Graco 332144K, Reactor E-10hp Instructions

Instructions
Reactor® E-10hp
332144K
EN
For spraying or dispensing polyurea coatings and polyurethane foam. For professional use
only.
Not approved for use in explosive atmospheres or hazardous (classified) locations.
3000 psi (21 MPa, 207 bar) Maximum Working Pressure
For model information, see page 10.
Important Safety Instructions
Read all warnings and instructions in this
manual before using the equipment.
Save these instructions.
ti21488a
Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Important Isocyanate (ISO) Information . . . . . . . . . 7
Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 7
Material Self-Ignition . . . . . . . . . . . . . . . . . . . . . . 8
Keep Components A and B Separate . . . . . . . . . 8
Moisture Sensitivity of Isocyanates . . . . . . . . . . . 8
Foam Resins with 245 fa Blowing Agents . . . . . . 8
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 8
Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Component Identification . . . . . . . . . . . . . . . . . . . 12
Controls and Indicators . . . . . . . . . . . . . . . . . . . . . 13
Heater Controls . . . . . . . . . . . . . . . . . . . . . . . . . 13
System Controls . . . . . . . . . . . . . . . . . . . . . . . . 13
Controls and Indicators . . . . . . . . . . . . . . . . . . . 14
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Locate Reactor. . . . . . . . . . . . . . . . . . . . . . . . . . 16
Electrical Requirements . . . . . . . . . . . . . . . . . . . 16
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Connect Fluid Hoses . . . . . . . . . . . . . . . . . . . . . 17
Connect Gun Air Hose . . . . . . . . . . . . . . . . . . . . 17
Connect Main Air Supply . . . . . . . . . . . . . . . . . . 17
Flush Before First Use . . . . . . . . . . . . . . . . . . . . 17
Fill Wet-Cups . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fill Fluid Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Purge Air and Flush Fluid From Lines . . . . . . . . 19
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Heatup Guidelines . . . . . . . . . . . . . . . . . . . . . . . 21
Heat Management Tips . . . . . . . . . . . . . . . . . . . 21
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Refill Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 24
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Purge Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Pump Control Status Codes . . . . . . . . . . . . . . . 28
DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . 30
Heat Control Diagnostic Codes . . . . . . . . . . . . . 32
Reactor Electronics . . . . . . . . . . . . . . . . . . . . . . 34
Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Proportioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Before Beginning Repair . . . . . . . . . . . . . . . . . . 39
Remove Supply Tank . . . . . . . . . . . . . . . . . . . . . 39
Replace Spray Valves. . . . . . . . . . . . . . . . . . . . . 40
Displacement Pump . . . . . . . . . . . . . . . . . . . . . . 41
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Pressure Transducers . . . . . . . . . . . . . . . . . . . . . 51
Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Replace Cycle Counter Switch. . . . . . . . . . . . . . 53
Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Tank Fluid Level Sensors . . . . . . . . . . . . . . . . . . 56
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
System Packages. . . . . . . . . . . . . . . . . . . . . . . . 58
E-10hp Proportioners . . . . . . . . . . . . . . . . . . . . . 59
24T954, 100-120VAC and 200-40VAC Bare
Proportioner . . . . . . . . . . . . . . . . . . . . . . . . . 65
24U009, 100-120VAC Heater
24T955, 200-240VAC Heater . . . . . . . . . . . . 67
24T962, Display . . . . . . . . . . . . . . . . . . . . . . . . . 68
Fluid Inlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
24T960, Fluid Manifold. . . . . . . . . . . . . . . . . . . . 70
25R000, Insulated Hose Bundle with
Recirculation Lines. . . . . . . . . . . . . . . . . . . . 71
Outlet Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . 71
Suggested Replacement Parts . . . . . . . . . . . . . . . 74
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Technical Specifications . . . . . . . . . . . . . . . . . . . . 75
California Proposition 65 . . . . . . . . . . . . . . . . . . . . 76
Graco Standard Warranty. . . . . . . . . . . . . . . . . . . . 78
332144K
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks.
When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings.
Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this
manual where applicable.
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause
electric shock.
•
•
•
•
•
Turn off and disconnect power cord before servicing equipment.
Connect only to 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.
•
Read Safety Data Sheets (SDSs) for handling instructions and to know the specific hazards of the
fluids you are using, including the effects of long-term exposure.
When spraying, servicing equipment, or when in the work area, always keep work area
well-ventilated and always wear appropriate personal protective equipment. See Personal
Protective Equipment warnings in this manual.
Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled or
swallowed.
•
•
PERSONAL PROTECTIVE EQUIPMENT
Always wear appropriate personal protective equipment and cover all skin when spraying, servicing
equipment, or when in the work area. Protective equipment helps prevent serious injury, including
long-term exposure; inhalation of toxic fumes, mists or vapors; allergic reaction; burns; eye injury and
hearing loss. This protective equipment includes but is not limited to:
•
•
332144K
A properly fitting respirator, which may include a supplied-air respirator, chemically impermeable
gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local
regulatory authority.
Protective eyewear and hearing protection.
3
Warnings
WARNING
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.
•
•
•
•
•
•
•
Engage trigger lock when not spraying.
Do not point gun at anyone or at any part of the body.
Do not put your hand over the spray tip.
Do not stop or deflect leaks with your hand, body, glove, or rag.
Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or
servicing equipment.
Tighten all fluid connections before operating the equipment.
Check hoses and couplings daily. Replace worn or damaged parts immediately.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or
solvent flowing through the equipment can cause static sparking. To help prevent fire and explosion:
•
•
•
•
•
•
•
•
•
•
4
Use equipment only in well-ventilated area.
Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic
drop cloths (potential static sparking).
Ground all equipment in the work area. See Grounding instructions.
Never spray or flush solvent at high pressure.
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.
Use only grounded hoses.
Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are anti-static or conductive.
Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment
until you identify and correct the problem.
Keep a working fire extinguisher in the work area.
332144K
Warnings
WARNING
THERMAL EXPANSION HAZARD
Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure due to
the thermal expansion. Over-pressurization can result in equipment rupture and serious injury.
•
•
Open a valve to relieve the fluid expansion during heating.
Replace hoses proactively at regular intervals based on your operating conditions.
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious
chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious
injury, or property damage.
•
•
•
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents.
Do not use chlorine bleach.
Many other fluids may contain chemicals that can react with aluminum. Contact your material
supplier for compatibility.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
•
•
•
•
•
•
•
•
•
•
•
•
•
332144K
Do not operate the unit when fatigued or under the influence of drugs or alcohol.
Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Specifications in all equipment manuals.
Use fluids and solvents that are compatible with equipment wetted parts. See Technical
Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For
complete information about your material, request Safety Data Sheets (SDSs) from distributor or
retailer.
Do not leave the work area while equipment is energized or under pressure.
Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
Do not alter or modify equipment. Alterations or modifications may void agency approvals and
create safety hazards.
Make sure all equipment is rated and approved for the environment in which you are using it.
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.
5
Warnings
WARNING
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
•
•
•
Keep clear of moving parts.
Do not operate equipment with protective guards or covers removed.
Equipment can start without warning. Before checking, moving, or servicing equipment, follow the
Pressure Relief Procedure and disconnect all power sources.
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe
burns:
•
6
Do not touch hot fluid or equipment.
332144K
Important Isocyanate (ISO) Information
Important Isocyanate (ISO) Information
Isocyanates (ISO) are catalysts used in two component materials.
Isocyanate Conditions
Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and atomized
particulates.
•
•
•
•
•
•
•
Read and understand the fluid manufacturer’s warnings and Safety Data Sheets (SDSs) to know specific
hazards and precautions related to isocyanates.
Use of isocyanates involves potentially hazardous procedures. Do not spray with this equipment unless you
are trained, qualified, and have read and understood the information in this manual and in the fluid
manufacturer’s application instructions and SDSs.
Use of incorrectly maintained or mis-adjusted equipment may result in improperly cured material, which
could cause off gassing and offensive odors. Equipment must be carefully maintained and adjusted
according to instructions in the manual.
To prevent inhalation of isocyanate mists, vapors and atomized particulates, everyone in the work area must
wear appropriate respiratory protection. Always wear a properly fitting respirator, which may include a
supplied-air respirator. Ventilate the work area according to instructions in the fluid manufacturer’s SDSs.
Avoid all skin contact with isocyanates. Everyone in the work area must wear chemically impermeable
gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local
regulatory authority. Follow all fluid manufacturer recommendations, including those regarding handling of
contaminated clothing. After spraying, wash hands and face before eating or drinking.
Hazard from exposure to isocyanates continues after spraying. Anyone without appropriate personal
protective equipment must stay out of the work area during application and after application for the time
period specified by the fluid manufacturer. Generally this time period is at least 24 hours.
Warn others who may enter work area of hazard from exposure to isocyanates. Follow the
recommendations of the fluid manufacturer and local regulatory authority. Posting a placard such as the
following outside the work area is recommended:
TOXIC FUMES
HAZARD
DO NOT ENTER DURING
SPRAY FOAM APPLICATION
OR FOR ___ HOURS AFTER
APPLICATION IS COMPLETE
DO NOT ENTER UNTIL:
DATE: ____________
TIME: ____________
332144K
7
Important Isocyanate (ISO) Information
Material Self-Ignition
Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings
and Safety Data Sheets (SDSs).
Keep Components A and B
Separate
Cross-contamination can result in cured material in
fluid lines which could cause serious injury or
damage equipment. To prevent cross-contamination:
•
•
Never interchange component A and component
B wetted parts.
Never use solvent on one side if it has been
contaminated from the other side.
Moisture Sensitivity of
Isocyanates
Exposure to moisture (such as humidity) will cause ISO
to partially cure, forming small, hard, abrasive crystal
that become suspended in the fluid. Eventually a film
will form on the surface and the ISO will begin to gel,
increasing in viscosity.
NOTE: The amount of film formation and rate of
crystallization varies depending on the blend of ISO, the
humidity, and the temperature.
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
NOTICE
Changing the material types used in your equipment
requires special attention to avoid equipment damage
and downtime.
• When changing materials, flush the equipment
multiple times to ensure it is thoroughly clean.
•
Always clean the fluid inlet strainers after flushing.
•
When changing between epoxies and urethanes or
polyureas, disassemble and clean all fluid
components and change hoses. Epoxies often
have amines on the B (hardener) side. Polyureas
often have amines on the B (resin) side.
•
Check with your material manufacturer for
chemical compatibility.
NOTICE
Partially cured ISO will reduce performance and the life
of all wetted parts.
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere. Never
store ISO in an open container.
• Keep the ISO pump wet cup or reservoir (if
installed) filled with appropriate lubricant. The
lubricant creates a barrier between the ISO and
the atmosphere.
• Use only moisture-proof hoses compatible with
ISO.
• Never use reclaimed solvents, which may contain
moisture. Always keep solvent containers closed
when not in use.
• Always lubricate threaded parts with an
appropriate lubricant when reassembling.
8
332144K
Systems
Systems
Part
APT100
P2T100
26B240
APT900
APT901
APT902
P2T900
P2T901
P2T902
26B241
FPT901
FPT902
24T900
24T901
24T902
332144K
Maximum
Working
Pressure,
psi
(MPa, bar)
3000
(21, 207)
3000
(21, 207)
3000
(21, 207)
3000
(21, 207)
3000
(21, 207)
3000
(21, 207)
3000
(21, 207)
3000
(21, 207)
3000
(21, 207)
3000
(21, 207)
3000
(21, 207)
3000
(21, 207)
3000
(21, 207)
3000
(21, 207)
3000
(21, 207)
Volts
Proportioner
Model
Gun
Unheated
Hose
35 ft (10.6 m)
Cord
Adapter
100-120 VAC
24T100
25R000
---
100-120 VAC
24T100
25R000
---
100-120 VAC
24T100
25R000
---
200-240 VAC
24R900
25R000
200-240 VAC
24R900
25R000
200-240 VAC
24R900
25R000
200-240 VAC
24R900
25R000
200-240 VAC
24R900
25R000
200-240 VAC
24R900
25R000
200-240 VAC
24R900
25R000
200-240 VAC
24R900
25R000
200-240 VAC
24R900
25R000
200-240 VAC
24R900
---
200-240 VAC
24R900
---
200-240 VAC
24R900
---
North
America
Europe
Australia/
Asia
North
America
Europe
Australia/
Asia
North
America
Europe
Australia/
Asia
North
America
Europe
Australia/
Asia
Model
Fusion® Air
Purge
Probler® P2
Fusion Pro
Connect
Fusion Air
Purge
Fusion Air
Purge
Fusion Air
Purge
Part
249810
GCP2RA
25T481
249810
249810
249810
Probler P2
GCP2RA
Probler P2
GCP2RA
Probler P2
GCP2RA
Fusion Pro
Connect
Fusion Pro
Connect
Fusion Pro
Connect
25T481
25T481
25T481
---
---
---
---
---
---
9
Models
Models
The model number, series letter, and serial number are located on the back of the cart. For faster assistance, please
have that information ready before calling Customer Service.
Bare
Proportioner
Part, Series
24T100, A
24R900, A
Volts
100-120
VAC
200-240
VAC
* Electrical
Connection
20 A cord
(motor)
Maximum Working Pressure,
psi (MPa, bar)
3000 (21, 207)
20 A cord
(heaters)
15 A cord
(motor)
15 A cord
(heaters)
Approvals
3000 (21, 207)
9902471
Conforms to ANSI/UL
Std. 499 Certified to
CAN/CSA Std.
C22.2 Number 88
* See page 16 for detailed electrical requirements.
Related Manuals
The following manuals are for Reactor E-10hp components and accessories. Some are supplied with your package,
depending on its configuration. Manuals are also available at www.graco.com.
Manual in
English
Description
Displacement Pump
311076
Instruction-Parts Manual
Fusion Air Purge Spray Gun
309550
Instruction-Parts Manual
Probler P2 Spray Gun
313213
Instruction-Parts Manual
Probler P2 Recirculation Kit
406842
Instruction-Parts Manual
Lift Ring Kit
332977
Instruction-Parts Manual
10
332144K
Overview
Overview
The Reactor E-10hp is a portable, electric-powered, 1:1
mix ratio proportioner for use with:
The Reactor E-10hp has two recirculation speeds, slow
and fast, and an adjustable pressure output.
•
•
•
Slow Recirculation
Polyurea
Polyurea hybrid coatings
Polyurethane foam
Material may be applied with impingement mix spray
guns.
The Reactor E-10hp is gravity-fed from 6 gal. (22.7 liter)
supply tanks mounted on the unit.
Severe duty, positive displacement reciprocating piston
pumps meter fluid flow to the gun for mixing and
applying. When set to recirculation mode, the Reactor
E-10hp will circulate fluids back to the supply tanks.
•
•
•
•
Fast Recirculation
The Reactor E-10hp uses primary heating rods and
boost heating rods, for each fluid, and an insulated
hose bundle with circulation return hoses. This allows
the hoses and gun to be preheated to the desired
temperature before spraying. The boost heating rods
are used during circulation mode to reduce heatup
time. Digital displays show the temperatures of the two
fluids.
•
Electronic controls monitor fluid pressures, drive the
motor, and alerts the operator if errors occur. See
Motor/Pump Status Codes, page 15, for further
information.
•
332144K
Slow circulation results in a higher temperature
transfer in the heater, so hoses and gun heat up
quicker.
Good for touchup or low flow spraying, up to
moderate temperature.
Not used to circulate full tanks up to temperature.
Use with 245 fa blowing agent foams, to minimize
heat returned to tank and reduce frothing.
•
•
Use to support higher flow rates or higher
temperatures by preheating the tanks.
Agitates fluid within tanks, to avoid heating only the
fluid at the top of the tank.
Use for flushing.
Pressure Adjust
Automatically maintains selected pressure output
for dispensing or spraying.
11
Component Identification
Component Identification
J
V
B
P
G
A
F
T
S
N
E
T
G
S
ti21488a
K
P
D
Z
L
H
ti21488a
W
R
C
X
AZ
FIG. 1 Component Identification
Key
A
B
C
D
E
F
G
H
J
K
L
M
12
Supply Tank (ISO)
Supply Tank (RES)
Pump (ISO)
Pump (RES)
Heater (under shroud)
Fluid Pressure Gauges
Spray and Overpressure Relief Valves
Tank Level Sensors (bottom of tanks)
Control Panel; see FIG. 2, page 13
Electric Motor and Drive Housings
Insulated Hose Bundle (includes circulation
return hoses)
Fusion Air Purge Spray Gun
M
ti6987b
Key
N
P
R
S
T
U
V
W
X
Y
Z
AZ
Desiccant Dryer
Recirculation Tubes
Air Line Inlet (quick-disconnect fitting)
Outlet Hose Connections
Return Hose Connections
Fluid Temperature Sensors (located on heater
assembly, under shroud)
Hose Rack and Control Shield
Fluid Inlet Ball Valves (each side)
Fluid Inlet Strainers (each side)
Power Cords (not shown)
Fluid Temperature Gauges (each side)
Air Filter/Moisture Separator
332144K
Controls and Indicators
Controls and Indicators
See Controls and Indicators identification table, page
14.
NOTICE
To prevent damage to the soft key buttons, do not
press the buttons with sharp objects such as pens,
plastic cards, or fingernails.
Heater Controls
AL
AM
AA
AE
AB
AN
AF
AC
AD
AR
AP AO
AG
AH
AS
°F
AJ
°C
AK
FIG. 2 Heater Controls and Indicators
System Controls
AW
AX
AY
-
STATUS
1
AT
I
0
I
2
3
4
5
6
++
7
AV
8
--
9
10
AU
ti21962a
FIG. 3 System Controls and Indicators
332144K
13
Controls and Indicators
Controls and Indicators
Key
Name
Heater Controls
AA
ISO Setpoint Increase
AB
ISO Setpoint Decrease
AC
RES Setpoint Increase
AD
RES Setpoint Decrease
AE
ISO Heater On/Off Key
AF
RES Heater On/Off Key
AG
Actual Temperature Key
AH
Target Temperature Key
AJ
AK
AL
Temperature Scale Key °F
Temperature Scale Key °C
Temperature Display
Heater Indicators
AM
ISO Heater Activity
AN
RES Heater Activity
Description
Increases the temperature setpoint by one degree in the units selected
within the setpoint limits. Press target key prior to adjusting.
Decreases the temperature setpoint by one degree in the units
selected within the setpoint limits. Press target key prior to adjusting.
Increases the temperature setpoint by one degree in the units selected
within the setpoint limits. Press target key prior to adjusting.
Decreases the temperature setpoint by one degree in the units
selected within the setpoint limits. Press target key prior to adjusting.
Turns the heater on or off for ISO zone. Also clears heater zone
diagnostic codes, see page 32.
Turns the heater on or off for RES zone. Also clears heater zone
diagnostic codes, see page 32.
Press to display the actual temperature. Press and hold to display the
electrical current.
Press to display the target temperature. Press and hold to display the
heater control circuit board temperature.
Press to change the temperature scale to degrees Fahrenheit.
Press to change the temperature scale to degrees Celsius.
Show the actual temperature or target temperature of the heater
zones, depending on the selected mode. Defaults to actual at startup.
The range is 32-170°F (0-77°C) for ISO and RES.
The LEDs flash when heater zones are on. The duration
of each flash shows the extent that the heater is
turned on.
The LEDs flash when heater zones are on. The duration
of each flash shows the extent that the heater is
turned on.
The actual temperatures are displayed.
The target temperatures are displayed.
Indicates that temperatures are displayed in °F.
Indicates that temperatures are displayed in °C.
AO
Actual Temperatures Active
AP
Target Temperatures Active
AR
Fahrenheit Units Active
AS
Celsius Units Active
System Controls
AT
Heater Power
Enables heater control. The switch includes a 20 A circuit breaker.
AU
Motor Power
Enables motor. The switch includes a 20 A circuit breaker.
AV
Motor Pump Control Function Knob Selects operation mode / pressure setpoint. See Motor/Pump
Control Function Knob, page 15.
System Indicators
AW
Boost Heat Indicator
Indicates that the boost heat is active.
AX
Tank Level Indicator
See Tank Level Sensor LED, page 15.
AY
System Status Indicator
Flashes an error code if alarm or deviation is active. See Motor/Pump
Status Codes, page 15.
14
332144K
Controls and Indicators
Motor/Pump Control Function Knob
Use the knob (AV) to select desired function.
Icon
Setting
Park
Function
Stops motor and
automatically parks pumps.
Slow
Slow recirculation speed.
Recirculation
Fast
Fast recirculation speed.
Recirculation
Pressure
Adjust
Adjusts fluid pressure to
gun in spray mode.
Motor/Pump Status Codes
If error occurs, the status indicator (AY) will blink 1 to 19
times to indicate the status code, pause, then repeat, or
will blink other active error codes. See TABLE 1 for a
brief description of status codes.
Table 1: Motor/Pump Status Codes
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15-19
332144K
Name
Pressure imbalance between ISO and RES
sides
Pressure deviation from setpoint
Pressure transducer ISO failure
Pressure transducer RES failure
Excessive current draw
High motor temperature
No cycle counter switch input
High cycle rate deviation (more than 1.0
GPM)
High cycle rate shutdown (more than 1.1
GPM)
Low tank level
Not used
Locked motor rotor
Motor controller bus overvoltage
Motor controller bus undervoltage
Motor controller high temperature
Motor controller fault
NOTE: The default is to shut down if a status code
indication occurs.
Heater Control Diagnostic Codes
Heater control diagnostic codes appear on the
temperature display. These alarms turn off heat.
Table 2: Heater Control Diagnostic Codes
Code
01
02
03
04
05
06
09
99
Name
High fluid temperature
High zone current
No zone current with heater on
Thermocouple not connected
High controller temperature
No communications with zone
pod
Display is missing
No communication with heater
control module
Alarm Zone
Individual
Individual
Individual
Individual
Individual
Individual
Individual
Individual
Tank Level Sensor LED
The tank level sensor LED (AX) is triggered when
chemical is not present in either tank.
Table 3: Tank Level Indicator (AX)
Chemical
> 1 gallon
< 1 gallon
Status
Off
Flashing
15
Setup
Setup
Locate Reactor
Locate the Reactor on a level surface.
To avoid electric shock, always unplug both cords
before servicing the Reactor and wait one minute.
NOTE: Do not expose the Reactor to rain.
Electrical Requirements
Heater Power
1
Improper wiring may cause electric shock or other
serious injury if work is not performed properly. All
electrical wiring must be done by a qualified
electrician and comply with all local codes and
regulations.
2
1
1. Connect the Reactor to the correct power source
for your model. See TABLE 4. Power cords must be
connected to two separate, dedicated circuits. See
FIG. 4.
1
2. Some models include cord adapters for use outside
North America. Connect the appropriate adapter to
the unit’s power cord before connecting to your
power source.
2
TI7061a
Motor Power
Ensure no other high amp loads are connected while running
Reactor.
To verify separate circuits, plug in Reactor or a worklight and
cycle breakers on and off.
FIG. 4 Use Two Separate Circuits
Table 4: Electrical Requirements
Required Power
Source
200-240VAC, 1 phase, Two separate, dedicated
50/60 Hz, two 15 ft
circuits rated at minimum
(4.5 m) power cords
of 15 A each
Model
100-120VAC, 50/60
Hz, two 15 ft (4.5 m)
power cords
Two separate dedicated
circuits rated at minimum
of 20 A each
Power Cord
Connectors
Supplied Local Adapters
Two IEC 3-20 C20
Plugs
NEMA 6-15P
(North America)
Euro CEE74
(Europe)
YP-39 AS3112 (Australia/Asia)
Two NEMA
5-20P Plugs
Table 5: Extension Cord Requirements
Model
All models
Up to 50 ft (15 m)
AWG 12
Cords must be 3-conductor grounded, rated for your environment.
16
Required Wire Size
Up to 100 ft (30 m)
AWG 10
332144K
Setup
Grounding
The equipment must be grounded to reduce the risk
of static sparking and electric shock. Electric or static
sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock.
Grounding provides an escape wire for the electric
current.
Reactor: grounded through the power cord.
2. Connect the recirculation hoses from the gun
recirculation ports to the connections (S).
S
R
(RES)
S
R
ti21488A
(ISO)
Generator (if used): follow your local code. Start and
stop the generator with the power cord(s)
disconnected.
Spray gun: grounded through the supplied fluid hoses,
connected to a properly grounded Reactor. Do not
operate without at least one grounded fluid hose.
Object being sprayed: follow your local code.
Solvent pails used when flushing: follow your local
code. Use only metal pails, which are conductive,
placed on a grounded surface. Do not place pail on a
nonconductive surface, such as paper, plastic, or
cardboard, which interrupts grounding continuity.
To maintain grounding continuity when flushing or
relieving pressure: hold a metal part of spray gun
firmly to the side of a grounded metal pail, then trigger
gun.
Connect Fluid Hoses
1. Connect the fluid supply hoses to the outlet hose
connections (R, FIG. 5). Red hoses for ISO, blue for
RES. Fittings are sized to prevent connection
errors. Connect the other end of hoses to ISO and
RES inputs of gun.
NOTE: Probler guns use a Probler P2 recirculation
accessory kit.
Air
FIG. 5 Connect the Recirculation Hoses
ti6988b
Connect Gun Air Hose
1. Connect the gun air hose to the gun air input and to
the air filter outlet (Z). If you are using more than
one hose bundle, join the air hoses with the nipple
provided with the hose bundle.
2. On units with Fusion guns, connect the supplied
ball valve and quick-disconnect coupler to the gun
air hose, then connect the coupler to the gun air
fitting.
Connect Main Air Supply
Connect the main air supply to the quick disconnect
fitting (Q) on the unit. The air supply hose must be at
least 5/16 in. (8 mm) ID up to 50 ft (15 m) or 3/8 in. (10
mm) ID up to 100 ft (30 m).
NOTE: An air Filter/Moisture Separator (Z) is equipped
with an automatic moisture drain.
Flush Before First Use
The Reactor is tested with a plasticizer oil at the factory.
Flush out the oil with a compatible solvent before
spraying. See Flushing, page 26.
332144K
17
Setup
Fill Wet-Cups
Keep the felt washers in the pump wet-cups saturated
with ISO pump oil. The lubricant creates a barrier
between the ISO and the atmosphere.
Fill Fluid Tanks
NOTICE
The pump rod and connecting rod move during
operation. Moving parts can cause serious injury
such as pinching or amputation. Keep hands and
fingers away from wet-cup during operation. Shut off
Motor Power before filling the wet-cup.
Fill the wet-cups through slots in the plate (BA), or
loosen the screws and swing the plate aside.
To prevent cross-contamination of fluids and
equipment parts, never interchange (isocyanate) and
(resin) parts or containers.
Have at least two 5 gal. (19 liter) pails to transfer fluid
from drums to supply tanks. Label one pail “ISO” and
the other “RES”, using the red and blue labels
provided. Always double-check which material you
have before pouring it in the supply tanks. Pouring is
easier if pails are not filled to the top.
Open only one supply tank at a time, to avoid splashing material from one tank into the other when filling.
BA
NOTE: Using a drill and mixing blade, mix filled or
separated materials in the pail before adding to the
tanks. Material left in the tanks overnight may need to
be remixed in the tanks.
1. Lift the hose rack. Remove the tank cover and pour
ISO into the tank (red side, with the desiccant filter
in cover). Replace the cover
1
.
RES
ti21488A
ISO
ti21488A
1
Add a thin coating of grease lubricant to the tank
o-ring if the lid is difficult to attach to the tank.
NOTE: The desiccant filter is blue when fresh, and turns
pink when saturated. Be sure the shipping plugs are
removed from openings on the desiccant filter.
2. Remove the tank cover and pour resin into RES
tank (blue side). Replace the cover.
NOTE: Add thin coating of grease lubricant to tank
o-ring if lid is difficult to assemble to tank.
18
332144K
Setup
Purge Air and Flush Fluid From
Lines
6. Set Recirc/Spray valves to Recirc.
To avoid fire and explosion:
•
•
•
5. Turn on Motor Power. System status indicator (AY)
should turn on.
Flush equipment only in a well-ventilated area.
Ensure main power is off and heater is cool before
flushing.
Do not turn on heater until fluid lines are clear of
solvent.
1. Remove both recirculation tubes (P) from the tanks
and secure each one in a dedicated waste
container.
P
ti21495a
7. Set function knob to Slow Recirc
Recirc
or Fast
.
1
0
2
3
1
4
2
0
5
3
4
5
6
+
8
-
6
OR
7
9
10
+
7
8
-
9
10
ti21489a
ti21488A
2. Set function knob to Stop/Park
.
8. When clean fluids exit both recirculation tubes (P),
set function knob to Stop/Park
1
1
0
2
3
0
4
.
4
5
6
+
6
7
7
8
-
8
-
9
9
10
10
ti21490a
3. Plug in power cords(s). See Table 2, page 16.
4. Open both pump fluid inlet valves (V, shown in
open position).
332144K
3
5
+
V
2
ti21490a
9. Replace the recirculation tubes (P) in the supply
tanks.
ti21917a
19
Startup
Startup
Heated fluid can cause equipment surfaces to
become very hot. To avoid severe burns:
•
•
•
Do not operate Reactor without all covers and
shrouds in place.
Do not touch hot fluid or equipment.
Allow equipment to cool completely before
touching it.
b. Press
to display target temperatures.
c. To set
heat zone target temperature,
press
or
until the display shows
desired temperature. Repeat for
zone.
1. Perform Setup, page 16.
2. Set the function knob to Slow Recirc
Recirc
or Fast
-
1
2
0
3
7. Adjust the heat controls as necessary for a stable
spray temperature.
-
-
-
STATUS
4
5
6
+
7
8
-
9
OR
10
1
0
2
3
4
5
6
+
7
8
-
9
10
ti21489a
3. See Heatup Guidelines, page 21, then continue
with steps 3-6.
4. Turn on Heater Power.
°F
or
Table 6: Approximate heatup time for starting a cold
machine with 5 gallons (19 liters) per side
Fluid Spray Target
Temperature
125°F (52°C)
170°F (77°C)
120VAC
230VAC
15 minutes
40 minutes
10 minutes
20 minutes
35 ft (10.7 m) Hose
(1 bundle)
NOTE: Heatup times are based on 70°F (21°C) starting
material temperature and 70°F (21°C) ambient
temperature.
5. Set temperatures:
°C
temperature scale.
20
to display actual temperatures.
6. Circulate through the heater until temperature
readouts display desired temperature. See TABLE 6.
.
STATUS
a. Press
d. Press
to change the
NOTE: Different fluids will absorb heat at different
rates. When refilling a warm machine, heatup times will
be less.
332144K
Startup
Heatup Guidelines
The fluids must be circulated from the pumps through
the heater, hoses, and back to the tanks to ensure
warm fluids are supplied to the gun.
Heat Management Tips
•
Heaters perform better with lower flow rates or
smaller mix modules.
•
Triggering the gun for short periods helps maintain
efficient heat transfer, keeping material at the
desired temperature. Triggering the gun for a long
period may not allow enough heating time,
depending on material temperature in tanks.
•
If the temperature displays fall below acceptable
Slow Recirculation
•
•
Slow Recirc results in a higher temperature transfer
in the heater, so hoses and gun heat up quicker.
Good for touchup or low flow spraying, up to
moderate temperature.
Fast Recirculation
Fast Recirc keeps heaters on full-time to bring fluid
tanks up to temperature. The higher your flow rate, the
more heat needed in the tanks before spraying.
•
For 200-240VAC systems: Use Fast Recirc until
the pump inlet fluid temperature gauges (Y) are
within 45°F (25°C) of target outlet temperature.
•
For 100-120VAC systems: Use Fast Recirc until
the pump inlet fluid temperature gauges (Y) are
within 30°F (17°C) of target temperature.
•
Volume in tanks: Use only what you need. For
example, 2.5 gal. (10 l) in each tank will heat up
almost twice as fast as 5 gal. (20 l).
•
Mixes fluid within tanks, to avoid heating only the
fluid at the top of the tank.
•
Use for flushing.
332144K
limits, set the function knob to Slow Recirc
and circulate again to bring temperatures back up.
•
Each 35 ft (10.7 m) hose bundle adds about 5
minutes to heatup time, with most materials. The
maximum recommended hose length is 105 ft (32
m).
•
For a quicker start, do initial heatup circulation with
the tanks 1/4 to 1/3 filled, then add more material.
21
Operation
Operation
Spraying
NOTE: Air is supplied to the spray gun with the gun
piston safety lock or trigger safety lock engaged and
the gun fluid manifold valves closed (if present).
4. Check fluid pressure gauges to ensure proper
pressure balance. If imbalanced, reduce pressure
of higher component by slightly turning
Recirc/Spray valve for that component toward
Recirc, until gauges show balanced pressures. The
pressure imbalance alarm (Status Code 1) is
inactive for 10 seconds after entering spray
pressure mode, to allow time to balance pressures.
In this example, RES side
pressure is higher, so use
the RES side valve to balance pressures.
ti21493a
Fusion
Probler
1. Set function knob to Stop/Park
system status indicator LED is on.
2
1
3
. Verify
4
0
5
NOTE: Watch gauges for 10 seconds to be sure
pressure holds on both sides and pumps are not
moving.
5. Open gun fluid manifold valves (impingement mix
guns only).
6
+
7
8
-
9
ti21490a
10
Fusion
2. Set Recirc/Spray valves to Spray.
NOTE: On impingement guns, never open fluid
manifold valves or trigger gun if pressure are
imbalanced.
ti21491a
3. Turn function knob to Pressure Adjust
6. Disengage piston safety lock or trigger safety lock.
. Keep
turning to the right until fluid pressure gauges show
desired pressure.
1
0
2
3
Fusion
4
5
6
+
7
8
-
9
10
22
ti21492a
Probler
Probler
7. Test spray onto cardboard or plastic sheet. Verify
that material fully cures in the required length of
time, and is the correct color. Adjust pressure and
temperature to get desired results. Equipment is
ready to spray.
332144K
Operation
Pause
Refill Tanks
1. Engage the piston safety lock or trigger safety lock.
If you are operating at high temperatures or flow rates,
follow Pause instructions, page 23, to bring the tanks
up to temperature.
To bring the hose and gun back to spray temperature
after a brief break, use the following procedure.
Material can be added to the tanks at any time. See Fill
Fluid Tanks, page 18.
NOTICE
To prevent cross-contamination of fluids and
equipment parts, never interchange ISO and RES
parts or containers.
Probler
Fusion
2. Set the function knob to Slow Recirc
.
-
1
0
2
-
-
STATUS
3
Have at least two 5 gal. (19 liter) pails to transfer fluid
from drums to supply tanks. Label one pail “ISO” and
the other “RES”, using the red and blue labels
provided. Always double-check which material you
have before pouring it in the supply tanks. Pouring is
easier if pails are not filled to the top.
-
STATUS
4
5
6
+
7
8
-
9
OR
1
0
2
3
4
5
6
+
7
8
-
10
9
10
ti21489a
Open only one supply tank at a time, to avoid splashing material from one tank into the other when filling.
3. Set the Spray valves to Recirc until the temperature
readouts come back up.
ti21495a
NOTE: If you stop spraying for more than 2 minutes
when using an impingement mix gun, close gun fluid
valves. Doing this will keep the internal parts of the gun
cleaner and prevent crossover.
Fusion
332144K
Probler
23
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
Shutdown
For longer breaks (more than 10 minutes) use the
following procedure. If you will be shutdown for more
than 3 days, first see Flushing, page 26.
1. Shut off Heater Power.
2. Shut off Motor Power.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop spraying and before
cleaning, checking, or servicing the equipment.
1. Engage piston safety lock or trigger safety lock.
2. Set function knob to Stop/Park
1
0
2
3
4. Close the gun fluid valves ISO and RES. Doing this
will keep the internal parts of the gun cleaner and
prevent crossover.
Fusion
Probler
5. Refer to your separate gun manual and perform
Shutdown procedure.
Probler
Fusion
3. Follow all steps of the Pressure Relief Procedure,
page 24.
.
4
5
6
+
7
8
-
9
10
ti21490a
3. Turn Recirc/Spray valves to Recirc. Fluid will be
dumped to supply tanks. Pumps will move to the
bottom of their stroke. Ensure gauges drop to 0.
ti21495a
24
332144K
Maintenance
Maintenance
•
Check pump wet-cups fluid level daily, page 18.
•
Throat u-cup is not adjustable. Do not overtighten
packing nut/wet-cup.
•
Keep component ISO from exposure to moisture in
atmosphere, to prevent crystallization.
•
Wipe supply tank lid o-ring, inner rim, and inner
tank walls daily to prevent ISO crystallization. Keep
film of grease on o-ring and inside of lid.
•
Check desiccant filter weekly. Filter is blue when
fresh, and turns pink when saturated.
•
Remove plug (X) and clean fluid inlet strainer (S) as
needed. Always clean the fluid inlet strainers after
flushing.
•
Generally, flush if you will shutdown for more than
three days. Flush more often if material is moisture
sensitive and humidity is high in the storage area, or
if material may separate or settle out over time.
•
If using an impingement mix gun, close gun fluid
valves when not spraying. Doing this will keep the
internal parts of the gun cleaner and prevent
crossover. Clean gun mix chamber ports and check
valve screens regularly. See gun manual.
Fusion
•
Probler
If using an Fusion Air Purge impingement mix
gun, always grease the gun after use until purge air
carries grease mist out the front of the gun. See
your gun manual.
S
X
ti21836a
332144K
25
Flushing
Flushing
4. Remove recirculation tubes (P) from supply tanks
and place in original containers or waste
containers.
To avoid fire and explosion, always ground
equipment and waste container. To avoid static
sparking and injury from splashing, always flush at
the lowest possible pressure. Hot solvent may ignite.
To avoid fire and explosion:
•
•
•
Flush equipment only in a well-ventilated area
Ensure main power is off and heater is cool before
flushing
Do not turn on heater until fluid lines are clear of
solvent
Flush if you will be shut down for more than 3 days.
Flush more often if material is moisture sensitive
and humidity is high in the storage area, or if
material may separate or settle out over time.
• For long term storage, flush out the solvent with a
storage fluid or, at minimum, clean motor oil
• Flush with a fluid that is compatible with the fluid
being dispensed and the equipment wetted parts.
• Always leave some type of fluid in system. Do not
use water.
1. Engage piston safety lock or trigger safety lock.
Close fluid valves ISO and RES. Leave air on.
P
ti21488a
5. Turn Recirc/Spray valves to Recirc.
•
ti21495a
6. Set function knob to Fast Recirc
. Pump
material from supply tanks until no more comes
out.
2
1
3
4
0
5
6
+
7
8
-
9
10
ti31496a
7. Set function knob to Stop/Park
Probler
Fusion
2
1
3
.
4
0
5
6
+
7
8
-
9
2. Set function knob to Stop/Park
1
0
2
3
.
4
5
6
+
7
8
-
9
10
ti21490a
3. Shut off Heater Power. Allow system to cool.
10
ti21490a
8. Wipe out any remaining material from the supply
tanks. Fill each supply tank with 1-2 gal. (3.8-7.6 l)
of solvent recommended by your material
manufacturer.
9. Set function knob to Fast Recirc
. Pump
solvent through system to waste containers.
1
0
2
3
4
5
6
+
7
8
-
9
10
26
ti31496a
332144K
Flushing
10. When nearly clear solvent comes from recirculation
tubes, set function knob to Stop/Park
.
Return recirculation tubes to supply tanks.
2
1
3
4
0
5
6
+
7
Purge Hoses
Disconnect hoses from gun and secure back into the
tanks for thorough cleaning with solvent.
•
Turn Spray valve ISO to Spray.
•
Open the gun into a waste ISO container.
•
Set the function knob to Slow Recirc
hose is flushed.
•
•
Set the function knob to Park
Repeat for the RES side.
.
13. Set the function knob to Park
.
8
-
9
10
ti21490a
11. Set function knob to Fast Recirc
. Circulate
solvent through system for 10-20 minutes to ensure
thorough cleaning.
1
0
2
3
4
5
6
+
7
8
-
9
10
ti31496a
12. To flush the gun, refer to your gun instruction
manual.
until
14. Solvent flushing is a two step process. Go back to
step 4, drain the solvent, and flush again with fresh
solvent.
15. Leave unit filled with solvent, plasticizer, clean
motor oil, or refill supply tanks with new material
and reprime.
NOTE: Never leave the unit dry unless it has been
disassembled and cleaned. If fluid residue dries in the
pumps, the ball checks may stick the next time you use
the unit.
332144K
27
Troubleshooting
Troubleshooting
Pump Control Status Codes
Determine the status code by counting the number of
times the system status indicator blinks. The status
indicator will blink 1-19 times to indicate a status code.
Multiple active status codes are separated by a longer
duration pause.
Status Code 1: Pressure Imbalance
The unit does not check for pressure imbalance at
setpoints less than 300 psi (2.1 MPa, 21 bar).
The unit does not check for pressure imbalance for 10
sec after entering pressure mode.
The unit senses pressure imbalance between
components ISO and RES, and warns or shuts down,
depending on settings of DIP switches 1 and 2. To turn
off automatic shutdown and/or tighten pressure
tolerances for status code 1, see DIP Switch Settings,
page 30.
1. Reduce pressure of higher component by slightly
turning Recirc/Spray valve for that component
toward Recirc, until gauges show balanced
pressures.
In this example, RES side
pressure is higher, so use
the RES side valve to balance pressures.
ti21493a
2. If pressure imbalance continues, see Proportioner,
page 36.
Status Code 2: Pressure Deviation from
Setpoint
The unit does not check for pressure deviation at
setpoint less than 400 psi (2.8 MPa, 28 bar).
The unit senses pressure deviation from a setpoint, and
warns or shuts down, depending on the settings of DIP
switches 3 and 4. If the equipment cannot maintain
enough pressure for a good mix with an impingement
mix gun, try using a smaller mix chamber or nozzle.
28
To turn off automatic shutdown and/or change
pressure tolerances for status code 2, see DIP Switch
Settings, page 30.
Deviation can occur if power is turned on if the function
knob (AV) is not set to Park. Leave knob in Park mode
until the status indicator LED turns on.
Status Code 3: Pressure Transducer ISO
Failure
1. Check transducer ISO electrical connection (J11) at
the board, FIG. 12, page 45.
2. Reverse ISO and RES transducer electrical
connections at the board, FIG. 12, page 45. If the
error moves to transducer RES (Status Code 4),
replace transducer ISO.See Pressure
Transducers, page 51.
Status Code 4: Pressure Transducer RES
failure
1. Check transducer RES electrical connection (J12)
at the board, FIG. 12, page 45.
2. Reverse ISO and RES transducer electrical
connections at the board, FIG. 12, page 45. If the
error moves to transducer ISO (Status Code 3),
replace transducer RES. See Pressure
Transducers, page 51.
Status Code 5: Excessive Current Draw
1. Shut off the unit and retry operation. The brushes
may not be fully seated.
2. Check fan operation. Elevated temperature can
cause excessive current draw.
3. Locked rotor; motor unable to turn. Replace the
motor. See Electric Motor, page 54.
4. Short on the control board. Replace the board. See
Motor Control, page 44.
5. Worn or hung up motor brush causing arcing of
brush at the commutator. Replace the brushes. See
Motor Brushes, page 55.
6. Disconnect motor connections from the control
board. Cycle power.
332144K
Troubleshooting
a. If status code 5 is still present, replace the
board.
b. If status code 5 is not active, test the motor.
See Test Motor, page 54.
Status Code 6: High Motor Temperature
The motor is running too hot.
1. Reduce the pressure duty cycle, gun tip size, or
move the Reactor to a cooler location. Allow 1 hour
for cooling.
2. Check the fan operation. Clean the fan and motor
housing.
3. Check J9 overtemperature connector on the
control board.
Status Code 7: No Cycle Counter Switch
Input
Have not received input from cycle counter switch for
10 seconds after selecting Recirc mode or unit is
unable to park within 15 seconds of entering park
mode.
1. Verify that the recirc valves are open and the unit is
set to Recirc mode.
2. Check the cycle counter switch connection to the
board (J10), see FIG. 12, page 45.
3. Check that the magnet (224) and cycle counter
switch (223) are in place under the RES side motor
end cover (229). Replace if necessary.
Status Code 8: High Cycle Rate
The system is spraying more than 1 gpm. The system
will shutdown if spraying more than 1.1 gpm.
1. Reduce the pressure and/or gun tip size.
Status Code 9: Low Tank Level
The tank level sensors sense ISO and RES material
density inside the tank, and warns or shuts down,
depending on settings of DIP switch 5. See DIP Switch
Settings, page 30.
1. Add material to the supply tank, if necessary.
332144K
2. Check that the tank level sensor is in contact with
the surface of the tank. Replace if necessary. See
Tank Fluid Level Sensors, page 56.
3. Check J6 connections on the control board. TABLE
8, page 45.
Level Sensor
Status
LED
Green - on
Green - off
Yellow - on
Yellow - off
Sensor is powered
Sensor is not powered
Sensor detects material
Sensor does not detect material
Status Code 11: Locked Motor Rotor
Verify that the pumps are not seized and move freely.
The motor is unable to turn. Replace the motor, page
54.
Shut off the unit and contact your distributor before
resuming operation.
Status Code 12: Motor Controller
Overvoltage
Too much voltage connected to the control board. See
, page 74, for power requirements.
Cycle the power and check the status indicator to see if
the error is still active.
Status Code 13: Motor Controller
Undervoltage
Not enough voltage connected to the control board.
See page 74, for power requirements.
Cycle the power and check the status indicator to see if
the error is still active.
Status Code 14: Motor Controller High
Temperature
The motor control board is too hot.
Shutdown and move the Reactor to a cooler location.
Allow 1 hour for cooling.
Status Code 15-19: Motor Controller Faults
Cycle power. If the error is still present, replace the
board. See Motor Control, page 44.
29
Troubleshooting
DIP Switch Settings
3. Locate the DIP switch on the control board.
To avoid electric shock, always unplug both power
cords before servicing Reactor and wait one minute.
1. Turn power off and unplug the power cords from
the wall outlets.
2. Remove the screws (21) and display cover (26).
FIG. 6 DIP Switch
21
26
4. Set the DIP switches to the desired positions. See
DIP Switch Settings and Functions, page 31
5. Replace the display cover (26) and plug in the unit.
6. Cycle the power switch to activate changes to the
DIP switch.
30
332144K
Troubleshooting
DIP Switch Settings and Functions
DIP Switch and Function
DIP Switch Settings and Functions
OFF
ON
DIP Switch 1
DEVIATION
If selected, displays a status code or displays a status code
and causes shutdown if the pressure imbalance exceeds
selection made in DIP Switch 2.
DEVIATION AND
SHUTDOWN
DIP Switch 4
Causes deviation if pressure setpoint is greater than:
300 psi (2.1 MPa, 21
bar)
*500 psi (3.5 MPa, 35
bar)
*DEVIATION
SHUTDOWN
DISABLE
*ENABLE
DIP Switch 2
See Dip Switch 1 and 2 Settings table, page 31
Select pressure imbalance limits, that if exceeded, will cause
a deviation and a shutdown (if enabled).
DIP Switch 3
DEVIATION
*SHUTDOWN
If selected, causes shutdown or displays a status code due
to deviation of pressure from setpoint exceeds selection
made in DIP Switch 4.
DIP Switch 5
Causes shutdown or displays a status code for low fluid
level in tanks.
DIP Switch 6
Enables or disables boost heat.
DIP Switch 7
(40% if < 800 psi [5.6
MPa, 56 bar])
Not used
DIP Switch 8
*
(25% if < 800 psi [5.6
MPa, 56 bar])
Not used
Default DIP Switch Settings
DIP
Switch 1
DIP Switch 1 and 2 Settings
DIP Switch
Deviation
2
Off
Off
Off
*On
*On
Off
*On
*On
332144K
Shutdown
300 psi (2.1
MPa, 21 bar)
---
300 psi (2.1
MPa, 21 bar)
500 psi (3.5
MPa, 35 bar)
500 psi (3.5
MPa, 35 bar)
500 psi (3.5
MPa, 35 bar)
---
800 psi (5.6
MPa, 56 bar)
31
Troubleshooting
Heat Control Diagnostic Codes
Heat control diagnostic codes appear on the
temperature display.
These alarms turn off heat. Codes E03 and E04 can be
cleared by pressing
. To clear other codes:
E01: High Fluid Temperature
•
•
•
1. Shut off Heater Power.
•
•
2. Shut off Motor Power.
•
•
3. Turn on Motor Power and Heater power to clear.
Code
01
Code Name
High fluid temperature
02
High zone current
04
Thermocouple not
connected
03
No zone current
Alarm
Zone
Individual
Individual
Individual
Individual
Corrective
Action page
32
33
33
33
•
The thermocouple ISO or RES (310) senses a fluid
temperature above 260°F (71°C).
The overtemperature switch ISO or RES (308)
senses a fluid temperature above 230°F (110°C)
and opens. At 190°F (87°C) the switch closes again.
The thermocouple ISO or RES (310) fails, is
damaged, is not touching the heater element (307),
or has a poor connection to the temperature control
board.
The overtemperature switch (308) fails in the open
position.
The temperature control board fails to turn off any
heat zone.
The zone power wires or thermocouples are
switched from one zone to another.
Failed heater element where thermocouple is
installed.
A loose wire
E01 Checks
Troubleshooting this equipment requires access to
parts that may cause electric shock or other serious
injury if work is not performed properly. Have a
qualified electrician perform all electrical
troubleshooting. Be sure to shut off all power to the
equipment before repairing.
Before checking the thermocouple, note which zone
(ISO or RES) has high fluid temperature.
1. Check that connector B is firmly plugged into the
heater control module. See Temperature Control
Modules Connections, page 47.
2. Clean and re-plug the connections.
3. Check the connections between the temperature
control module and overtemperature switch, and
between the temperature control module and
thermocouples. Ensure all wires are securely
connected to connector B on heater control
module. See TABLE 7, page 33.
4. Remove connector B from heater control module
and check continuity of thermocouples by
measuring resistance across pins on the plug end.
32
332144K
Troubleshooting
5. Verify fluid temperature, using an external
temperature sensing device.
Table 7: Connector B Resistance Measurements
120V
Connector
B1
B2
B2
B2
B2
B2
Pin
1, 2
1
2
4
5
3
230V
Connector
B1
B1
B1
B1
B1
B1
Pin
1, 2
5
6
8
9
3-4,7,10
Description
Overtemperature Switch
Thermocouple ISO, R (red)
Thermocouple ISO, Y (yellow)
Thermocouple RES, R (red)
Thermocouple RES, Y (yellow)
Unused
If temperature is too high (sensor reading is 260°F
[127°C] or above):
6. Check if the thermocouples are damaged, or not
contacting the heater element, see FIG. 16, page
50.
7. Check if the temperature control module turns off
when the equipment reaches the temperature
setpoint:
a. Set the temperature setpoints far below the
displayed temperature.
b. Turn the zone on. If the temperature rises
steadily, the power board is failing.
c. Verify by exchanging with another power
module. See Replace Temperature Control
Modules, page 46.
d. If the exchanged module does not fix the
problem, the power module is not the cause.
8. Verify the continuity of heater elements with an
ohmmeter. See Test Heater Element, page 49.
Reading
nearly 0 ohms
4-6 ohms
4-6 ohms
N/A
E02: High zone current
When there is a high current error, the LED on that
zone’s module will turn red while the error is displayed.
1. See Before Beginning Repair, page 39.
2. Exchange the zone module with another one. Turn
the zone on and check for an error. If the error
disappears, replace the faulty module.
E03: No zone current
When a no current error occurs, the LED on the specific
zone’s module turns red when the error is displayed.
1. Check for a tripped circuit breaker on the Reactor
or at the power source of that zone. Replace the
circuit breaker if it trips habitually.
2. Check for a loose or broken connection at that
zone.
3. Exchange the zone module with another one. Turn
the zone on and check for an error. See Replace
Temperature Control Modules, page 46. If the
error disappears, replace faulty module.
4. If E03 occurs for all zones, the contactor may not
be closing. Verify wiring from the heater control to
the contactor coil.
E04: Thermocouple disconnected
1. Check the temperature sensor connections to the
green connectors (B) on the temperature control
module. See Temperature Control Modules
Connections, page 47.
2. Unplug and re-plug the sensor wires.
332144K
33
Troubleshooting
Reactor Electronics
2. Shut off Motor Power.
3. Relieve the pressure. Follow Pressure Relief
Procedure, page 24.
4. Allow the equipment to cool.
Before performing any troubleshooting procedures:
1. Shut off Heater Power.
PROBLEM
Temperature display
does not illuminate.
Erratic display;
display turns on and
off.
Display does not
respond properly to
button pushes.
Fan not working.
34
5. Try the recommended solutions in the order given
for each problem to avoid unnecessary repairs.
Also, determine that all circuit breakers, switches,
and controls are properly set and wiring is correct
before assuming there is a problem.
CAUSE
SOLUTION
Display disconnected.
Check the cable connections, FIG. 12, page 45.
Display cable damaged or corroded. Clean the connections; replace the cable if it is
damaged.
Blown fuse.
Replace the fuse (73) in the fuse holder on the DIN
rail assembly located under the electronics cover
(55).
Failed circuit board.
The display is failing. Replace.
Loose display cables on control
Check the cable connections to each display, FIG.
23 on page 72.
board.
Failed control board (displays get
Remove the access panel. Check if board LED is
power from control board).
lighted. If not, replace the board. See Motor
Control, page 44.
Inadequate power to control board. Check that the power supply meets requirements.
Loose power cable.
Check the cable connections, FIG. 23, page 72.
Heater power switch circuit breaker Display is powered from heater power circuit
tripped.
breaker. Cycle heater power off
, then on
Low voltage.
to reset breaker.
Ensure the input voltage is within specifications, ,
page 74.
Poor display connection.
Check the cable connections, FIG. 23, page 72.
Replace the damaged cable.
Display cable damaged or corroded. Clean connections; replace the cable if is damaged.
Poor display connection.
Check the cable connections, FIG. 23, page 72.
Replace the damaged cable.
Display cable damaged or corroded. Clean connections, FIG. 23, page 72. Replace the
damaged cable.
Ribbon cable on display circuit
Connect the cable, FIG. 23, page 72, or replace.
board disconnected or broken.
Broken display button.
Replace. See Control Panel, page 42.
Loose wire.
Check the fan wire.
Defective fan.
Replace. See Fans, page 55.
332144K
Troubleshooting
Heaters
2. Shut off Motor Power.
3. Relieve the pressure. Follow the Pressure Relief
Procedure, page 24.
Before performing any troubleshooting procedures:
1. Shut off Heater Power.
PROBLEM
Primary heater(s) does not
heat.
4. Allow the 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.
CAUSE
Heat turned off.
SOLUTION
Press
or
zone
keys.
Temperature control alarm.
Check the temperature display for diagnostic
code. See Heat Control Diagnostic Codes,
page 32.
Signal failure from thermocouple. See E04: Thermocouple disconnected, page
33.
Failed heater element.
Check the resistance of the heater elements.
See Test Heater Element, page 49.
Control of primary heat is
Dirty thermocouple connections.
abnormal; high temperature
overshoots or E01 error occurs
intermittently.
Thermocouple not contacting
heater element.
Examine the connection of the thermocouples
to long the green plug on the heater control
board. Unplug and re-plug the thermocouple
wires, cleaning off any debris. For
100-120VAC, unplug and re-plug the long
green connector. For 200-240V, unplug and
re-plug the green connector(s) B.
Loosen the ferrule nut (N), push in the
thermocouple (310) so tip (T) contacts the
heater element (307). Holding the
thermocouple tip (T) against the heater
element, tighten the ferrule nut (N) 1/4 turn
past tight. See FIG. 16, page 50 for illustration.
Failed heater element.
See Heaters, page 35.
Thermocouple wired incorrectly.
See E04: Thermocouple disconnected, page
33. Power up the zones one at a time and
verify that the temperature for each zone rises.
Signal failure from thermocouple. See E04: Thermocouple disconnected, page
33.
332144K
35
Troubleshooting
Proportioner
2. Shut off Motor Power.
3. Relieve the pressure. Follow the Pressure Relief
Procedure, page 24.
Before performing any troubleshooting procedures:
1. Shut off Heater Power.
PROBLEM
The Reactor does not operate.
No power.
CAUSE
4. Allow the 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 both power cords.
Cycle Motor Power and Heater Power
off
The motor does not operate.
The pump output is low.
36
, then on
both breakers.
Power turned on while function knob
Set the function knob to Park
set to a run position.
to reset
,
once status LED turns on. Then select
the desired function.
Loose connection on control board. Check the connection at the motor
power connections on the bottom
board. See FIG. 12, page 45.
Worn brushes.
Check both sides. Replace brushes
worn to less than 1/2 in. (13 mm). See
Motor Control, page 55.
Broken or misaligned brush springs. Realign or replace. See Motor
Brushes, page 55.
Brushes or springs binding in brush
Clean the brush holder and align the
holder.
brush leads for free movement.
Shorted armature.
Replace motor. Electric Motor, page
54.
Check motor commutator for burn
Remove the motor. Have a motor shop
spots, black pitting, or other damage. resurface the commutator, or replace
the motor. See Electric Motor, page
54.
Failed control board.
Replace the board. See Motor
Control, page 44.
Plugged fluid inlet strainer.
Clear. See Maintenance, page 25.
Leaking or plugged piston valve or
Check the valves. See your pump
intake valve in displacement pump.
manual.
332144K
Troubleshooting
PROBLEM
One side doesn’t come up to
pressure in spray mode.
CAUSE
Low fluid in the tank.
Dirty or damaged Spray valve.
Plugged fluid inlet strainer.
Pump intake valve plugged or stuck
open.
Material is too viscous to pump.
Pressure is higher on one side
when setting pressure with
function knob.
Pump intake valve partially plugged.
Fluid leak in pump packing nut
area.
Pressure doesn’t hold when
stalled against gun in spray
mode.
Worn throat seals.
Air in hose. Fluid is compressible.
Unequal size hoses or unequal hose
construction.
Pressures are not balanced when Unequal viscosities.
running, but pressure is
generated and holds on both
strokes.
Restriction on one side.
Pressure is higher on RES side
during startup of recirculation,
especially in High Recirc mode.
One gauge shows half as many
pulses as the other when pumps
are cycling.
Status indicator not lit.
ISO side rich; lack of RES side.
332144K
SOLUTION
Refill.
Clean or repair. See Replace Spray
Valves, page 40.
Clear. See Maintenance, page 25.
Clean the pump intake valve. See
Remove Intake Valve Only, page 41.
Warm the material before adding to the
tanks.
Clean the pump intake valve. See
Remove Intake Valve Only, page 41.
Purge air from the hose.
Use matching hoses, or balance
pressures before spraying.
Change the temperature setting to
balance viscosities.
Change the restrictor at mix point to
balance back pressure.
Clean the mix module or restrictor at
the mix manifold.
Clean the gun check valve screens.
Replace. See pump manual.
Leaking Spray valve.
Repair. See Replace Spray Valves,
page 40.
Leaking piston valve or intake valve in Repair. See you pump manual.
displacement pump.
Leaking gun shutoff.
Repair. See you gun manual.
This is normal. RES is typically higher No action required.
viscosity than ISO until the material is
heated during recirculation.
Loss of pressure on downstoke.
The intake valve is leaking or not
closing. Clean or replace valve. See
Replace Spray Valves, page 40.
Loss of pressure on upstoke.
The piston valve is leaking or not
closing. Clean or replace the valve or
packings. See Replace Spray Valves,
page 40.
The function knob is not set to Park
Turn the function knob to Park.
when power is applied.
Loose indicator cable.
Check that the cable is connected at J3
on the top motor control board. See
FIG. 12, page 45.
Failed control board.
Replace the board. See Motor
Control, page 44.
Shorted pressure transducer or
See Control Board LEDs, page 44 for
potentiometer input.
troubleshooting.
ISO side gauge is low.
RES side restriction downstream of the
gauge. Check the gun check valve
screen, mix module, or mix manifold
restrictor.
RES side gauge is low.
RES side material supply problem.
Check RES side inlet strainer and
pump intake valve.
37
Troubleshooting
PROBLEM
RES side rich; lack of ISO side.
CAUSE
ISO side gauge is low.
RES side gauge is low.
Tank level sensor does not sense Material build up.
empty tank (indicator LED on
control panel never blinks).
LED wires disconnected inside
control panel.
Tank level sensor sensitivity is too
high.
SOLUTION
ISO side material supply problem.
Check ISO side inlet strainer and pump
intake valve.
ISO side restriction downstream of
gauge. Check gun check valve screen,
mix module, or mix manifold restrictor.
Flush and clean the inside of the tanks.
Clean the outside of the sensor and
recessed area on tank.
Reconnect the LED wires.
Reset the tank fluid level sensor
sensitivity. See Reset Sensitivity, page
57.
Tank level sensor does not sense Tank level sensor is too far away from Check the position of both tank level
full tank (indicator LED on control tank.
sensors. See Tank Fluid Level
panel always blinking).
Sensors, page 56.
Sensor wires disconnected.
Reconnect the sensor wires in the
display panel.
Tank level sensor sensitivity is too
Reset the tank fluid level sensor
low.
sensitivity. See Reset Sensitivity, page
57.
38
332144K
Repair
Repair
Before Beginning Repair
Remove Supply Tank
1. See Before Beginning Repair, page 39.
Repairing this equipment requires access to parts
which may cause electric shock or other serious
injury if work is not performed properly. Have a
qualified electrician connect power and ground to
main power switch terminals, see page 16. Be sure to
shut off all power to the equipment before repairing
1. Flush if possible, see page 26. If not possible, clean
all parts with solvent immediately after removal, to
prevent isocyanate from crystallizing due to
moisture in the atmosphere.
2. Set function knob to Stop/Park
1
0
2
3
.
2. Relieve the pressure, Pressure Relief Procedure,
page 24.
3. Flush the system. Refer to Flushing, page 26.
4. Place a waste container under the y-strainer.
5. Close the fluid valve (V).
N
V
ti21893a
4
5
6
+
7
8
-
9
10
ti21490a
3. Shut off Motor Power.
6. Remove the filter drain hex nut (N) and drain
material.
7. Remove recirculation tubes (P) and place in waste
containers.
P
4. Shut off Heater Power. Allow system to cool.
ti21488a
8. Disconnect the swivel elbow at the pump fluid inlet.
5. Relieve the pressure. Follow Pressure Relief
Procedure, page 24.
9. Remove the six screws (28) holding the tank (27) to
the cart frame.
6. Disconnect the heater and motor power cords.
332144K
39
Repair
S
27
Replace Spray Valves
1. See Before Beginning Repair, page 39.
2. Relieve the pressure. Follow Pressure Relief
Procedure, page 24.
28
ti21837a
10. Loosen the nut and slide the tank level sensor (S)
away from the tank.
11. Pivot the top of tank to the side and remove the
tank with fluid inlet fittings, off the cart.
12. Reinstall in reverse order. Torque the screws (28) to
125 in.-lb (14 N•m).
3. See FIG. 7, page 40. Disassemble the Spray valves.
Clean and inspect all parts for damage.
4. Ensure that the seat (453a) and gasket (453b) are
positioned inside each valve cartridge (453).
5. Apply PTFE pipe sealant to all tapered pipe threads
before reassembling.
6. Reassemble in reverse order, following all notes in
FIG. 7, page 40.
455a (Red)
456
455b (Blue)
454
453
1
453a
453b
2
3
3
ti21838a
1
Torque to 250 in-lb (28 N•m).
2
Use blue threadlocker on valve cartridge threads into manifold.
3
Part of item 453.
FIG. 7 Spray Valves
40
332144K
Repair
Displacement Pump
Remove Entire Pump Assembly
7. Disconnect the fluid inlet (C) and outlet (D) lines.
Also disconnect the steel outlet tube (46) from the
heater inlet.
NOTE: Use a dropcloth or rags to protect the Reactor
and surrounding area from spills.
1. See Before Beginning Repair, page 39.
2. Relieve the pressure. Follow Pressure Relief
Procedure, page 24.
3. Close both fluid valves (V).
N
V
ti21893a
NOTE: Use dropcloth or rags to protect Reactor and
surrounding area from spills.
8. Remove the pump rod cover (222). Push the clip up
in back and push pin (217) out. Loosen the locknut
(218) by hitting firmly right-to-left with a
non-sparking hammer. Unscrew the pump. Refer to
your pump manual for repair instructions and parts.
9. Install the pump in reverse order of disassembly,
following all notes in FIG. 8, page 41. Clean strainer
(51). Reconnect the fluid inlet (C) and outlet (D)
lines.
10. Tighten the fluid outlet fitting (D), then tighten the
locknut (218) by hitting firmly with a non-sparking
hammer.
11. Set the function knob to Slow Recirc
. Purge air
and prime. See Purge Air and Flush Fluid From
Lines, page 19.
4. Open the filter drain hex nut (N) on the y-strainer.
217
Remove Intake Valve Only
D
If the pump is not generating any pressure, the intake
ball check may be stuck closed with dried material.
222
If the pump is not generating pressure on the
downstroke, intake ball check may be stuck open.
E
Either of these conditions can be serviced with the
pump in place.
5. Disconnect the fluid inlet (C) and swing it aside.
6. Remove the intake valve by the hitting ears (E)
firmly, right-to-left, with a non-sparking hammer.
Unscrew from the pump. See your displacement
pump manual for repair and parts information.
332144K
2
ti21839a
2
C
51
1
Flat side faces up. Tighten by hitting
firmly with non-sparking hammer.
2
Lubricate threads with ISO oil or grease.
218
1
2
41
Repair
Control Panel
Replace Temperature Display
NOTICE
Before handling the board, put on a static
conductive wrist strap to protect against static
discharge which can damage the board. Follow the
instructions provided with your wrist strap.
1. See Before Beginning Repair, page 39.
2. Remove screws (21) and display cover (26).
9. Reassemble in reverse order, see FIG. 10, page 43.
Apply medium strength thread sealant where
shown.
Replace Function Knob/Potentiometer
1. See Before Beginning Repair, page 39.
2. Remove the screws (21) and the back cover (26).
3. Disconnect the potentiometer wires from J5 on the
motor control board (354). See FIG. 12, page 45.
4. See FIG. 9. Remove two setscrews (356a) and pull
the function knob (356) off of the potentiometer
(357) shaft.
5. Remove the nut (N, part of 357) and the detent
plate (358).
21
26
ti21923a
3. Put on a static conductive wrist strap.
6. Install the new potentiometer (357) in reverse order.
Position the potentiometer so the slot (S) is
horizontal. Position the knob (356) so the pointer (P)
faces up. Install the knob on the shaft so the slot (S)
engages the alignment pin in the knob. Push the
knob onto the shaft against the detent spring
before tightening the setscrews (356a).
7. Reconnect the potentiometer wires to J5.
4. Disconnect the main display cable (81) from the
upper right corner of the temperature display (353).
See FIG. 10, page 43.
5. Remove the jumper (373) from the back of the
display (353). Set aside and install the jumper on
the new display.
P
S
357
6. Disconnect the ribbon cable(s) (R) from the back of
the display; see FIG. 10, page 43.
7. Remove the nuts (360) from the plate (351).
8. Disassemble the display (353), see detail in FIG. 10,
page 43.
356a
42
N
356 356a
358
ti21840a
332144K
Repair
353
373
360
352
351
363
354
ti21841a
357
FIG. 10 Control Panel
332144K
43
Repair
Motor Control
Replace Control Board
Power Bootup Check
Power must be on to check. See FIG. 11 or location.
Function is:
•
•
•
Motor ready: LED on.
Motor not ready: LED off.
Status code (motor not running): LED blinks status
code.
Multiple status codes are separated by a longer
LED off duration.
•
Check the motor before replacing the board. See Test
Motor, page 54.
1. See Before Beginning Repair, page 39.
2. Remove the display cover (26) on back of the cart
to expose the control board (354).
26
Control Board LEDs
If LEDs on the bottom board are on and the top board
LEDs are off, the following may have occurred:
•
•
A pressure transducer shorted out.
A short occurred between the power and ground
pin of the potentiometer.
Board
Top
LED
R4
State
Red: on
Bottom
G1
D4
Green: on
Red: on
D16
Green: on
354
ti21923a
3. Disconnect all cables and connectors from the
board (354). See Table 8, page 45.
4. Remove the six nuts (363) and remove the board
from the control board (354). See FIG. 10, page 43.
5. Install the new board in reverse order.
J3
J4
J5
J2
R4
G1
Description
Hardware or software
failure
Power on
Hardware or software
failure
Power on
J1
J6
J98
J9
J11
J12
J8
J10
D16
D4
(under C52)
(bottom side
of board)
FIG. 11
44
332144K
Repair
Table 8: Control Board Connectors (see FIG. 12)
Top Board Connectors
Board
Jack
J1
Pin
n/a
Not Used
J2
n/a
Not Used
J3
J4
J5
J6
n/a
n/a
n/a
1
2
3
4
5
6
n/a
n/a
n/a
n/a
n/a
Error LED
Tank Level LED
Function Knob
Brown - ISO Sensor V+
Blue - ISO Sensor VBlack - ISO Sensor Signal
Brown - RES Sensor V+
Blue - RES Sensor VBlack - RES Sensor Signal
Boost Power Relay
Motor Overtemperature
Cycle Switch
ISO Pressure Transducer
RES Pressure Transducer
J8
J9
J10
J11
J12
Description
Bottom Board Connectors
Connector
Description
Female Quick
Connect Terminals
Plug Housing with
Male Blades
Power
Motor Power
Top
J3
J4
J5
Bottom
J2
J1
J6
J98
J9
J11
J12
J8
J10
FIG. 12 Wiring Connections
332144K
45
Repair
Replace Temperature Control Modules
NOTICE
Before handling the assembly put on a static
conductive wrist strap to protect against discharge
which can damage the assembly. Follow the
instructions provided with your wrist strap.
3. Put on a static conductive wrist strap.
4. Disconnect all cables and connectors from the
temperature control module (59).
59
56
1. See Before Beginning Repair, page 39.
2. Remove the heater shroud (89) and the electronics
cover (55).
55
89
FIG. 13
ti21844a
5. Remove the hex nut (56) and replace the defective
module.
6. Install the new module in reverse order. Connect all
cables and connectors.
46
332144K
Repair
Temperature Control Modules Connections
Table 9: Heater Control Module Connections
Description
Table 9: Heater Control Module Connections
Description
100-120VA
C
Connector
DATA (A)
Sensor (B)
DISPLAY (C)
COMMUNICATION
(D)
PROGRAM (E)
BOOT (F)
Connector
200-240VA
C
POWER/RELAY (G)
Not used
See Table 11
Display
Communication to power
boards
Software programming
Software bootloader
100-120VA
C
200-240VA
C
Circuit board power input
and contactor control output
Table 10: Temperature Power Module Connections
Connector
COMMUNICATION
(H)
POWER (J)
Description
Communication to control
board
Power to heater
Table 11: Sensor B Connections
100-120VAC
Connector
B1
B2
B2
B2
B2
B2
332144K
Pin
1, 2
1
2
4
5
3
200-240VAC
Connector
B1
B1
B1
B1
B1
B1
Pin
1, 2
5
6
8
9
3-4,7,10
Description
Overtemperature Switch
Thermocouple ISO, R (red)
Thermocouple ISO, Y (yellow)
Thermocouple RES, R (red)
Thermocouple RES, Y (yellow)
Unused
47
Repair
H
J
H
ti9843a4
ti21843b
100-120VAC
G
200-240VAC
F
E
C
B1
B2
A
C
B1
A
D
FIG. 14 Temperature Control Module Connections
48
332144K
Repair
Heater
Nominal
Heater
Voltage
Test Heater Element
120
230
Heater
Wattage Per
Zone
1500
2000
Element
Wattage
Ohms
1000
12-16
1380
32-43
500
620
24-32
73-94
Remove Heater Element
1. See Before Beginning Repair, page 39.
2. Wait for the heater to cool.
3. Remove heater shroud (90) and electronics cover
(55).
1. To remove the heater element (307), first remove
the thermocouple (310) to avoid damage, see step
7, page 50.
2. Remove the heater element (307 or 316) from the
housing (301). Be careful not to spill any fluid left in
the housing.
3. Inspect the element.
55
90
It should be relatively smooth and shiny. If there is a
crusted, burnt, ash-like material adhered to the element
or sheath shows pitting marks, replace the element.
4. Install the new heater element (307 or 316). Hold
the mixer (309) so it does not block the
thermocouple port (P), for (307) only.
5. Reinstall the thermocouple. See step 8, page 50.
6. Reconnect the heater element leadwires to the
heater wire connector.
FIG. 15
ti21845a
4. Disconnect the heater element wires from the
heater wire connector. Test with an ohmmeter.
Replace the heater element if the resistance
reading does not fall within the range.
332144K
7. Replace the heater shroud (90) and the electronics
cover (55).
Line Voltage
The primary heaters output their rated wattage at their
nominal voltage of either 120VAC or 230VAC,
depending on system. Low line voltage will reduce
power available and the heaters will not perform at full
capability.
49
Repair
Thermocouple
8. Replace the thermocouple, FIG. 16.
a. Remove the protective tape from the
thermocouple tip (T).
2. Wait for the heaters to cool.
b. Apply PTFE tape and thread sealant to male
threads and tighten the thermocouple housing
(H) into the adapter (305).
3. Remove the heater shroud (90) and the electronics
cover (55). See FIG. 13, page 46.
c. Push in the thermocouple (310) so the tip (T)
contacts the heater element (307).
1. See Before Beginning Repair, page 39.
4. Loosen and remove the temperature control
module bracket mounting fasteners (56). Move the
control module up and out of the way to access the
thermocouple.
5. Disconnect the thermocouple wires from B on the
temperature control module. See Temperature
Control Modules Connections, page 47.
6. Clip the cable ties as necessary. Note the path as
wires must be replaced in the same way.
7. See FIG. 16. Loosen the ferrule nut (N). Remove the
thermocouple (310) from the heater housing (301),
then remove thermocouple housing (H). Do not
remove the thermocouple adapter (305) unless
necessary. If the adapter must be removed, ensure
that the mixer (309) is out of the way when
replacing the adapter.
310
S
9. Route the wires (S) into the cart and thread into a
bundle as before. Reconnect the wires to the
board.
10. Replace the heater shroud (90) and the electronics
cover (55). See FIG. 13, page 46.
11. Turn on the heaters ISO and RES simultaneously to
test. Temperatures should rise at same rate. If one
heater is low, loosen the ferrule nut (N) and tighten
the thermocouple housing (H) to ensure the
thermocouple tip (T) contacts the element (307).
N
H
1
d. Holding the thermocouple (T) against the heater
element, tighten the ferrule nut (N) 1/4 turn past
tight.
301
1
Apply PTFE tape and thread sealant.
2
Apply 110009 thermal heatsink compound.
307
2
308
305
T
309
FIG. 16 Thermocouple
50
ti7924a
332144K
Repair
Overtemperature Switch
1. See Before Beginning Repair, page 39.
2. Wait for the heaters to cool.
3. Remove the heater shroud (90) and the electronics
cover (55). See FIG. 13, page 46.
4. Disconnect one leadwire from the overtemperature
switch (308), FIG. 16, page 50. Test across the
switch with an ohmmeter. Resistance must be
approximately 0 ohms.
5. If the switch fails test, remove the wires and
screws. Discard the failed switch. Apply thermal
compound, install the new switch in the same
location on the housing (301), and secure with
screws (311). Reconnect the wires.
3. Disconnect the transducer cables from J11 and J12
connectors. Reverse ISO and RES transducer
connections and check if status codes follows the
bad transducer.
4. Replace the transducer if the transducer fails the
test.
a. Remove the supply tank. See Remove Supply
Tank, page 39.
b. Follow the transducer cable on the cart frame
and cut the zip ties. Disconnect the transducer
from the pump outlet manifold.
c. Install an o-ring (553) on the new transducer
(554). Apply lubricant to the o-ring (553).
d. Install the transducer (554) in manifold. Mark
the end of the cable with tape (red = ISO, blue =
RES).
If wires need replacement, disconnect from the heater
control module. See FIG. 24 on page 73.
e. Route the cable back through the cart frame to
the control board. See FIG. 12, page 45.
Pressure Transducers
f.
Install the supply tank.
554
1. See Before Beginning Repair, page 39.
553
2. Remove back cover (26).
26
FIG. 17 Transducer
ti21923a
332144K
354
51
Repair
Drive Housing
Installation
Removal
NOTE: The RES side crankshaft (210) includes the
cycle counter magnet (224). When reassembling, be
sure to install the crankshaft with the magnet on RES
side.
1. See Before Beginning Repair, page 39.
2. Remove the screws (207) and end covers (229), see
FIG. 18, page 53.
Examine the connecting rod (216). If the rod needs
replacing, first remove the pump (219). See
Displacement Pump, page 41.
NOTICE
To prevent equipment damage, do not drop the gear
reducer (214) and crankshaft (210) when removing the
drive housing (215). These parts may stay engaged in
the motor end bell (MB) or may pull away with the
drive housing.
3. Disconnect pump inlet and outlet lines. Remove
screws (220) and pull drive housing (215) off motor
(201) Connecting rod (216) will disengage from
crankshaft (210).
4. Examine crankshaft (210), gear reducer (214), thrust
washers (208, 212), and bearings (209, 211, 213).
1. Apply grease liberally to the washers (208, 212),
bearings (209, 211, 213), gear reducer (214),
crankshaft (210), and inside the drive housing (215).
Grease is supplied with the replacement parts kits.
If replacing the crankshaft, remove the magnet (224).
Reinstall the magnet in the center of the offset shaft on
the new crankshaft. Position the shaft in the Park
position.
2. Install the bronze bearings (211, 213) in the drive
housing (215), as shown.
3. Install the bronze bearings (209, 211) and steel
washer (208) on the crankshaft (210). Install the
bronze bearing (213) and steel washer (212) on the
gear reducer (214).
4. Install the gear reducer (214) and crankshaft (210)
into the motor end bell (MB).
NOTE: The crankshaft (210) must be in line with the
crankshaft at other end of the motor. The pumps will
move up and down together.
NOTE: If the connecting rod (216) or pump (219) were
removed, reassemble the rod in housing and install the
pump. See page Displacement Pump, page 41.
5. Push the drive housing (215) onto the motor (201).
Install the screws (220).
6. Install the drive housing covers (229) and screws
(207). The pumps must be in phase (both at same
position in stroke).
52
332144K
Repair
Replace Cycle Counter Switch
223
The RES side drive housing cover (229) includes the
cycle counter switch (223), mounted in the cover. When
reassembling, be sure to install the cover with the
switch on RES side.
0.6 in. (15.2 mm)
from inside edge
1.0 in. (25.4 mm)
from inside bottom
edge
TI7028a
233
201
221
MB
208
(steel)
223
209
(bronze)
211
(bronze)
220
215
1
210
224
229
214
207
213
(bronze)
213
(bronze)
212
(steel)
216
89
219
1
91
ti21847a
Crankshaft must be in line with crankshaft at other end of motor,
so pumps move up and down in unison.
FIG. 18 Drive Housing
332144K
53
Repair
Electric Motor
Test Motor
If the motor is not locked up by the pumps, it can be
tested using a 9 V battery.
1. Open the recirculating valves.
2. Disconnect the motor connections from the control
board, see FIG. 12, page 45. Touch jumpers from
battery to the motor connections. The motor should
turn slowly and smoothly.
Removal
8. Cut the zip ties.
9. Thread the motor power switch harness and over
the temp switch out the bottom of the control
module and cable channel to free the motor.
NOTICE
Dropping the motor could cause damage to the
motor. To prevent dropping the motor, two people
may be required to lift.
10. Remove the screws (15) holding the motor (201) to
the bracket. Lift the motor off the unit.
11. If replacing the motor, remove the shroud mounting
bolts (207) and brackets (233) and set aside.
Installation
1. If replacing the motor, install the fan assemblies
(16) and shroud mounting brackets (233) on the
new motor (201).
See wiring schematic, page 45.
1. See Before Beginning Repair, page 39.
2. Relieve the pressure. Follow the Pressure Relief
Procedure, page 24
3. Remove the four screws (91), shroud (89), and
mounting brackets (233). See FIG. 18.
4. Remove the fans (16) and disconnect the cable
(80). See FIG. 20.
5. Remove the drive housing. See Drive Housing,
page 52.
6. Remove the display control cover (26). Disconnect
the motor cables as follows:
a. Unplug the motor power connector before the
ferrite (88).
b. Unplug the motor temp switch harness from
connector J9 and remove the grounding cable
from the grounding screw.
2. Place the motor (201) and fans (16) on the unit.
Thread the motor switch harness through the
grommets in the cart and into the back of the
display. See FIG. 24, page 73.
3. Fasten the motor (201) with the screws (15)
underneath. Do not tighten yet.
4. Plug the motor temp switch harness to connector
J9 and the grounding cable from the grounding
screw.
5. Plug in the motor power connector.
6. Secure all cables to the cart frame with zip ties.
7. Install the display control cover (26).
8. Install the supply tank.
9. Install the drive housing. See Drive Housing, page
52. Reconnect the inlet assemblies to the pumps.
10. Torque the screws (15) to 150 in.-lb (17 N•m).
11. Return to service.
7. Remove the RES supply tank. See Remove Supply
Tank, page 39.
54
332144K
Repair
Motor Brushes
b. Remove the old brushes and install the new
ones supplied in kit.
9. See the instruction sheet included with your brush
repair kit.
Replace brushes worn to less than 1/2 in. (13 mm).
Brushes wear differently on each side of motor; check
both sides.
The motor commutator should be smooth. If not,
resurface the commutator or replace the motor.
1. See Before Beginning Repair, page 39.
2. Relieve the pressure. Follow the Pressure Relief
Procedure, page 24.
3. Remove the four screws (91) and the motor shroud
(89). See FIG. 18, page 53.
4. Remove the fans (16) and disconnect the cable
(80). See FIG. 20, page 55.
5. Loosen the pump inlet and outlet connections.
6. Remove the display control cover (26). Disconnect
the motor cables as follows:
a. Unplug the motor power connector.
b. Unplug the motor temp switch harness from
connector J9. Disconnect the grounding cable
from the grounding screw.
7. To replace the front motor brush:
ti21916a
FIG. 19 Motor Brushes
Fans
1. Disconnect the fan cable (80) from the fan (16). With
Motor Power on, test the cable connector for line
voltage (100-120VAC or 200-240VAC).
2. If voltage is within the described range for that
system, the fan is defective. Remove the screws
holding the fan to the shield (17). Install the new fan
in reverse order.
3. If voltage is not within the appropriate range,
check the fan cable connection at terminal blocks 1
and 2; see FIG. 23 on page 72.
17
80
16
a. Remove the two bolts and access the cover
plate. See FIG. 19, page 55.
b. Remove the old brushes and install the new
ones supplied in kit.
8. To replace the rear motor brush:
a. Remove the motor mounting bolts. Slide the
motor forward and lean on the cart frame.
a. Remove the two bolts and access cover plate.
See FIG. 19, page 55.
332144K
FIG. 20 Fans
ti21848a
55
Repair
Tank Fluid Level Sensors
Adjust
Adjust the position of the tank fluid level sensor (57) so
that the sensor contacts the surface of the tank.
1. Loosen the sensor jam nuts and the press sensor
(57) against the tank.
2. Spin on the inner jam nut until flush, then tighten
the inner jam nut one more turn.
3. Retighten outer jam nut.
6. Route the new tank level sensor cable through the
grommet on the bottom of the cart and through the
grommet on the bottom of the control panel.
Connect the new level sensor (57) to J6.
7. Install the display control cover (26).
8. Zip tie the tank level sensor cable with other low
voltage cables.
9. Reinstall the supply tank. See Remove Supply
Tank, page 39.
10. Adjust the position of the level sensor assembly
(57). See Adjust, page 56.
11. Set the sensitivity. See Reset Sensitivity, page 57.
12. Check the operation of both sensors.
a. Hold one hand inside both tanks for 5 seconds,
near the inner wall, where the tank level sensor
is located.
b. The tank level indicator LED on the control
panel will stop flashing when it senses both of
your hands.
57
ti21849a
Replace
1. Loosen the jam nuts and remove the level sensor
assembly (57).
2. Remove the supply tank. See Remove Supply
Tank, page 39.
c. The tank level indicator LED will flash if either
tank sensor indicates that it is low. Alternately,
remove each hand away from inner wall for 5
seconds. The tank level indicator LED on the
control panel will flash.
Table 12: Sensor LED Identification
LED
Status
3. Cut the zip ties securing the sensor cable to the
cart.
Green - on
Green - off
Yellow - on
4. Remove the display control cover (26).
Yellow - off
26
ti21923a
5. Disconnect the level sensor connector from J6 on
the control board. See FIG. 12, page 45.
56
Sensor is powered
Sensor is not powered
Sensor detects material (immediate, no
5 second display)
Sensor does not detect material
FIG. 21 Sensor LEDs
ti21963a
332144K
Repair
Reset Sensitivity
The tank fluid level sensor sensitivity may need to be
adjusted when:
5. Use a small flathead screwdriver and slowly turn
the adjustment screw (S) clockwise until the yellow
LED turns on.
•
A new tank has a different insulation density than
the previous tank.
6. Slowly turn the adjustment screw (S)
counterclockwise until the yellow LED barely turns
off.
•
Material build-up is on the inside or outside of the
tank. Adjust sensitivity rather than thoroughly
cleaning the tank.
7. Slowly turn the adjustment screw (S)
counterclockwise an additional 1/2 turn.
•
Level sensor sensitivity comes out of alignment
through misuse or harsh environment.
•
Material density is less than normally pumped
materials.
NOTE: The yellow LED should stay turned off.
8. Fill the tank with desired material and verify that the
sensor detects material. The yellow LED will turn on
when the material reaches the one gallon mark.
3. Ensure that the sensor (57) and tank are properly
installed. See Adjust, page 56.
NOTE: If the yellow LED does not turn on after two
gallons of the material, then the material density may be
too low and is not detected by the sensor. Turn the
adjustment screw clockwise in 1/8 turn increments until
sensor detects the material and the yellow LED turns
on.
4. Locate the adjustment screw (S) above the green
and yellow LEDs.
If the adjustment screw is turned a total 1/2 turn, then it
will not detect an empty tank.
NOTE: The adjustment screw on some tank level
sensors is covered by white tape. Remove the white
tape to access the adjustment screw.
9. Reinstall the shroud (89).
1. Ensure that the tank is completely empty.
2. Remove the shroud (89) to expose the sensors.
S
FIG. 22 Adjustment Screw
332144K
ti21963a
57
Parts
Parts
System Packages
104
101
16W239
15G958
15G962
ti21924a
102
103
ti6987b
ti21488a
System
Package
APT100
P2T100
APT900
Hose
101
see page 59
102
see page 71
103
24T100
25R000
249810
24T100
24R900
Gun
25R000
GCP2RA*
25R000
Power Cord Adapter
104
Part
Number
Region
✖
✖
✖
✖
249810
16W239
North America
249810
15G962
Australia/Asia
APT901
24R900
25R000
249810
P2T900
24R900
25R000
GCP2RA*
16W239
North America
GCP2RA*
15G962
Australia/Asia
APT902
P2T901
P2T902
*
Proportioner
24R900
24R900
24R900
25R000
25R000
25R000
GCP2RA*
15G958
15G958
Europe
Europe
Probler packages use recirc accessory kit 24E727.
✖ Not included.
58
332144K
Parts
E-10hp Proportioners
24T100, 100-120VAC, Proportioner
24R900, 200-240VAC, Proportioner
26
92
102
21
2
5
94
98
Apply sealant to threads of nut cap.
Torque to 125 in-lb (14 N•m).
93
25
24
2
97
99
97
84
77
5
42
49
28
91
49
42
96
50
32
90
31
96
89
97
48
33
56
29
35
30, 30a
332144K
27
56
55
99
ti21853b
59
Parts
3
4
8
10
1
Apply lubricant to thread and axle of cart.
8
Apply even distribution of thermal grease on bottom
of metal surface of solid state relays.
Orient SSR with terminals 1 and 2 towards the top.
Orient heater module with fins outwards.
4
5
6
3
99
6
7
2
41
40
39
3
56
9
38
37
21
56
67
58
10
59
8
4
66 71
72
12
13
66
70
64
64
66
11
11
36
73
10
56
59
10
56
60
68
66
74
60
56
21
69 65
61
56
58
ti21855b
332144K
Parts
47
6
7
9
11
22
19
Assemble nut to finger tight only.
Orient fan to flow down and connector plug towards the back.
Assemble sensor flush to tank surface.
47
18
17
9
Torque to 150 in-lb (17 N•m).
46
16
42
43
44
45
21
11
57
7
42 43
14
44 45
20
46
21
52
54
57
52
53
332144K
15
11
ti21854a
6
61
Parts
24T100, 100-120VAC, Proportioner
24R900, 200-240VAC, Proportioner
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
30a
31
32
33
35
36
37
62
Part
Description
--24T950
24T951
24T952
24T953
110996
101765
119975
154636
116411
116477
116478
101242
24T954
117493
24K985
24K986
115836
120094
24U009
24T955
167002
108296
24T960
24T962
117623
24U005
24T970
24R648
24T973
111800
127148
24T975
24T974
24K976
101044
119973
24K984
162453
100176
CART
BRACKET, tank mount
BRACKET, crossbar
BRACKET, gusset, cart
BRACKET, motor mount
NUT, hex, flange head
GROMMET
GRIP, vinyl, gray; 1.25 in.
WASHER, flat
SPRING, compression
WASHER, flat, nylon
WHEEL, pneumatic
RING, retaining, ext.
PROPORTIONER, see page 65
SCREW, mach, hex washer hd; 1/4-20
FAN, cooling, 120 VAC
FAN, cooling, 230 V
GUARD, finger
SCREW, pan hd, phil, zinc
HEATER, assy; 120V, 1000W; see page 67
HEATER, assy; see page 67
INSULATOR, heat
SCREW, mach, hex wash hd
MANIFOLD, outlet/recirc; see page 70
DISPLAY, control; see page 68
NUT, cap; 3/8-16
DIODE, light-emitting,120 V
DIODE, light-emitting, 230 V
COVER, display
TANK
SCREW, cap, hex hd
SCREW, set, 7/16-14, 1/2, black
LID; includes o-ring (30a)
O-RING
MUFFLER,1/4 NPT
WASHER, plain
CABLE, sst lanyard; 14 in.
DRYER, desiccant, mini in-line
FITTING; 1/4 npsm x 1/4 npt
BUSHING, hex
Quantity
24T100, 100-120 VAC
1
1
1
1
1
18
3
2
4
2
4
2
2
1
4
2
2
8
1
2
10
1
1
4
1
1
2
12
2
2
2
1
1
2
1
1
1
24R900, 200-240 VAC
1
1
1
1
1
18
3
2
4
2
4
2
2
1
4
2
2
8
1
2
10
1
1
4
1
1
2
12
2
2
2
1
1
2
1
1
1
332144K
Parts
Ref.
Part
Description
38
24K977
38a
15D909
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
157350
104641
169970
116704
117506
--556765
24T977
24T978
24T979
24T980
24T981
114225
119992
24T982
24T986
24T987
115942
24T988
24T990
247828
24T989
24T308
24T307
24U006
24T991
112144
126811
24U007
24T992
126817
126818
126810
24T993
255043
255023
127239
127240
120748
FILTER, regulator, air; with 3/8 npt auto
drain; includes 64a
ELEMENT, 5 micron; polypropylene; not
shown
ADAPTER
FITTING, bulkhead
FITTING, line air; 1/4-18 npt
ADAPTER, 9/16-18 JIC x 1/4 NPT
FITTING, swivel, 1/4 npt x #6 JIC
MANIFOLD, assembly, outlet; see page 71
FITTING, #6 JIC 1/4PM
TUBE, pump outlet, ISO
TUBE, heater outlet, ISO
HOSE, coupled, recirc, ISO
TUBE, recirculation
HOSE, coupled, recirc, RES
TRIM, edge protection
FITTING, pipe, nipple, 3/4 x 3/4 npt
MANIFOLD, inlet, RES; see page 69
MANIFOLD, inlet, ISO; see page 69
COVER, electronics
NUT, hex, flange head
SENSOR, tank level
PANEL, heater control mount
MODULE, heater
PANEL, logic control mount
MODULE, heater control,120 V
MODULE, heater control, 230V
RELAY, SSR, 120 V
RELAY, SSR, 230 V
SCREW, mach, pan hd
BLOCK, clamp end
CONNECTOR, contactor; 120 V
CONNECTOR, contactor; 230 V
COVER, end
BLOCK, terminal 3-wire
RELAY, cradle
RELAY, 12V
HOLDER, fuse terminal block; 5 x 20mm
FUSE, 5A, 5 x 20 mm
CONNECTOR, 5 pin
CONNECTOR, 10 pin
CONNECTOR, 2 pin
64
65
66
67
68
69
70
71
72
73
74†
75†
332144K
Quantity
24T100, 100-120 VAC
24R900, 200-240 VAC
1
1
1
1
1
1
1
4
2
2
2
2
2
1
2
1
1
2
1
1
1
12
2
2
2
1
1
1
1
1
4
2
2
2
2
2
1
2
1
1
2
1
1
1
12
2
2
2
1
2
4
4
1
1
2
1
1
2
2
1
2
1
2
4
4
1
1
2
1
1
2
2
1
1
63
Parts
Ref.
76
77
78✖†
79✖†
80✖†
81✖†
82✖†
83
84
85
88✖†
89
90
91
92
93
94
95
96
97
98▲
99▲
104
Part
Description
127237
116171
16W761
24T994
24T995
CONNECTOR, 6 pin
BUSHING, strain relief
BUSHING, strain relief
HARNESS, POWER; see FIG. 23 on page 72.
CABLE, communication, heater control
module
CABLE, FAN, 29 in. (736.6 mm)
CABLE, control, display
CABLE, harness, overtemperature
CONNECTOR, jumper
CORD, 20A, 120 V
CORD, 16A, 230 V
NUT, keps, hex hd
CLIP, ferrite bead
COVER, proportioner, lower
COVER, proportioner, upper
SCREW, mach, slot hex wash hd
GUARD, splash, hose rack
RACK, hose
PLUG, tube
ISOLATOR, pad, rubber
BOLT, shoulder
WASHER, flat, nylon,1/4
LABEL, safety, warning, multiple
LABEL, electric shock
LUBRICANT, ISO pump
24T996
24T997
24T998
24T999
24U008
24U000
113505
125835
24U001
24U002
115492
24U003
24U004
120008
120150
119999
110533
15G280
189930
217374
Quantity
24T100, 100-120 VAC
1
2
▲ Replacement safety labels, tags, and cards are available at no cost.
24R900, 200-240 VAC
1
1
2
1
1
1
2
1
1
2
2
2
1
1
2
2
2
1
1
10
1
1
4
2
2
4
1
2
1
2
2
2
1
1
10
1
1
4
2
2
4
1
2
1
✖ Not shown.
† See FIG. 23 on page 72.
--- Not available for purchase.
64
332144K
Parts
24T954, 100-120VAC and 200-40VAC Bare Proportioner
207
201
1
8
9
210
211
(bronze)
3
4
8
223
213
(bronze)
6
10
91
(ref)
89
(ref)
220
207
7
215
6
217
6
221
209
(bronze)
214
222
207
208
(steel)
229
207
233
216
2
218
5
219
213
(bronze)
212
(steel)
ti21847a
3
223
0.6 in. (15.2 mm)
from inside edge
1.0 in. (25.4 mm)
from inside bottom
edge
TI7028a
1
2
3
4
5
6
Apply lubricant to all gear teeth, motor pinion, and motor
endbell on both sides of motor.
Apply lubricant to rectangular cavity on connecting link.
Apply lubricant to threads of pump cylinder before assembly
into housing. Align top of cylinder flush within 0.06 to inside
bottom of pump mounting hole.
Torque fasteners to 140-160 in-lb (15-18 N•m).
Assemble nut to finger tight only.
7
8
9
Switch mounts to cover opposite brush end of motor only.
Housing must be installed on motor with crankshafts aligned
with each other.
Assemble magnet to center of offset crankshaft on switch
cover side of motor and adjust for park location.
10 Affix switch to motor cover with double-sided tape. Cut to 2
in. (50.8 mm). Mount cover on side opposite brush end of
motor.
Torque fasteners to 30-35 in-lb. Applies only when fasteners
are assembled in plastic housings (215).
332144K
65
Parts
Ref. Part
201 24T758
207‡ 115492
208*
209*
210*
211*
212†
213†
214†
215‡
216◆
217◆
218
219
220‡
221‡
222‡
223
224
116074
107434
300001
180131
116073
116079
244242
287055
287053
196762
195150
24L006
117493
300002
15B589
117770
24K982
227
229
233
115711
300003
16W162
*
Description
MOTOR, electric
SCREW, mach, slot hex wash
hd
WASHER, thrust
BEARING, thrust
KIT, crankshaft
BEARING, thrust
WASHER, thrust
BEARING, thrust
GEAR, reducer (first stage)
HOUSING, drive
KIT, repair, connecting, rod
PIN, straight
NUT, jam, pump
PUMP, displacement
SCREW, mach, hex washer hd
KIT, cover; includes switch
COVER, pump rod
SWITCH, reed with cable
MAGNET, disc, 0.38 dia.,
0.100 thick; not shown
TAPE, foam, 1/2 wide
KIT, cover
BRACKET, shroud tab
Qty
1
10
2
2
2
2
2
4
2
2
2
2
2
2
8
1
2
1
1
1
1
2
Included in 300001 Crankshaft Kit (210).
† Included in 244242 Gear Reducer Kit (214).
‡ Included in 287055 Drive Housing Kit (215).
◆ Included in 287053 Connecting Rod Kit (216).
66
332144K
Parts
24U009, 100-120VAC Heater
24T955, 200-240VAC Heater
4
6
2
307
310
305
306
311
3
2
5
5
308
304
309
1
307
316
312
5
1
ti21850a
316
1
1
301
1
2
3
4
303
4
302
1
5
Torque to 120 ft-lb (163 N•m).
Torque to 23 ft-lb (31 N•m).
Apply 110009 thermal heat sink compound.
Apply sealant and tape to all non-swiveling and threads
without o-rings.
Ref. Part
Description
Qty.
301
--BLOCK, heater
1
302 15H302 FITTING, reducer 1-3/16 SAE x 1/2
4
npt
303 16V432 FITTING, adapter, #6 JIC x npt,
4
mxm
304 15H304 FITTING, plug, 9/16 SAE
2
305 15H306 ADATPER, thermocouple, 9/16 x
2
1/8
306 120336 O-RING, packing
2
307 24T958 HEATER, fire rod, 230 V, 24T955
2
only
24U012 HEATER, fire rod, 120 V, 24U009
2
only
332144K
5
6
Apply lubricant to o-rings before assembling in heater
housing.
Tighten NPT fitting from sensor to heater housing as shown.
Remove tape from probe tip prior to inserting. Insert probe
until tip bottoms on heater element. Tip must touch heating
element. Insert ferrule and tighten ferrule nut to sensor probe.
Orient sensor as shown and torque 1/4 turn past tight.
Ref.
308
309
310
311
312
316
Part
15B137
16U940
117484
--124132
24T959
Description
SWITCH, overtemperature
MIXER, heater
SENSOR,
SCREW, mach; #6-32
O-RING
HEATER, fire rod, 230 V; 24T955
only
24U014 HEATER, fire rod, 120 V; 24U009
only
Qty.
1
4
2
2
4
2
2
--- Not available for purchase.
67
Parts
24T962, Display
361
359
359
353
373
366
363
388
360
351
367
365
363
355
354
357
356
Ref.
351
352
353
354
355
Part
24T963
24T964
24T966
24T967
24K983
356
357
24L001
24L002
358
359
15G053
300005
68
352
364
ti21841a
358
Description
Qty.
1
PLATE, display, front
1
ENCLOSURE, control
1
DISPLAY, heat two zone
1
CONTROL, board, assy
2
SWITCH, rocker, w/breaker, 240v,
20a
1
KNOB, control, w/ball plunger
1
POTENTIOMETR, adjustment,
pressure
1
PLATE, detent, display
2
FILTER, board
Ref.
360
361
363
364
365
366
367
368
373
Part
117523
127157
127158
24T968
24T971
--113505
101765
127019
Description
NUT, cap (#10)
SCREW, mach, captive, #8
NUT, captive, #8
DIODE, light-emitting, red
DIODE, light-emitting, yellow
CLAMP, cable
NUT, keps, hex hd
GROMMET
CONNECTOR, jumper, e-stop
Qty.
4
8
8
1
1
2
6
3
1
--- Not available for purchase.
332144K
Parts
Fluid Inlets
24T986, ISO Inlet
24T982, RES Inlet
5
405
406
2
4
3
4
404
407
401
1
5
6
1
Align Y-strainer as shown
Apply sealant to all npt threads. Do not apply to JIC threads.
Apply thermal lubricant to thermometer probe.
Torque fitting of bent tube to 45-50 ft-lb (61-67 N•m).
Align bent tube to fitting within 2°.
Align thermometer dial as shown.
ti21851a
402
403
3
24T986
6
24T982
6
ti21852a
Ref
Part
.
401 101078
402 15D757
403 102124
404 24T983
405 24T984
Description
Qty.
1
STRAINER, Y
1
HOUSING, thermometer, Viscon HP
1
THERMOMETER, dial
1
VALVE, ball, 3/4 npt, mxf, T-handle
1
FITTING, adapter JIC-12 X 3/4 npt,
mxm
1
406 24T985 TUBE, assy, inlet
1
407 160327 FITTING, union adapter, 90°
332144K
69
Parts
24T960, Fluid Manifold
2
452
455a (Red)
456
4
455b (Blue)
4
6
6
1
2
3
454
4
453
3
4
5
6
Apply sealant to assembled non-swiveling
pipe threads.
Apply sealant and PTFE tape to threads.
Apply sealant to valve threads. Torque to
240-260 in-lb (27-29 N•m).
Apply lubricant to mating surfaces of valve
base and handle.
Apply lubricant to o-rings on fittings. Torque
to 16-20 ft-lb (22-27 N•m).
Align handles as shown when open.
451
460
461
464
459
463
Ref.
451
452
453
453a
453b
454
455a
455b
456
457
458
459
70
Part
24T961
102814
239914
15E022
111699
224807
17X499
17X521
111600
16V434
458
5
462
5
Description
MANIFOLD, fluid
GAUGE, pressure, fluid
VALVE, drain
SEAT
GASKET
BASE, valve
HANDLE, valve, drain, red
HANDLE, valve, drain, blue
PIN, grooved
FITTING, 90 elbow, JIC-6 x
SAE-ORB
119789 FITTING, elbow, street, 45°
162453 FITTING; 1/4 npsm x 1/4 npt
457
5
Qty.
1
2
2
1
1
2
1
1
2
2
1
ti21838a
Ref.
460
Part
Description
127130 FITTING, straight, JIC-5 x
SAE-ORB
461 127128 FITTING, 45° elbow, JIC-5, mxf,
swivel
462 127131 FITTING, straight, JIC-6 x
SAE-ORB
463 127129 FITTING, 45° elbow, JIC-6, mxf,
SWIVEL
464▲ 189285 LABEL, warning, hot surface
Qty.
2
2
2
2
1
▲ Replacement safety labels, tags, and cards are
available at no cost.
2
2
332144K
Parts
25R000, Insulated Hose Bundle with Recirculation Lines
501
502
502 (Ref)
304
503 (Ref)
505
503
TI6991a
Ref. Part
Description
Qty.
501 24R996 HOSE, fluid (component ISO),
2
moisture guard; 1/4 in. (6 mm) ID;
number 5 JIC fittings (mxf); 35 ft
(10.7 m)
502 24R997 HOSE, fluid (component RES); 1/4
2
in. (6 mm) ID; number 6 JIC
fittings (mxf); 35 ft (10.7 m)
Ref. Part
Description
Qty.
503 15G342 HOSE, air; 1/4 in. (6 mm) ID; 1/4
1
npsm (fbe); 35 ft (10.7 m)
504 buy
TUBE, foam, insulated; 1-3/8 in.
1
locally (35 mm) ID; 31 ft (9.5 m)
505 156971 NIPPLE; 1/4 npt; for joining air line
1
to another hose bundle
Outlet Manifold
554
553
2
1
551
552
ti21846a
1
Apply lubricant to o-rings.
2
Ref.
551
552
553
554
Orient housing with exhaust hole pointing down.
Part
24T976
247520
111457
24K999
332144K
Description
Qty.
MANIFOLD, fluid, pump, outlet
1
HOUSING, rupture disc
1
PACKING, o-ring
1
TRANSDUCER, pressure, control
1
71
+
+
+
+
665 ,62
+
%2267 ,62
9
0$,1 ,62
%2267 ,62
%2267 5(6
0$,1 5(6
0$,1 ,62
&
+
+
+
+
%2267 +($7 5(6
0$,1 +($7 5(6
&
-
&RQWDFWRU
0$,1 +($7 ,62
&
9
%2267 +($7 ,62
&
+
+
+
+
+
+
+
+
+
+
&
&
7
7
5(/$<
)
)
+
+
+
+
+
+
)DQ
)DQ
-
+
+
+
+
5(6 665
WLD
+
+
+
+
&
+
+
+
&
+
+
+
+
&
%2267 5(6
0$,1 5(6
72
Parts
FIG. 23 Power Harness (78) Wire Identification
332144K
Parts
%52:1
+
5('02725 /('
%/8(
%/$&.
<(//2:7$1./('
%52:1
7$1
02725
%/8(
%/$&.
7$1
%52:1
+
+
5('%2267 +($7/('
%/8(
+($7(5
%/$&.
02725 3:5
7$1. /9/ 6(1625
02725 27 6:,7&+
+
+
5((' 6(1625
%/$&.
0RWRU
%/$&.
+HDWHU
*1' *1'
+
+($7(5
%52:1
WLD
+
%/8(
*5((1
02725
%/8(
73
332144K
*5((1
75$16'8&(5 ,62
75$16'8&(5 5(6
*5((1
%/8(
+
%/$&.
7$1
7$1
FIG. 24
Suggested Replacement Parts
Suggested Replacement
Parts
Part
Description
24K984 DRYER, desiccant
24K983 SWITCH, motor or heater power, with circuit
breaker
101078 Y-STRAINER
26A349 KIT, filter, replacement (2 pack)
26A350 KIT, filter replacement (10 pack)
15D909 ELEMENT, air filter, 5 micron; polypropylene
239914 VALVE, spray; includes seat and gasket
24L002 POTENTIOMENTER, control knob
24K999 TRANSDUCER, pressure
24L006 PUMP, displacement; fits either side
249855 REPAIR KIT, displacement pump; includes
seals, balls, bearings, intake seat)
24T974 O-RING, tank lid
Accessories
Part
24E727
24U342
25M269
25P193
Description
Probler Recirc Kit
Lift Ring Kit
DataTrak Control Kit
DataTrak Control Kit (for sale in Europe)
Dimensions
46 in.
(116.8 cm)
36 in.
(91.4 cm)
29 in.
(73.6 cm)
ti21488a
74
332144K
Technical Specifications
Technical Specifications
Reactor E-10hp
Maximum fluid working pressure
3000 psi
Maximum spray pressure: 120 V
2200 psi
Maximum fluid temperature
170 °F
Maximum output
1 gal/min
Maximum spray pressure: 230 V
Maximum ambient temperature
Output per cycle (ISO and RES)
Air inlet
6 gal
Recommended Mix Chamber Sizes
230 V
Generator Size
120 V
230 V
Heater Power
120 V
230 V
Sound Pressure
In fast recirculation mode
Measure at 2500 psi
(17 MPa, 172 bar), 1 gpm (3.8 lpm)
332144K
0.014 liters/cycle
Spray valves automatically relieve excessive fluid pressure back to supply
tanks
Fusion Gun (purge air and operating air): 4 scfm (0.112 m3/min)
239 lb
120 V
3.8 liters/min
1/4 npsm(m)
Weight (empty)
Electrical Requirements
48 °C
1/4 in. quick-disconnect industrial type pin fitting
105 ft
Probler® P2
77 °C
0.0038 gallons/cycle
Maximum hose length
Fusion® Air Purge
20.6 MPa, 206 bar
17.2 MPa, 172 bar
120 °F
Overpressure relief
Tank capacity each (nominal)
Metric
15.2 MPa, 152 bar
2500 psi
Air outlet
Gun compressed air requirements
US
32 m
22.7 liters
108 kg
000, AW2222 (00 and 01 at reduced spray pressure)
AA (00 and 01 at reduced spray pressure)
100-120 VAC, 1 phase, 50/60 Hz, 3840 W; requires two separate,
dedicated 20 A circuits. Full load peak amperage 16 A per circuit.
200-240VAC, 1 phase, 50/60 Hz, 5520 W; requires two separate,
dedicated 15 A circuits. Full load peak amperage 12 A per circuit.
5000 W minimum
7500 W minimum
3000 W during recirculation, 2000 W during pressure spray mode
4000 W during recirculation, 2760 W during pressure spray mode
71.3 dB(A)
85.6 dB(A)
75
Technical Specifications
Reactor E-10hp
US
Sound Power*
In fast recirculation mode
79.9 dB(A)
Measure at 2500 psi
(17 MPa, 172 bar), 1 gpm (3.8 lpm)
93.3 dB(A)
Fluid Outlets
ISO Side
-5 JIC male
RES Side
-6 JIC male
Fluid Circulation Returns
ISO side
-5 JIC male
RES side
-6 JIC male
Hose Markings
ISO side
Red
RES side
Wetted Parts
Wetted parts on all models
Notes
Metric
Blue
Aluminum, stainless steel, carbon steel, brass, carbide, chrome, chemically
resistant o-rings, PTFE, ultra-high molecular weight polyethylene
* Sound power measured per ISO-9614-2.
All trademarks or registered trademarks are the property of their respective owners.
California Proposition 65
CALIFORNIA RESIDENTS
WARNING: Cancer and reproductive harm – www.P65warnings.ca.gov.
76
332144K
Technical Specifications
332144K
77
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification
of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be
returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or
workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT
LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental
or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder,
or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered
into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu
que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés,
à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
For patent information, see www.graco.com/patents.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211, Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2021, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision K, July 2021

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