2 m); PTFE

95  ----

96  ----

97  ----

102

110

111

112

113

115

117

119

BOLT; hex hd; pages 56-58

LOCKWASHER; 3/8; pages 56-58

NUT, channel; pages 56-58

STRAP, motor; pages 56-58

----

117502 REDUCER; #5 x #8 JIC

117677 REDUCER; #6 x #10 JIC

246928 RESERVOIR; includes 110-119; see

309911

054826 TUBE; PTFE; 1/4 in. (6 mm) ID;

2 ft (0.6 m)

118433 VALVE, check

118432 VALVE, check

116746 FITTING, barbed

15C568 BRACKET, reservoir

206995 THROAT SEAL LIQUID; 1 qt (1 liter)

191892 ELBOW; 1/8 npt (m x f)

120  171001 LABEL, warning

121

122

123

124

125

----

LABEL; pages 56-58

INSULATOR, heat; pages 56-58

247782 SPACER

247854 COVER, connector, module

114331 SCREW, machine; 6-32 x 0.375 in. (9.5 mm)

127  261821 CONNECTOR, wire

138  24W204 ENCLOSURE, TB

139  25A234 ENCLOSURE, cover

140  189930 LABEL, caution

141  16X129 SCREW

142  17C082 CABLE, lanyard

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

* See quantity on referenced pages.

† Not shown.

 Required for all A-F series models.

Included in Knob

Repair Kit 258920 (purchase separately).

 Not required for slotted U-Channel style heater support rails.

 For models series A - E.

 For models series F.

312066ZAF 55

Parts

Parts that Vary by Model

Use the following tables on this and the next two pages to find parts that vary by model. Find the reference number and of part in left column and Reactor model in top row. Intersection is correct part number.

See page 55 for parts common to all models.

Reactor Models

Ref. Description

259024

E-XP1

259025

E-20

259026

E-30

259028

E-XP2

259029

E-XP1

259030

E-20

259031

E-30

259032

E-XP2

259033

E-XP1

259034

E-20

259035

E-30

259036

E-XP2

2 HEATER;

pages 62 and

3 MODULE, proportioner;

page 59

6 CONTROL, motor; page

247509

(qty: 2) 247507 247506 247507

247509

(qty: 2)

245956 245956 245957 245959 245956 245956 245957 245959 245956 245956 245957 245959

24G879 24G879 24G881 24G881 24G879 24G879 24G881 24G881 24G879 24G879 24G881 24G881

8 TRANSFORM

ER;

247840 247840 247812 247812 247840 247840 247812 247812 247840 247840 247812 247812

9 SHIELD 276878 276878 276879 276879 276878 276878 276879 276879 276878 276878 276879 276879

14 TUBE, heater, component A 247920 247920 247920 247915 247920 247920 247920 247915 247920 247920 247920 247915

15 TUBE, pump, component A 247912 247912 247919 247914 247912 247912 247919 247914 247912 247912 247919 247914

16 TUBE, heater, component B 247918 247918 247918 247917 247918 247918 247918 247917 247918 247918 247918 247917

17 TUBE, pump, component B 247913 247913 247921 247916 247913 247913 247921 247916 247913 247913 247921 247916

21 CONNECTOR

, tube

121310 121310 121311 121311 121310 121310 121311 121311 121310 121310 121311 121311

28 MODULE, breaker; page

C C F F B B E E A A D D

36 SWITCH, added pole;

380V

39 FILTER; 230V 117667 117667

123968 123968 123968 123968

117667 117667 117667 117667

Qty.

56 312066ZAF

Parts

Reactor Models

Ref. Description

259024

E-XP1

259025

E-20

259026

E-30

259028

E-XP2

259029

E-XP1

259030

E-20

259031

E-30

259032

E-XP2

259033

E-XP1

259034

E-20

259035

E-30

259036

E-XP2 Qty.



LABEL, warning

52 CABLE, harness, filter

198278 198278

15B385 15B385

198278 198278

15B385 15B385

198278 198278

15B385 15B385

65 KIT, fluid inlet 234366 234366 234367 234366 234366 234366 234367 234366 234366 234366 234367 234366

65a ELBOW, swivel; 3/4 npt(m) x 1” npt(f)

160327 160327 118463 160327 160327 160327 118463 160327 160327 160327 118463 160327

71 SCREW, machine

72  BRACKET, heater

BRACKET, heater

73 WASHER, lock

76 CAPACITOR

---

247523 247523 247523

---

247523

103181 103181

244733 244733

---

247523 247523 247523

---

247523

103181 103181

244733 244733

---

247523 247523 247523

---

247523

103181 103181

244733 244733

77 BRACKET 197999 197999

86 CABLE, overtemperatu re, jumper

15H187 15H187 15H187

197999 197999

15H187 15H187 15H187

197999 197999

15H187 15H187 15H187

95  BOLT; hex hd;

3/8-16

100469 100469 100469

BOLT; hex hd;

3/8-16

100469

100469 100469 100469

100469

100469 100469 100469

100469

96  LOCKWASHE

R; 3/8

100133 100133 100133

LOCKWASHE

R; 3/8

100133

100133 100133 100133

100133

100133 100133 100133

100133

97  NUT, channel 118446 118446 118446

NUT, channel 118446

102 STRAP, motor 15B107 15B107 15B108 15B108 15B107 15B107 15B108 15B108 15B107 15B107 15B108 15B108

121 LABEL 15M504 15M500 15M499 15M501 15M504 15M500 15M499 15M501 15M504 15M500 15M499 15M501

122 INSULATOR

118446 118446 118446

118446

167002

118446 118446 118446

(qty: 4) 167002 167002 167002

118446

167002

(qty: 4)

312066ZAF 57

Parts

Parts that Vary by Model (continued)

Reactor Models

Ref. Description

259057

E-30

(15.3 kW)

259058

E-30

(15.3 kW)

259059

E-30

(15.3 kW) Qty.

2 HEATER; pages

62 and 63

3 MODULE, proportioner;

page 59

247509 247509 247509

245957 245957 245957

6 CONTROL,

motor; page 67

24G881 24G881 24G881

8 TRANSFORMER; 247812 247812 247812

9 SHIELD 276879 276879 276879

14 TUBE, heater, component A

15 TUBE, pump, component A

16 TUBE, heater, component B

17 TUBE, pump, component B

247915

247914

247917

247916

247915

247914

247917

247916

247915

247914

247917

247916

21 CONNECTOR, tube

28 MODULE,

breaker; page 69

121311

36 SWITCH, added pole; 380V

123968

39 FILTER; 230V 117667 117667 117667

51  LABEL, warning 198278 198278 198278

52 CABLE, harness, filter

15B385 15B385 15B385

234367 234367 234367 65 KIT, fluid inlet

65a ELBOW, swivel;

3/4 npt(m) x 1” npt(f)

118463 118463 118463

71 SCREW, machine

-------

72  BRACKET, heater

247523 247523 247523

73 WASHER, lock 103181 103181 103181

76 CAPACITOR 244733 244733 244733

77 BRACKET

95  BOLT; hex hd;

3/8-16

197999 197999 197999

100469 100469 100469

96  LOCKWASHER;

3/8

LOCKWASHER;

3/8

100133 100133 100133

Reactor Models

Ref. Description

259057

E-30

(15.3 kW)

259058

E-30

(15.3 kW)

259059

E-30

(15.3 kW) Qty.

97  NUT, channel

NUT, channel 118446 118446 118446

102 STRAP, motor 15B108 15B108 15B108

121 LABEL

122 Insulator

15M499

167002

15M499

167002

15M499

167002

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

 Not required for slotted U-Channel style heater support rails.

--- Not for sale.

58 312066ZAF

Sub Assemblies

Proportioner Module

245956 Module for E-20 and EXP-1

245957 Module for E-30

245959 Module for EXP-2

209

226

217

205‡

203‡

213

216†‡

210†‡**

211†‡

215‡

206B‡

212

214

202

201

219

214

218

208*

208* 204 207*

225

216†‡

210†‡**

211†‡

224†

206A†

TI2511a

1 Flat side faces up.

Detail of Cycle Counter Switch

220

221

TI3250a

Parts

312066ZAF 59

Parts

Proportioner Module Parts List

Ref.

201

202

203‡

Part Description

24V618 MOTOR

24V500 MOTOR

245968 HOUSING, drive

245969 HOUSING, drive

240523 HOUSING, bearing

241015 HOUSING, bearing

245927 HOUSING, bearing

204

205‡

244264 GEAR; includes items 207, 208

244265 GEAR; includes items 207, 208

241008 ROD, connecting; includes item 210

241279 ROD, connecting; includes item 210

206A† 246830 PUMP, displacement, component A; see 309577

246831 PUMP, displacement, component A; see 309577

246832 PUMP, displacement, component A; see 309577

206B‡ 245970 PUMP, displacement, component B; see 309577

207*

208*

209

245971 PUMP, displacement, component B; see 309577

245972 PUMP, displacement, component B; see 309577

114699 WASHER, thrust; steel

114672 WASHER, thrust; bronze

114418 SCREW, self-tapping; 8-32 x 1 in. (25 mm)

114818 SCREW, self-tapping; 8-32 x 1-1/4 in. (31 mm)

210†‡** 176817 CLIP, wire

183169 CLIP, wire

211†‡ 176818 PIN

183210 PIN

212 107218 SCREW, cap, socket-hd; 1/4-20 x 2-3/4 in. (70 mm)

114686 SCREW, cap, socket-hd; 5/16-18 x 3-1/4 in. (83 mm)

213

214

107210 SCREW, cap, socket-hd; 3/8-16 x 1-1/2 in. (38 mm)

114666 SCREW, cap, socket-hd; 3/8-16 x 2-1/4 in. (57 mm)

105510 WASHER, lock; 1/4

104008 WASHER, lock; 5/16

215‡ 106115 WASHER, lock; 3/8 size

216†‡ 192723 NUT, retaining

193031 NUT, retaining

193394 NUT, retaining

217

218

179899 COVER

241308 COVER

116191 WASHER, thrust

116192 WASHER, thrust

219

220

221

100644 SCREW, cap, socket-hd; 1/4-20 x 3/4 in. (19 mm)

101864 SCREW, cap, socket-hd; 5/16-18 x 1 in. (25 mm)

116618 MAGNET

117770 SWITCH, cycle counter

Qty.

245956 245957 245959

1 1

2 2

8 8

2 2

4 4

8 8

2 2

60 312066ZAF

Ref.

223

Part Description

100643 SCREW, cap, socket-hd; 1/4-20 x 1 in. (25 mm

102962 SCREW, cap, socket-hd; 5/16-18 x 1-1/4 in. (31 mm)

224† 104765 PLUG

225 15C587 GUARD, finger

226

15C588 GUARD, finger

15M507 LABEL

15M508 LABEL

245956 245957 245959

Qty.

1 1

* Parts included in Gear Kit 244264 (245956) or

244265 (245957, 245959).

** Parts included in Connecting Rod Kit 241008

(245956) or 241279 (245957, 245959).

† Part included in E-20 and EXP-1 A Side Repair Kit

25E298.

‡ Part included in E-20 and EXP-1 B Side Repair Kit

25E299.

Parts

312066ZAF 61

Parts

Fluid Heaters

247506, 6.0 kW Fluid Heaters

247507, 10.2 kW Fluid Heaters

310

303

305

306

304

313

308

311

314

301

309 r_247507_312408

315

Ref Part Description

301 ---HOUSING, heater

303 121309 ADAPTER

304 15H304 PLUG

305 15H306 ADAPTER, thermocouple

306 120336 O-RING; fluoroelastomer

307 ---HEATER, immersion

16A110 2550W; 10.2kW heater only

16A112 1500 W; 6.0 kW heater only

308 15B137 SWITCH, overtemperature

309 15B135 MIXER, immersion heater

307

1 Apply 110009 thermal heatsink compound.

Qty.

Ref Part Description

310 117484 SENSOR

311 100518 SCREW, machine, pan hd

313 15H305 PLUG, hollow

314 247520 DISC, rupture

315 124132 O-RINGS

Qty.

62 312066ZAF

7.65 kW Single Zone Fluid Heater

(Two Per Machine)

Part 247509

306

305

310

311

308

303

304

314

301

304

309

313

Parts

307 r_247813_312066

Ref. Part

301 ----

Description

HOUSING, heater

303 121309 ADAPTER

304 15H304 PLUG

305 15H306 ADAPTER, thermocouple

306 120336 O-RING; fluoroelastomer

307 16A110 HEATER, immersion; 2550 W

308 15B137 SWITCH, overtemperature

309 15B135 MIXER, immersion heater

315

Qty

1 Apply 110009 thermal heatsink compound.

Ref. Part Description

310 117484 SENSOR

311 100518 SCREW, machine, pan hd

313 15H305 PLUG, hollow

314 247520 DISC, rupture; not shown

315 124132 O-RING

Qty

312066ZAF 63

Parts

Reactor Frame

405

401

Ref. Part

401 ----

Description

FRAME

402 116478 WHEEL

403 101242 RING, retaining

404 116477 WASHER, flat; nylon

405 112125 PLUG

406 116411 SPRING

407 154636 WASHER, flat

Qty.

407

406

404

402

404

403

TI2513a

64 312066ZAF

Display

502

503

511

507

506

502b

508

505

502a

506

Parts

501

502c

512

20 (Ref)

511

504

510 ti2574a

501c

501a

Ref. Part Description

501 24G884 DISPLAY, pressure; includes

501a-501c

501a 24G882 .BOARD, circuit

501b 246478 .SWITCH, membrane

501c 112324 .SCREW

502 24G883 DISPLAY, temperature; includes

502a-502c

502a 24G882 .BOARD, circuit

502b 246479 .SWITCH, membrane

502c 112324 .SCREW

503 15B293 GASKET

504 15B292 COVER

505 15B291 PLATE

Qty.

501b ti3172a

Ref. Part Description

506 246287 HARNESS, wire, red stop button

507 117499 HANDLE

508 117523 NUT, cap; 10-24

510 --SCREW, machine, pan-hd; M5 x

0.8; 16 mm

511 15B386 CABLE, display

512 195853 SCREW, machine; M2.5 x 6

Qty.

--- Not for sale.

312066ZAF 65

Parts

Temperature Control

606

601

604

602

605

To B

Heater

Module

604

To A

Heater

Module

To Hose

Heater

Module

604

603

Ref. Part Description

601 247772 PANEL, module mounting

602 247827 HOUSING, control module

603 247828 HOUSING, heater module

604 115942 NUT, hex

605 247801 CABLE, communication

606 247825 KIT, cover, connector with screws

Qty.

603

604

603

TI9843a

66 312066ZAF

Parts

Motor Control

24G879 Motor Control for E-20 and EXP-1

703

24G881 Motor Control for E-30 and EXP-2

701

704

701

707

703

705

702

Ref. Part Description

701 15B297 HEAT SINK

702 24G878 BOARD, motor control

703 107156 SCREW, machine; 6-32

TI3153a

Qty.

1 Apply 110009 thermal heatsink compound to mating surfaces.

2 702

TI2576a

Ref. Part Description

701 16F745 HEAT SINK

702 ---

703 ---

BOARD, motor control

SCREW, machine;

6-32 x 3/8 in. (10 mm)

704 117526 SPACER

705 117683 SCREW, 6-32 x 1-1/2 in. (38 mm)

707 15C007 INDUCTOR

709 15B408 CABLE, harness, motor

Qty.

1 Apply 110009 thermal heatsink compound to mating surfaces.

2 Motor harness (609) plugs in here.

---Not for sale.

312066ZAF 67

Parts

Fluid Manifold

Torque to 355-395 in-lb (40.1-44.6 N•m).

Apply sealant (113500) to threads.

Valve must be closed with handle position as shown on drawing.

** Apply PTFE tape or thread sealant to tapered threads.

808

806

818

802

802b

802a

814

803

805

815

804

807

816

814

801 812

813 817

TI10959a

Ref. Part Description

801  247837 MANIFOLD, fluid

Qty.

802† 247824 VALVE, drain cartridge 2

802a† 158674 . O-RING 1

802b† 247779 . SEAL, seat, valve 1

803 102814 GAUGE, pressure, fluid 2

804 162453 FITTING, 1/4 npsm x 1/4 npt 2

805 24K999 TRANSDUCER, pressure, control 2

806 247788 HANDLE, red 1

807 247789 HANDLE, blue 1

808† 112309 NUT, hex, jam 2

812‡ 17Y236 FITTING, 3/4 ORB x #8 JIC 1

117566 FITTING, #8 JIC x 1/2 npt 1

813‡ 17Y235 FITTING, 3/4 ORB x #10 JIC 1

117557 FITTING, #10 JIC x 1/2 npt 1

814 121312 ELBOW, 90 degrees 2

815 100840 ELBOW, street; 1/4 npsm x 1/4 npt 2

Ref. Part Description

816 111457 O-RING, PTFE

817  189285 LABEL, caution

818† 150829 SPRING, compression

Qty.

 Replacement Warning labels, signs, tags, and cards are available at no cost.

† Included in the following complete valve kits*:

ISO Valve Kit (left/red handle) 255149.

Resin Valve Kit (right/blue handle) 255150.

Valve Set Kit (both handles and grease gun) 255148.

* Complete valve kits also include thread sealant.

(Purchase kits separately).

‡ To order a replacement part, verify the type of fitting used with your fluid manifold (1/2 NPT or 3/4 ORB fitting).

 Part includes replacement ORB fittings (part 812 and

813).

68 312066ZAF

Parts

Circuit Breaker Modules

A: 230V, 3 Phase Circuit Breaker Modules

(E-20, EXP-1)

NOTE : For wiring and cable connections, refer to electrical diagrams manual 312067, supplied. See page

920

903, 904

905 906

910

911

914

917

902

916

168BR

178CB

187CB

197CB

172CB

915

908

901

918

909

912

913

919

907

B: 400V, 3 Phase Circuit Breaker Modules

(E-20, E-XP1)

NOTE : For wiring and cable connections, refer to electrical diagrams manual 312067, supplied. See page

920

905

910

906

911

903, 904

917

902

178CB

187CB

197CB

172CB

916

918

922 ti27064a_ 255185_va

908

901

909

912

913

919

907

922 ti27065a_ 255185_vb

312066ZAF 69

Parts

C: 230V, 1 Phase Circuit Breaker Modules

(E-20, EXP-1)

NOTE : For wiring and cable connections, refer to electrical diagrams manual 312067, supplied. See page

903, 904

920 905 906

910

911

914

902

168BR

178CB 187CB 197CB 172CB

916

917

915

908

901

918

909

912

913 919

907 922 ti27066a_ 255185_vc

D: 230V, 3 Phase Circuit Breaker Modules

(E-30, EXP-2)

NOTE : For wiring and cable connections, refer to electrical diagrams manual 312067, supplied. See page

920 905 906

910

911

914

903, 904

917

916

902

915

908

901

918

907

909

912

913

919

922

312066ZAF

Parts

E: 400V, 3 Phase Circuit Breaker Modules

(E-30, E-XP2)

NOTE : For wiring and cable connections, refer to electrical diagrams manual 312067, supplied. See page

920 905 906

910

911

903, 904

917

916

902

908

901

918

909

912

913

919

907 922

F: 230V, 1 Phase Circuit Breaker Modules

(E-30, EXP-2)

NOTE : For wiring and cable connections, refer to electrical diagrams manual 312067, supplied. See page

pumps and bearings, see Pump Removal (page 26)

920 905 906

910

911

914

903, 904

917

916

902

#" #" #" #"

915

908

901

312066ZAF

918

907

909

912

913

919

922

Parts

Circuit Breaker Modules Parts List

Ref. Description

901 RAIL, mounting

902 CLAMP, block, end

903 HOLDER, fuse terminal, block

904 FUSE

905 TERMINAL, block

906 TERMINAL, end cover

907 BRIDGE, plug in, jumper

908 BLOCK, terminal ground

909 BREAKER, 1 pole, 50A

910 CONTACTOR, relay, 65A

911 BREAKER, 2 phase, 40A

912 BREAKER, 2 phase, 25A

BREAKER, 2 phase, 40A

913 BREAKER, 2 phase, 20A

914 CONNECTOR, power lug

CONNECTOR, power lug

915 BAR, power buss, 3 phase

BAR, power buss, 1 phase

916 CABLE, harness lower

917 CABLE, harness upper

918 CONNECTOR, 2 pin large

919 CONNECTOR, 3 pin

920 CONNECTOR, 4 pin

922 CABLE, harness

---

255044

255046

255026

255022

247768

255050

247768

255049

117679

E-20 and EXP-1 Models

Breaker Modules

E-30 and EXP-2 Models

230V,

3 phase

255028

400V,

3 phase

255028

230V,

1 phase

255028

230V,

3 phase

255028

400V,

3 phase

255028

230V,

1 phase

255028

255045

255043

255023

255042

255045

255043

255023

255042

255045

255043

255023

255042

255045

255043

255023

255042

255045

255043

255023

255042

255045

255043

255023

255042

---

255044

255046

255026

255022

247768

255050

247768

255049

---

255044

255046

255026

255022

247768

255050

247768

255049

---

255044

255046

255026

255022

247768

255050

247768

255049

117679

---

255044

255046

255026

255022

247768

255050

247768

255049

---

255044

255046

255026

255022

247768

255050

247768

255049

117679 117679

117805 117805

247802

247805

255027

247522

255031

247791 †

17H075 ‡

247802

247806

255027

247522

255031

247791 †

17H075 ‡

117678

247802

247804

255027

247522

255031

247791 †

17H075 ‡

247802

247805

255027

247567

255031

247791

247802

247806

255027

247567

255031

247791

117678

247802

247804

255027

247567

255031

247791

Qty.

--- Not for sale.

† For models series A - E.

‡ For models series F - G

72 312066ZAF

303

316

306B

248669 Conversion Kit

248669 Conversion Kit

Convert and phase E-XP2 to and E-30 with 15.3 kW of heat by changing displacement pumps, bearings, and changing the Motor Control DIP settings to that of an

E-30. For removal and installation of displacement

and Pump Installation (page 28). For changing Motor

Control DIP settings, see Motor Control Board

, page

Ref. Part Description

65 118463 ELBOW, swivel; 3/4 npt(m) x 1 in. npt(f)

303 245927 HOUSING, bearing

306A 246832 PUMP, displacement, component

A; see 309557

306B 245972 PUMP, displacement, component

B; see 309577

316 193394 NUT, retaining

Qty.

306A

24G881 Motor

Control Board

DIP Switch

(SW2) need to be set for an

E-30. 1,2,3, ON -

4 OFF. See page