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Instructions
Reactor
®
E-10hp
332144H
EN
For spraying or dispensing polyurea coatings and polyurethane foam.
For professional use only.
Not approved for use in explosive atmospheres or hazardous locations.
3000 psi (21 MPa, 207 bar) Maximum Working Pressure
For model information, see page 9.
Important Safety Instructions
Read all warnings and instructions in this manual before using the equipment.
Save these instructions. ti21488a
2
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Pressure Transducers . . . . . . . . . . . . . . . . . . . . 50
Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Replace Cycle Counter Switch . . . . . . . . . . . . . . 52
Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Tank Fluid Level Sensors . . . . . . . . . . . . . . . . . . 55
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
System Packages. . . . . . . . . . . . . . . . . . . . . . . . 57
E-10hp Proportioners . . . . . . . . . . . . . . . . . . . . . 58
24T954, 100-120VAC and 200-40VAC Bare
Proportioner . . . . . . . . . . . . . . . . . . . . . . . . . 64
24T955, 200-240VAC Heater . . . . . . . . . . . 66
24T962, Display . . . . . . . . . . . . . . . . . . . . . . . . . 67
Fluid Inlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
24T960, Fluid Manifold . . . . . . . . . . . . . . . . . . . . 69
25R000, Insulated Hose Bundle with
Recirculation Lines. . . . . . . . . . . . . . . . . . . . 70
Outlet Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Suggested Replacement Parts . . . . . . . . . . . . . . . 73
Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Technical Specifications . . . . . . . . . . . . . . . . . . . . 74
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 76
332144H
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.
ELECTRIC SHOCK HAZARD
WARNING
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.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled or swallowed.
• Read 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.
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:
• 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.
332144H 3
4
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:
• 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.
332144H
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.
332144H
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.
• 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:
• Do not touch hot fluid or equipment.
6 332144H
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: ____________
332144H 7
Important Isocyanate (ISO) Information
8
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
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.
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.
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.
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.
• Check with your material manufacturer for chemical compatibility.
• 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.
332144H
Systems
Systems
Part
APT100
P2T100
APT900
APT901
APT902
P2T900
P2T901
P2T902
24T900
24T901
24T902
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)
Volts
100-120 VAC
100-120
ProblerVAC
200-240 VAC
200-240 VAC
200-240 VAC
200-240 VAC
200-240 VAC
200-240 VAC
200-240 VAC
200-240 VAC
200-240 VAC
Proportione r Model
24T100
Unheated
Hose
35 ft (10.6 m)
25R000
24T100
24R900
24R900
24R900
24R900
24R900
24R900
24R900
24R900
24R900
25R000
25R000
25R000
25R000
25R000
25R000
25R000
---
---
---
Gun
Cord
Adapter
---
Model Part
Fusion ® Air Purge 249810
---
North
America
Europe
Australia/
Asia
North
America
Europe
Australia/
Asia
North
America
Europe
Australia/
Asia
Probler
Fusion ® Air Purge 249810
Fusion
Fusion
®
®
Air Purge
Air Purge
Probler
Probler
Probler
---
---
---
®
®
®
®
P2
P2
P2
P2
GCP2RA
249810
249810
GCP2RA
GCP2RA
GCP2RA
---
---
---
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)
20 A cord
(heaters)
15 A cord
(motor)
15 A cord
(heaters)
Maximum Working Pressure, psi (MPa, bar)
3000 (21, 207)
3000 (21, 207)
Approvals
9902471
Conforms to ANSI/UL
Std. 499 Certified to
CAN/CSA Std.
C22.2 Number 88
* See page 16 for detailed electrical requirements.
332144H 9
Related Manuals
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 332144H
Overview
Overview
The Reactor E-10hp is a portable, electric-powered, 1:1 mix ratio proportioner for use with:
• 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.
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.
The Reactor E-10hp has two recirculation speeds, slow and fast, and an adjustable pressure output.
Slow Recirculation
• 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.
Fast Recirculation
• 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.
332144H 11
Component Identification
Component Identification
J
V
B
P
A
N
F
G T S
G
T ti21488a
S
P
D
Z
E
K
L
Key
E
F
G
H
A
B
C
D
J
K
L
M
H
W
R
C X
F IG . 1 Component Identification
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 F IG . 2, page 13
Electric Motor and Drive Housings
AZ ti21488a
Insulated Hose Bundle (includes circulation return hoses)
Fusion Air Purge Spray Gun
M
Key
N
P
R
S
T
U
X
Y
V
W
Z
AZ
12 ti6987b
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
332144H
Controls and Indicators
Controls and Indicators
See Controls and Indicators identification table, page
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
AM
AL
AE
AA
AB
AN AF
AC
AD
AG
AH
F IG . 2 Heater Controls and Indicators
System Controls
AW
AP
AO
AX
AR
AS
° F
° C
AY
AJ
AK
AT
I I
-
-
STATUS
2
1
0
3
-
4
10
5
9
6
7
8
AV
AU
F IG . 3 System Controls and Indicators
332144H ti21962a
13
Controls and Indicators
Controls and Indicators
Key Name Description
Heater Controls
AA
AB
AC
AD
AE
AF
AG
AH
AJ
AK
AL
ISO Setpoint Increase
ISO Setpoint Decrease
RES Setpoint Increase
RES Setpoint Decrease
ISO Heater On/Off Key
RES Heater On/Off Key
Actual Temperature Key
Target Temperature Key
Temperature Scale Key °F
Temperature Scale Key °C
Temperature Display
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.
Heater Indicators
AM ISO Heater Activity
System Indicators
AW Boost Heat Indicator
AX
AY
Tank Level Indicator
System Status Indicator
The LEDs flash when heater zones are on. The duration of each flash shows the extent that the heater is turned on.
AN RES Heater Activity
AO Actual Temperatures Active
AP Target Temperatures Active
AR
AS
Fahrenheit Units Active
Celsius Units Active
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.
System Controls
AT
AU
AV
Heater Power
Motor Power
Enables heater control. The switch includes a 20 A circuit breaker.
Enables motor. The switch includes a 20 A circuit breaker.
Motor Pump Control Function Knob Selects operation mode / pressure setpoint. See
Indicates that the boost heat is active.
See
Flashes an error code if alarm or deviation is active. See
14 332144H
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
Recirculation
Fast
Recirculation
Pressure
Adjust
Slow recirculation speed.
Fast recirculation speed.
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 T ABLE 1 for a brief description of status codes.
Table 1: Motor/Pump Status Codes
7
8
5
6
2
3
4
9
10
11
12
13
14
15-19
Number Name
1 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 Alarm Zone
High fluid temperature
High zone current
Individual
Individual
No zone current with heater on Individual
Thermocouple not connected Individual
High controller temperature
No communications with zone pod
Display is missing
No communication with heater control module
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)
> 1 gallon
< 1 gallon
Chemical Status
Off
Flashing
332144H 15
Setup
Setup
Locate Reactor
Locate the Reactor on a level surface.
NOTE: Do not expose the Reactor to rain.
Electrical Requirements
To avoid electric shock, always unplug both cords before servicing the Reactor and wait one minute.
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.
1. Connect the Reactor to the correct power source for
your model. See T ABLE 4. Power cords must be
connected to two separate, dedicated circuits. See
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.
F
1
2
IG
2
TI7061a
1
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.
. 4 Use Two Separate Circuits
Table 4: Electrical Requirements
Model
200-240VAC, 1 phase,
50/60 Hz, two 15 ft
(4.5 m) power cords
Required Power Source
Two separate, dedicated circuits rated at minimum of 15 A each
Power Cord
Connectors
Two IEC 3-20 C20
Plugs
Supplied Local Adapters
NEMA 6-15P
Euro CEE74
YP-39 AS3112
(North America)
(Europe)
(Australia/Asia)
100-120VAC, 50/60
Hz, two 15 ft (4.5 m) power cords
Two separate dedicated circuits rated at minimum of 20 A each
Two NEMA
5-20P Plugs
Table 5: Extension Cord Requirements
Model
All models
Cords must be 3-conductor grounded, rated for your environment.
Required Wire Size
Up to 50 ft (15 m)
AWG 12
Up to 100 ft (30 m)
AWG 10
16 332144H
Grounding
2. Connect the recirculation hoses from the gun recirculation ports to the connections (S).
Setup
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.
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, F IG . 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.
(RES) S
S
R ti21488A
R
(ISO) ti6988b
Air
F IG . 5 Connect the Recirculation Hoses
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.
332144H 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
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.
BA ti21488A
NOTICE
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.
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
ISO
1 ti21488A
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 332144H
Setup
Purge Air and Flush Fluid From
Lines
5. Turn on Motor Power. System status indicator (AY) should turn on.
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.
1. Remove both recirculation tubes (P) from the tanks and secure each one in a dedicated waste container.
6. Set Recirc/Spray valves to Recirc.
ti21495a
P ti21488A
2. Set function knob to Stop/Park
STATUS
1
2
+
-
0
3
4
10
5
6
9
8
7 ti21490a
.
3. Plug in power cords(s). See Table 2, page 16.
4. Open both pump fluid inlet valves (V, shown in open position).
7. Set function knob to Slow Recirc
.
-
+
STATUS
2
1
0
3
-
4
10
5
9
8
6
7
OR
or Fast Recirc
+
-
STATUS
2
1
0
-
3
4
10
5
9
6
7
8 ti21489a
8. When clean fluids exit both recirculation tubes (P), set function knob to Stop/Park
+
-
0
1
2
3
4
10
5
9
6
7
8 ti21490a
.
9. Replace the recirculation tubes (P) in the supply tanks.
V ti21917a
332144H 19
Startup
Startup
b. Press to display target temperatures.
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.
1. Perform
2. Set the function knob to Slow Recirc
Recirc .
or Fast
-
+
-
STATUS
1
2
0
-
3
4
10
5
9
8
6
7
OR
-
+
-
STATUS
1
2 3
0
-
4
10
5
6
9
8
7 ti21489a
3. See
Heatup Guidelines , page 21, then continue
with steps 3-6.
4. Turn on Heater Power.
5. Set temperatures: a. Press ° F or temperature scale.
° C to change the c. To set press
heat zone target temperature,
or until the display shows desired temperature. Repeat for zone.
d. Press to display actual temperatures.
6. Circulate through the heater until temperature
readouts display desired temperature. See T ABLE 6.
7. Adjust the heat controls as necessary for a stable spray temperature.
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
35 ft (10.7 m) Hose
(1 bundle)
15 minutes
40 minutes
10 minutes
20 minutes
NOTE: Heatup times are based on 70°F (21°C) starting material temperature and 70°F (21°C) ambient temperature.
NOTE: Different fluids will absorb heat at different rates.
When refilling a warm machine, heatup times will be less.
20 332144H
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.
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.
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 limits, set the function knob to Slow Recirc circulate again to bring temperatures back up.
and
• 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.
332144H 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 status indicator LED is on.
+
-
0
1
2 3
4
10
5
6
7
9
8
. Verify system ti21490a
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).
2. Set Recirc/Spray valves to Spray .
ti21491a
Fusion Probler
NOTE: On impingement guns, never open fluid manifold valves or trigger gun if pressure are imbalanced.
6. Disengage piston safety lock or trigger safety lock.
3. Turn function knob to Pressure Adjust . Keep turning to the right until fluid pressure gauges show desired pressure.
2
+
-
0
1
3
4
10
5
9
8
6
7 ti21492a
Fusion 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.
22 332144H
Operation
Pause
To bring the hose and gun back to spray temperature after a brief break, use the following procedure.
1. Engage the piston safety lock or trigger safety lock.
Fusion
Probler
2. Set the function knob to Slow Recirc .
-
+
-
STATUS
2
1
0
3
-
4
10
5
6
7
8
9
OR
-
+
-
STATUS
2
1
0
-
3
4
10
5
9
6
7
8 ti21489a
3. Set the Spray valves to Recirc until the temperature readouts come back up.
Refill Tanks
Material can be added to the tanks at any time. See Fill
If you are operating at high temperatures or flow rates,
follow Pause instructions, page 23, to bring the tanks up
to temperature.
NOTICE
To prevent cross-contamination of fluids and equipment parts, never interchange ISO and RES 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.
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 Probler
332144H 23
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever you see this symbol.
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.
Shutdown
For longer breaks (more than 10 minutes) use the following procedure. If you will be shutdown for more than 3 days, first see
1. Shut off Heater Power.
2. Shut off Motor Power.
3. Follow all steps of the
,
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.
Fusion
Probler
2. Set function knob to Stop/Park
+
-
0
1
2
3
4
10
5
6
7
9
8 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 332144H
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.
X
S ti21836a
332144H 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.
+
-
0
1
2 3
4
10
5
9
8
6
7 ti31496a
Fusion Probler
2. Set function knob to Stop/Park
+
-
0
1
2 3
4
10
5
6
9
8
7 ti21490a
.
3. Shut off Heater Power. Allow system to cool.
7. Set function knob to Stop/Park
STATUS
2
+
-
0
1
3
4
10
5
9
8
6
7 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 through system to waste containers.
. Pump solvent
+
-
0
1
2 3
4
10
5
9
8
6
7 ti31496a
26 332144H
Flushing
10. When nearly clear solvent comes from recirculation tubes, set function knob to Stop/Park recirculation tubes to supply tanks.
STATUS
+
-
0
1
2
3
4
10
5
6
7
9
8 ti21490a
. Return
Purge Hoses
Disconnect hoses from gun and secure back into the tanks for thorough cleaning with solvent.
• Turn Spray valve ISO to Spray.
11. Set function knob to Fast Recirc . Circulate solvent through system for 10-20 minutes to ensure thorough cleaning.
0
1
2
+
-
3
4
10
5
6
9
8
7 ti31496a
•
• Open the gun into a waste ISO container.
Set the function knob to Slow Recirc is flushed.
until hose
• Set the function knob to Park
• Repeat for the RES side.
.
12. To flush the gun, refer to your gun instruction manual.
13. Set the function knob to Park .
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.
332144H 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
,
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.
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, F IG . 12, page 45.
2. Reverse ISO and RES transducer electrical
connections at the board, F IG . 12, page 45. If the
error moves to transducer RES (Status Code 4),
replace transducer ISO.See Pressure
Status Code 4: Pressure Transducer RES failure
1. Check transducer RES electrical connection (J12)
at the board, F IG . 12, page 45.
2. Reverse ISO and RES transducer electrical
connections at the board, F IG . 12, page 45. If the
error moves to transducer ISO (Status Code 3), replace transducer RES. See
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
4. Short on the control board. Replace the board. See
5. Worn or hung up motor brush causing arcing of brush at the commutator. Replace the brushes. See
6. Disconnect motor connections from the control board. Cycle power.
28 332144H
Troubleshooting a. If status code 5 is still present, replace the board. b. If status code 5 is not active, test the motor. See
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 F IG . 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
1. Add material to the supply tank, if necessary.
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 55.
3. Check J6 connections on the control board. T ABLE
Level Sensor
LED Status
Green - on Sensor is powered
Green - off Sensor is not powered
Yellow - on Sensor detects material
Yellow - off 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
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 73, 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 73, 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.
332144H 29
Troubleshooting
DIP Switch Settings
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).
3. Locate the DIP switch on the control board.
21
26
F IG . 6 DIP Switch
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 332144H
Troubleshooting
DIP Switch Settings and Functions
DIP Switch Settings and Functions
DIP Switch and Function
DIP Switch 1
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.
DIP Switch 2
OFF
DEVIATION
ON
DEVIATION AND
SHUTDOWN
See Dip Switch 1 and 2 Settings
Select pressure imbalance limits, that if exceeded, will cause a deviation and a shutdown (if enabled).
DIP Switch 3
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 4
Causes deviation if pressure setpoint is greater than:
DEVIATION
300 psi (2.1 MPa, 21 bar)
*
*
SHUTDOWN
500 psi (3.5 MPa, 35 bar)
(25% if < 800 psi [5.6
MPa, 56 bar])
DIP Switch 5
Causes shutdown or displays a status code for low fluid level in tanks.
* DEVIATION
DIP Switch 6
Enables or disables boost heat.
DISABLE
DIP Switch 7
DIP Switch 8
(40% if < 800 psi [5.6
MPa, 56 bar])
SHUTDOWN
* ENABLE
Not used
Not used
*
Default DIP Switch Settings
DIP Switch 1 and 2 Settings
DIP Switch
1
DIP Switch
2 Deviation Shutdown
Off Off
---
Off
*
*
On
On
*
Off
*
On
On
300 psi (2.1
MPa, 21 bar)
500 psi (3.5
MPa, 35 bar)
300 psi (2.1
MPa, 21 bar)
500 psi (3.5
MPa, 35 bar)
---
500 psi (3.5
MPa, 35 bar)
800 psi (5.6
MPa, 56 bar)
332144H 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:
1. Shut off Heater Power.
2. Shut off Motor Power.
3. Turn on Motor Power and Heater power to clear.
E01: High Fluid Temperature
• 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
01
02
03
04
Code Code Name Alarm
Zone
High fluid temperature Individual
High zone current
No zone current
Thermocouple not connected
Individual
Individual
Individual
Corrective
Action page
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 T ABLE
4. Remove connector B from heater control module and check continuity of thermocouples by measuring resistance across pins on the plug end.
32 332144H
Troubleshooting
5. Verify fluid temperature, using an external temperature sensing device.
Table 7: Connector B Resistance Measurements
120V 230V
Connector Pin Connector Pin
B1
B2
B2
B2
B2
B2
1, 2
1
2
4
5
3
B1
B1
B1
B1
B1
B1
1, 2
5
6
8
Description
Overtemperature Switch
Thermocouple ISO, R (red)
Thermocouple ISO, Y (yellow)
Thermocouple RES, R (red)
9 Thermocouple RES, Y (yellow)
3-4,7,10 Unused
If temperature is too high (sensor reading is 260°F
[127°C] or above): nearly 0 ohms
4-6 ohms
E02: High zone current
Reading
4-6 ohms
N/A
When there is a high current error, the LED on that zone’s module will turn red while the error is displayed.
6. Check if the thermocouples are damaged, or not contacting the heater element, see F IG . 16, page
49.
7. Check if the temperature control module turns off when the equipment reaches the temperature setpoint:
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. a. Set the temperature setpoints far below the displayed temperature.
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.
b. Turn the zone on. If the temperature rises steadily, the power board is failing.
c. Verify by exchanging with another power module. See
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.
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 48.
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
2. Unplug and re-plug the sensor wires.
332144H 33
Troubleshooting
Reactor Electronics
2. Shut off Motor Power.
Before performing any troubleshooting procedures:
1. Shut off Heater Power.
3. Relieve the pressure. Follow
4. Allow the equipment to cool.
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.
PROBLEM
Temperature display does not illuminate.
CAUSE SOLUTION
Display disconnected.
Check the cable connections, F IG . 12, page 45.
Display cable damaged or corroded. Clean the connections; replace the cable if it is
Blown fuse.
damaged.
Replace the fuse (73) in the fuse holder on the DIN
Failed circuit board.
Loose display cables on control board.
Failed control board (displays get power from control board).
rail assembly located under the electronics cover
(55).
The display is failing. Replace.
Check the cable connections to each display, F IG .
Remove the access panel. Check if board LED is lighted. If not, replace the board. See
Inadequate power to control board.
Check that the power supply meets requirements.
Loose power cable.
Check the cable connections, F IG . 23, page 71.
Heater power switch circuit breaker tripped.
Display is powered from heater power circuit breaker. Cycle heater power off , then on
Erratic display; display turns on and off.
Display does not respond properly to button pushes.
Fan not working.
to reset breaker.
Low voltage.
Poor display connection.
Ensure the input voltage is within specifications, , page 73.
Check the cable connections, F IG . 23, page 71.
Replace the damaged cable.
Display cable damaged or corroded. Clean connections; replace the cable if is damaged.
Poor display connection.
Check the cable connections, F IG . 23, page 71.
Replace the damaged cable.
Display cable damaged or corroded. Clean connections, F IG . 23, page 71. Replace the
damaged cable.
Connect the cable, F IG . 23, page 71, or replace.
Ribbon cable on display circuit board disconnected or broken.
Broken display button.
Loose wire.
Defective fan.
Replace. See
Check the fan wire.
34 332144H
Troubleshooting
Heaters
2. Shut off Motor Power.
Before performing any troubleshooting procedures:
1. Shut off Heater Power.
3. Relieve the pressure. Follow the Pressure Relief
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.
PROBLEM
Primary heater(s) does not heat.
CAUSE
Heat turned off.
SOLUTION
Control of primary heat is abnormal; high temperature overshoots or E01 error occurs intermittently.
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
,
Failed heater element.
Check the resistance of the heater elements.
See Test Heater Element , page 48.
Dirty thermocouple connections.
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.
Thermocouple not contacting heater element.
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 F IG . 16, page 49 for illustration.
Failed heater element.
Signal failure from thermocouple. See
E04: Thermocouple disconnected
,
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.
332144H 35
Troubleshooting
Proportioner
2. Shut off Motor Power.
Before performing any troubleshooting procedures:
1. Shut off Heater Power.
3. Relieve the pressure. Follow the
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.
PROBLEM
The Reactor does not operate.
The motor does not operate.
The pump output is low.
No power.
CAUSE SOLUTION
Plug in both power cords.
Cycle Motor Power and Heater Power off , then on to reset both breakers.
Power turned on while function knob set to a run position.
Set the function knob to Park ,
Loose connection on control board.
Worn brushes.
Plugged fluid inlet strainer.
Leaking or plugged piston valve or intake valve in displacement pump.
once status LED turns on. Then select the desired function.
Check the connection at the motor power connections on the bottom board. See
Check both sides. Replace brushes worn to less than 1/2 in. (13 mm). See
Broken or misaligned brush springs.
Brushes or springs binding in brush holder.
Shorted armature.
Clean the brush holder and align the brush leads for free movement.
, page
Check motor commutator for burn spots, black pitting, or other damage.
Remove the motor. Have a motor shop resurface the commutator, or replace the motor. See
Failed control board.
Replace the board. See Motor Control , page 44.
Clear. See Maintenance , page 25.
Check the valves. See your pump manual.
36 332144H
Troubleshooting
PROBLEM
One side doesn’t come up to pressure in spray mode.
Pressure is higher on one side when setting pressure with function knob.
Pressures are not balanced when running, but pressure is generated and holds on both strokes.
Fluid leak in pump packing nut area.
Pressure doesn’t hold when stalled against gun in spray mode.
Leaking Spray valve.
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.
CAUSE SOLUTION
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.
Restriction on one side.
Worn throat seals.
Refill.
Clean or repair. See Replace Spray
Clear.
See
Clean the pump intake valve. See
Remove Intake Valve Only , page 41.
Warm the material before adding to the tanks.
Pump intake valve partially plugged.
Clean the pump intake valve. See
Remove Intake Valve Only , page 41.
Air in hose. Fluid is compressible.
Unequal size hoses or unequal hose
Purge air from the hose.
Use matching hoses, or balance construction.
Unequal viscosities.
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 piston valve or intake valve in displacement pump.
Leaking gun shutoff.
This is normal. RES is typically higher viscosity than ISO until the material is heated during recirculation.
Loss of pressure on downstoke.
Loss of pressure on upstoke.
The function knob is not set to Park when power is applied.
Loose indicator cable.
Repair. See you pump manual.
Repair. See you gun manual.
No action required.
The intake valve is leaking or not closing. Clean or replace valve. See
Replace Spray Valves , page 40.
The piston valve is leaking or not
, closing. Clean or replace the valve or
packings. See Replace Spray Valves
,
Turn the function knob to Park.
ISO side rich; lack of RES side.
Failed control board.
Shorted pressure transducer or potentiometer input.
ISO side gauge is low.
RES side gauge is low.
Check that the cable is connected at J3
on the top motor control board. See F IG .
Replace the board. See
,
See
Control Board LEDs , page 44 for
troubleshooting.
RES side restriction downstream of the gauge. Check the gun check valve screen, mix module, or mix manifold restrictor.
RES side material supply problem.
Check RES side inlet strainer and pump intake valve.
332144H 37
Troubleshooting
PROBLEM
RES side rich; lack of ISO side.
Tank level sensor does not sense empty tank (indicator LED on control panel never blinks).
Tank level sensor does not sense full tank (indicator LED on control panel always blinking).
CAUSE
ISO side gauge is low.
RES side gauge is low.
Material build up.
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.
LED wires disconnected inside control panel.
Tank level sensor sensitivity is too high.
Tank level sensor is too far away from tank.
Sensor wires disconnected.
Tank level sensor sensitivity is too low.
Reset the tank fluid level sensor sensitivity. See
Check the position of both tank level
Reconnect the sensor wires in the display panel.
Reset the tank fluid level sensor sensitivity. See
38 332144H
Repair
Repair
Before Beginning Repair Remove Supply Tank
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.
1. See
Before Beginning Repair , page 39.
2. Relieve the pressure,
,
3. Flush the system. Refer to
4. Place a waste container under the y-strainer.
5. Close the fluid valve (V).
N
2. Set function knob to Stop/Park
+
-
0
1
2 3
4
10
5
9
8
6
7 ti21490a
3. Shut off Motor Power.
.
V
P ti21893a
6. Remove the filter drain hex nut (N) and drain material.
7. Remove recirculation tubes (P) and place in waste containers.
4. Shut off Heater Power. Allow system to cool.
5. Relieve the pressure. Follow
6. Disconnect the heater and motor power cords.
ti21488a
8. Disconnect the swivel elbow at the pump fluid inlet.
9. Remove the six screws (28) holding the tank (27) to the cart frame.
332144H 39
Repair
S
27
Replace Spray Valves
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).
1. See Before Beginning Repair , page 39.
2. Relieve the pressure. Follow
3. See F IG . 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
455a (Red)
456 455b (Blue)
454
453
1 2
453a
453b
3
3 ti21838a
1
2
Torque to 250 in-lb (28 N•m).
Use blue threadlocker on valve cartridge threads into manifold.
3 Part of item 453.
F IG . 7 Spray Valves
40 332144H
Repair
Displacement Pump
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
3. Close both fluid valves (V).
V
N ti21893a
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.
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 F IG . 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
NOTE: Use dropcloth or rags to protect Reactor and surrounding area from spills.
4. Open the filter drain hex nut (N) on the y-strainer.
Remove Intake Valve Only
If the pump is not generating any pressure, the intake ball check may be stuck closed with dried material.
If the pump is not generating pressure on the downstroke, intake ball check may be stuck open.
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.
E
2
C 51
1 Flat side faces up. Tighten by hitting firmly with non-sparking hammer.
2 Lubricate threads with ISO oil or grease.
F IG . 8 Displacement Pump
218
1 2
217
D
2
222 ti21839a
332144H 41
Repair
Control Panel
Replace Temperature Display
9. Reassemble in reverse order, see F IG . 10, page 43.
Apply medium strength thread sealant where shown.
Replace Function Knob/Potentiometer
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
NOTICE
Before Beginning Repair , page 39.
2. Remove screws (21) and display cover (26).
21
26 ti21923a
3. Put on a static conductive wrist strap.
4. Disconnect the main display cable (81) from the upper right corner of the temperature display (353).
5. Remove the jumper (373) from the back of the display (353). Set aside and install the jumper on the new display.
6. Disconnect the ribbon cable(s) (R) from the back of
the display; see F IG . 10, page 43.
7. Remove the nuts (360) from the plate (351).
8. Disassemble the display (353), see detail in F IG . 10, page 43.
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 F IG . 12, page 45.
4. See F IG . 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).
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.
P
S
358
356a
N
356a
356
F IG . 9 Function Knob/Potentiometer
357 ti21840a
42 332144H
360
351
357
F IG . 10 Control Panel
353
373
354
363 ti21841a
352
Repair
332144H 43
Repair
Motor Control Replace Control Board
Power Bootup Check
Power must be on to check. See F IG . 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
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 LED
Top R4
Bottom
G1
D4
D16
State
Red: on
Green: on
Red: on
Green: on
Description
Hardware or software failure
Power on
Hardware or software failure
Power 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 F IG . 10, page 43.
5. Install the new board in reverse order.
J2
J1
R4
G1 J98
J6
J9
J8
J10
D16
(under C52)
D4
(bottom side of board)
F IG . 11
44 332144H
Board
Jack
J1
J2
J3
J4
J5
J6
J8
J9
J10
J11
J12
Table 8: Control Board Connectors (see F IG . 12)
Top Board Connectors Bottom Board Connectors
Pin n/a
Description
Not Used n/a Not Used n/a Error LED n/a Tank Level LED n/a Function Knob
1 Brown - ISO Sensor V+
2
3
Blue - ISO Sensor V-
Black - ISO Sensor Signal
4
5
Brown - RES Sensor V+
Blue - RES Sensor V-
6 Black - RES Sensor Signal n/a Boost Power Relay n/a Motor Overtemperature n/a Cycle Switch n/a ISO Pressure Transducer n/a RES Pressure Transducer
Connector
Female Quick
Connect Terminals
Plug Housing with
Male Blades
Description
Power
Motor Power
Top
Bottom
J2
J1
J98
J6
J9
J8
J10
F IG . 12 Wiring Connections
Repair
332144H 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.
1. See
Before Beginning Repair , page 39.
2. Remove the heater shroud (89) and the electronics cover (55).
3. Put on a static conductive wrist strap.
4. Disconnect all cables and connectors from the temperature control module (59).
59
56
55
89 ti21844a
F IG . 13
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 332144H
Repair
Temperature Control Modules Connections
Table 9: Heater Control Module Connections
Connector
DATA (A)
Sensor (B)
DISPLAY (C)
COMMUNICATION
(D)
PROGRAM (E)
BOOT (F)
Description
100-120VAC 200-240VAC
Not used
See Table 11
Display
Communication to power boards
Software programming
Software bootloader
Table 9: Heater Control Module Connections
Description
Connector 100-120VAC 200-240VAC
POWER/RELAY (G) 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
H
Table 11: Sensor B Connections
100-120VAC 200-240VAC
Connector Pin Connector Pin
B1
B2
B2
B2
B2
B2
1, 2
1
2
4
5
3
B1
B1
B1
B1
B1
B1
1, 2
5
6
8
Description
Overtemperature Switch
Thermocouple ISO, R (red)
Thermocouple ISO, Y (yellow)
Thermocouple RES, R (red)
9 Thermocouple RES, Y (yellow)
3-4,7,10 Unused
H
J ti9843a4
100-120VAC ti21843b
200-240VAC
G
F
E
D
C B1 B2 A C
F IG . 14 Temperature Control Module Connections
B1
332144H
A
47
Repair
Heater
Test 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).
55
90 ti21845a
F IG . 15
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.
Nominal
Heater
Voltage
120
230
Heater
Wattage Per
Zone
1500
2000
Element
Wattage Ohms
500
1000
620
1380
24-32
12-16
73-94
32-43
Remove Heater Element
1. To remove the heater element (307), first remove the thermocouple (310) to avoid damage, see step
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.
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 49.
6. Reconnect the heater element leadwires to the heater wire connector.
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.
48 332144H
Repair
Thermocouple
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 F IG . 13, page 46.
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
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 F IG . 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.
8. Replace the thermocouple, F IG . 16. a. Remove the protective tape from the thermocouple tip (T).
b. Apply PTFE tape and thread sealant to male threads and tighten the thermocouple housing
(H) into the adapter (305).
c. Push in the thermocouple (310) so the tip (T) contacts the heater element (307).
d. Holding the thermocouple (T) against the heater element, tighten the ferrule nut (N) 1/4 turn past tight.
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 F IG . 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).
S
1
310
N
H
305
301
1 Apply PTFE tape and thread sealant.
2 Apply 110009 thermal heatsink compound.
307
2
308
T
309 ti7924a
F IG . 16 Thermocouple
332144H 49
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 F IG . 13, page 46.
4. Disconnect one leadwire from the overtemperature switch (308), F IG . 16, page 49. 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.
If wires need replacement, disconnect from the heater
control module. See F IG . 24 on page 72.
Pressure Transducers
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
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).
e. Route the cable back through the cart frame to
the control board. See F IG . 12, page 45.
f.
Install the supply tank.
554
553
1. See
Before Beginning Repair , page 39.
2. Remove back cover (26).
26
F IG . 17 Transducer
354 ti21923a
50 332144H
Repair
Drive Housing
Removal
1. See Before Beginning Repair , page 39.
2. Remove the screws (207) and end covers (229), see F IG . 18, page 52.
Examine the connecting rod (216). If the rod needs replacing, first remove the pump (219). See
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).
Installation
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.
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.
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
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).
332144H 51
Repair
Replace Cycle Counter Switch
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
233
201
207
229
MB
208
(steel)
209
(bronze)
220
211
(bronze)
215
1
210
224
214
213
(bronze)
213
(bronze)
212
(steel)
216
219
1 Crankshaft must be in line with crankshaft at other end of motor, so pumps move up and down in unison.
F IG . 18 Drive Housing
223
1.0 in. (25.4 mm) from inside bottom edge
TI7028a
223
221
89
91 ti21847a
52 332144H
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 F IG . 12, page 45. Touch jumpers from
battery to the motor connections. The motor should turn slowly and smoothly.
Removal
See wiring schematic, page 45.
1. See Before Beginning Repair , page 39.
2. Relieve the pressure. Follow the
3. Remove the four screws (91), shroud (89), and mounting brackets (233). See F IG . 18.
4. Remove the fans (16) and disconnect the cable
(80). See F IG . 20.
5. Remove the drive housing. See
,
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.
7. Remove the RES supply tank. See
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).
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 F IG . 24, page 72.
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
51. Reconnect the inlet assemblies to the pumps.
10. Torque the screws (15) to 150 in.-lb (17 N•m).
11. Return to service.
332144H 53
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
3. Remove the four screws (91) and the motor shroud
(89). See F IG . 18, page 52.
4. Remove the fans (16) and disconnect the cable
(80). See F IG . 20, page 54.
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: a. Remove the two bolts and access the cover
plate. See F IG . 19, page 54.
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.
ti21916a
F IG . 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 F IG . 23 on page 71.
80
F IG . 20 Fans
17
16 ti21848a
54 332144H
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.
ti21849a
57
Replace
1. Loosen the jam nuts and remove the level sensor assembly (57).
2. Remove the supply tank. See Remove Supply
3. Cut the zip ties securing the sensor cable to the cart.
4. Remove the display control cover (26).
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
10. Adjust the position of the level sensor assembly
(57). See
11. Set the sensitivity. See
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.
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.
LED
Table 12: Sensor LED Identification
Status
Green - on Sensor is powered
Green - off Sensor is not powered
Yellow - on Sensor detects material (immediate, no
5 second display)
Yellow - off Sensor does not detect material
26 ti21923a
5. Disconnect the level sensor connector from J6 on
the control board. See F IG . 12, page 45.
332144H
F IG . 21 Sensor LEDs ti21963a
55
Repair
Reset Sensitivity
The tank fluid level sensor sensitivity may need to be adjusted when:
• A new tank has a different insulation density than the previous tank.
• Material build-up is on the inside or outside of the tank. Adjust sensitivity rather than thoroughly cleaning the tank.
• Level sensor sensitivity comes out of alignment through misuse or harsh environment.
• Material density is less than normally pumped materials.
1. Ensure that the tank is completely empty.
2. Remove the shroud (89) to expose the sensors.
3. Ensure that the sensor (57) and tank are properly
installed. See Adjust , page 55.
4. Locate the adjustment screw (S) above the green and yellow LEDs.
NOTE: The adjustment screw on some tank level sensors is covered by white tape. Remove the white tape to access the adjustment screw.
5. Use a small flathead screwdriver and slowly turn the adjustment screw (S) clockwise until the yellow LED turns on.
6. Slowly turn the adjustment screw (S) counterclockwise until the yellow LED barely turns off.
7. Slowly turn the adjustment screw (S) counterclockwise an additional 1/2 turn.
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.
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.
If the adjustment screw is turned a total 1/2 turn, then it will not detect an empty tank.
9. Reinstall the shroud (89).
S
F IG . 22 Adjustment Screw ti21963a
56 332144H
Parts
System Packages
101
104
15G962
15G958
16W239 ti21924a
102
System
Package
APT100
P2T100
APT900
APT901
APT902
P2T900
P2T901
P2T902
Proportioner
101
24T100
24T100
24R900
24R900
24R900
24R900
24R900
24R900 ti21488a
Hose
103
102
25R000
25R000
25R000
25R000
25R000
25R000
25R000
25R000
* Probler packages use recirc accessory kit 24E727.
Not included.
Gun
103
249810
GCP2RA*
249810
249810
249810
GCP2RA*
GCP2RA*
GCP2RA* ti6987b
Power Cord Adapter
104
Part
Number
16W239
15G958
15G962
16W239
15G958
15G962
Region
North America
Europe
Australia/Asia
North America
Europe
Australia/Asia
Parts
332144H 57
Parts
E-10hp Proportioners
24T100, 100-120VAC, Proportioner
24R900, 200-240VAC, Proportioner
26 21
102
98
25
24
2
99
77
48
42
49
84
5
28
96 97
33
29
30, 30a 27
35
92
94
93
97
97
96
49
42
50
32
31
91
56
56
55
99 ti21853b
90
89
58 332144H
Parts
1 8
5
4
3
6
99
7
6
41
40
39
2
56
21
58
10
59
8 4
64
66
56
60
66
74
56
56
38
37
3
9
10
11
67
66 71
36
73
72
66
70
64
56
59
10
68 69
65
21
58
61
56
332144H
12
11
13 ti21855b
59
Parts
47
22
19
17
9
16
18
46
7
14
52
54
52
42 43
44
45
11
57
42
43
44
45 46
47
53
60
21
20
21
15
6
57
11 ti21854a
332144H
Parts
3
4
1
2
5
6
7
Apply sealant to all non-swiveling pipe threads.
Apply sealant to threads of nut cap.
Apply lubricant to thread and axle of cart.
Apply even distribution of thermal grease on bottom of metal surface of solid state relays.
Torque to 125 in-lb (14 N•m).
Torque to 150 in-lb (17 N•m).
Assemble nut to finger tight only.
24T100, 100-120VAC, Proportioner
24R900, 200-240VAC, Proportioner
8
9
Orient SSR with terminals 1 and 2 towards the top.
Orient fan to flow down and connector plug towards the back.
10 Orient heater module with fins outwards.
11 Assemble sensor flush to tank surface.
12 Install clamp-on ferrite near termination of transducer wires.
13 Install clamp-on ferrite on black and red motor power wires.
17
18
19
23
24
25
20
21
22
Ref.
Part
11
12
13
14
8
9
10
15
16
6
7
4
5
1
2
3
26
Description
--CART
24T950 BRACKET, tank mount
24T951 BRACKET, crossbar
24T952 BRACKET, gusset, cart
24T953 BRACKET, motor mount
110996 NUT, hex, flange head
101765 GROMMET
119975 GRIP, vinyl, gray; 1.25 in.
154636 WASHER, flat
116411 SPRING, compression
116477 WASHER, flat, nylon
116478 WHEEL, pneumatic
101242 RING, retaining, ext.
24T954
117493 SCREW, mach, hex washer hd; 1/4-20
24K985 FAN, cooling, 120 VAC
24K986 FAN, cooling, 230 V
115836 GUARD, finger
120094 SCREW, pan hd, phil, zinc
24U009
HEATER, assy; 120V, 1000W; see page 66
24T955
167002 INSULATOR, heat
108296 SCREW, mach, hex wash hd
24T960
MANIFOLD, outlet/recirc; see page 69
24T962
117623 NUT, cap; 3/8-16
24U005 DIODE, light-emitting,120 V
24T970 DIODE, light-emitting, 230 V
24R648 COVER, display
Quantity
24T100, 100-120 VAC 24R900, 200-240 VAC
1
4
2
2
2
2
4
2
4
1
1
18
3
1
1
1
1
4
2
2
2
4
2
4
1
1
18
3
1
1
1
2
8
1
2
2
8
2
10
1
1
4
1
1
2
10
1
1
4
1
1
1
332144H 61
Parts
50
51
52
53
54
46
47
48
49
42
43
44
45
39
40
41
59
60
61
55
56
57
58
Ref.
Part
35
36
37
38
27
28
29
30
30a
31
32
33
38a
64
65
66
Description
24T973 TANK
111800 SCREW, cap, hex hd
127148 SCREW, set, 7/16-14, 1/2, black
24T975 LID; includes o-ring (30a)
24T974 O-RING
24K976 MUFFLER,1/4 NPT
101044 WASHER, plain
119973 CABLE, sst lanyard; 14 in.
24K984 DRYER, desiccant, mini in-line
162453 FITTING; 1/4 npsm x 1/4 npt
100176 BUSHING, hex
24K977 FILTER, regulator, air; with 3/8 npt auto drain; includes 64a
15D909 ELEMENT, 5 micron; polypropylene; not shown
157350 ADAPTER
104641 FITTING, bulkhead
169970 FITTING, line air; 1/4-18 npt
116704 ADAPTER, 9/16-18 JIC x 1/4 NPT
117506 FITTING, swivel, 1/4 npt x #6 JIC
---
MANIFOLD, assembly, outlet; see page 70
556765 FITTING, #6 JIC 1/4PM
24T977 TUBE, pump outlet, ISO
24T978 TUBE, heater outlet, ISO
24T979 HOSE, coupled, recirc, ISO
24T980 TUBE, recirculation
24T981 HOSE, coupled, recirc, RES
114225 TRIM, edge protection
119992 FITTING, pipe, nipple, 3/4 x 3/4 npt
24T982
MANIFOLD, inlet, RES; see page 68
24T986
MANIFOLD, inlet, ISO; see page 68
24T987 COVER, electronics
115942 NUT, hex, flange head
24T988 SENSOR, tank level
24T990 PANEL, heater control mount
247828 MODULE, heater
24T989 PANEL, logic control mount
24T308 MODULE, heater control,120 V
24T307 MODULE, heater control, 230V
24U006 RELAY, SSR, 120 V
24T991 RELAY, SSR, 230 V
112144 SCREW, mach, pan hd
126811 BLOCK, clamp end
1
1
1
2
1
1
1
1
2
2
2
2
2
1
4
1
1
2
12
2
2
2
1
1
Quantity
24T100, 100-120 VAC 24R900, 200-240 VAC
1
1
2
2
2
12
2
1
1
2
1
2
12
2
2
2
1
1
2
1
1
1
1 1
1
1
1
2
1
1
1
1
2
12
2
2
2
1
2
2
2
2
1
4
1
1
2
1
2
4
4
2
4
4
62 332144H
Parts
Quantity
Ref.
Part Description
94
95
96
97
91
92
93
98
99
104
67 24U007 CONNECTOR, contactor; 120 V
24T992 CONNECTOR, contactor; 230 V
126817 COVER, end 68
69
70
71
72
126818 BLOCK, terminal 3-wire
126810 RELAY, cradle
24T993 RELAY, 12V
255043 HOLDER, fuse terminal block; 5 x 20mm
255023 FUSE, 5A, 5 x 20 mm 73
74 †
75 †
76
77
127239 CONNECTOR, 5 pin
127240 CONNECTOR, 10 pin
120748
127237
CONNECTOR, 2 pin
CONNECTOR, 6 pin
116171 BUSHING, strain relief
16W761 BUSHING, strain relief
78 † 24T994
HARNESS, POWER; see F IG . 23 on page
79 † 24T995 CABLE, communication, heater control module
80 † 24T996 CABLE, FAN, 29 in. (736.6 mm)
81 † 24T997 CABLE, control, display
82 † 24T998 CABLE, harness, overtemperature
83 24T999 CONNECTOR, jumper
84 24U008 CORD, 20A, 120 V
24U000 CORD, 16A, 230 V
85 113505 NUT, keps, hex hd
88 † 125835 CLIP, ferrite bead
89
90
24U001
24U002
COVER, proportioner, lower
COVER, proportioner, upper
115492 SCREW, mach, slot hex wash hd
24U003 GUARD, splash, hose rack
24U004
15G280
189930
217374
RACK, hose
120008 PLUG, tube
120150 ISOLATOR, pad, rubber
119999 BOLT, shoulder
110533 WASHER, flat, nylon,1/4
LABEL, safety, warning, multiple
LABEL, electric shock
LUBRICANT, ISO pump
Replacement safety labels, tags, and cards are available at no cost.
24T100, 100-120 VAC 24R900, 200-240 VAC
1
1
2
1
1
2
2
1
1
2
2
2
1
1
1
2
1
2
1
1
1
2
1
1
2
1
1
2
2
2
2
1
1
10
1
1
4
2
2
4
1
2
1
1
1
2
1
1
2
2
1
4
1
2
2
1
4
1
1
10
1
2
2
2
Not shown.
--- Not available for purchase.
332144H 63
Parts
24T954, 100-120VAC and 200-40VAC Bare Proportioner
201 207 233
229
207
6
4
220
1 8 9
210
211
(bronze)
3 8
215
208
(steel)
209
(bronze)
214
213
(bronze)
213
(bronze)
212
(steel)
216
2
218
5
222
207
6
217
219
3
221
223
7 10
207
6
91
(ref)
89
(ref) ti21847a
223
64
1
2
3
4
5
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.
0.6 in. (15.2 mm) from inside edge
1.0 in. (25.4 mm) from inside bottom edge
TI7028a
6
7
Torque fasteners to 30-35 in-lb. Applies only when fasteners are assembled in plastic housings (215).
Switch mounts to cover opposite brush end of motor only.
8 Housing must be installed on motor with crankshafts aligned with each other.
9 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.
332144H
Parts
Ref.
Part Description
201 24T758 MOTOR, electric
207 ‡ 115492 SCREW, mach, slot hex wash hd
208* 116074 WASHER, thrust
209* 107434 BEARING, thrust
210* 300001 KIT, crankshaft
211* 180131 BEARING, thrust
212 † 116073 WASHER, thrust
213 † 116079 BEARING, thrust
214 † 244242 GEAR, reducer (first stage)
215 ‡ 287055 HOUSING, drive
216 287053 KIT, repair, connecting, rod
217 196762 PIN, straight
218 195150 NUT, jam, pump
219 24L006 PUMP, displacement
220 ‡ 117493 SCREW, mach, hex washer hd
221 ‡ 300002 KIT, cover; includes switch
222 ‡ 15B589 COVER, pump rod
223 117770 SWITCH, reed with cable
224 24K982 MAGNET, disc, 0.38 dia.,
0.100 thick; not shown
227 115711 TAPE, foam, 1/2 wide
229 300003 KIT, cover
233 16W162 BRACKET, shroud tab
* 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).
Qty
1
10
1
1
2
1
2
2
8
1
1
2
2
2
2
2
4
2
2
2
2
2
332144H 65
Parts
24U009, 100-120VAC Heater
24T955, 200-240VAC Heater
4 6
310
2
305
311
3
308
306
5
307
1
2 5
304
1
316
1
307
309
316
1
312
5 ti21850a
301
302
1 5
3
4
1
2
303
4
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.
5 Apply lubricant to o-rings before assembling in heater housing.
6
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. Part Description
301 --BLOCK, heater
302 15H302 FITTING, reducer 1-3/16 SAE x 1/2 npt
303 16V432 FITTING, adapter, #6 JIC x npt, mxm
304 15H304 FITTING, plug, 9/16 SAE
305 15H306 ADATPER, thermocouple, 9/16 x
1/8
306 120336 O-RING, packing
307 24T958 HEATER, fire rod, 230 V, 24T955 only
24U012 HEATER, fire rod, 120 V, 24U009 only
Qty.
1
4
4
2
2
2
2
2
Ref. Part Description Qty.
308 15B137 SWITCH, overtemperature
309 16U940 MIXER, heater
--SCREW, mach; #6-32
312 124132 O-RING
316 24T959 HEATER, fire rod, 230 V; 24T955
1
4
310 117484 SENSOR, 2
311 2
4
2 only
24U014 HEATER, fire rod, 120 V; 24U009 only
2
--- Not available for purchase.
66 332144H
Parts
24T962, Display
361
359
359
353
373
366
363
388
360
351
365
355
363
367
352
357
354 ti21841a
356
364
358
Ref. Part Description
351 24T963 PLATE, display, front
352 24T964 ENCLOSURE, control
353 24T966 DISPLAY, heat two zone
354 24T967 CONTROL, board, assy
355 24K983 SWITCH, rocker, w/breaker, 240v,
20a
356 24L001 KNOB, control, w/ball plunger
357 24L002 POTENTIOMETR, adjustment, pressure
358 15G053 PLATE, detent, display
359 300005 FILTER, board
Qty.
1
1
1
1
2
1
1
1
2
Ref. Part Description
360 117523 NUT, cap (#10)
361 127157 SCREW, mach, captive, #8
363 127158 NUT, captive, #8
364 24T968 DIODE, light-emitting, red
365 24T971 DIODE, light-emitting, yellow
366 --CLAMP, cable
367 113505 NUT, keps, hex hd
368 101765 GROMMET
373 127019 CONNECTOR, jumper, e-stop
--- Not available for purchase.
Qty.
4
8
1
2
8
1
6
3
1
332144H 67
Parts
Fluid Inlets
24T986, ISO Inlet
24T982, RES Inlet
404
405
4
5
406
407
401
1 ti21851a
3
4
1
2
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).
5
6
Align bent tube to fitting within 2°.
Align thermometer dial as shown.
402
403
3
24T986
6
Ref. Part Description
401 101078 STRAINER, Y
402 15D757 HOUSING, thermometer, Viscon HP
403 102124 THERMOMETER, dial
404 24T983 VALVE, ball, 3/4 npt, mxf, T-handle
405 24T984 FITTING, adapter JIC-12 X 3/4 npt, mxm
406 24T985 TUBE, assy, inlet
407 160327 FITTING, union adapter, 90°
Qty.
1
1
1
1
1
1
1
24T982
6 ti21852a
68 332144H
Parts
24T960, Fluid Manifold
2
452
455a (Red)
4 6
461
460
5
464
456 455b (Blue)
4 6
454
453
4
3
1
2
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
458
459
1
462
5
463
Ref. Part Description
451 24T961 MANIFOLD, fluid
452 102814 GAUGE, pressure, fluid
453 239914 VALVE, drain
453a 15E022 SEAT
453b 111699 GASKET
454 224807 BASE, valve
455a 17X499 HANDLE, valve, drain, red
455b 17X521 HANDLE, valve, drain, blue
456 111600 PIN, grooved
457 16V434 FITTING, 90 elbow, JIC-6 x
SAE-ORB
458 119789 FITTING, elbow, street, 45°
459 162453 FITTING; 1/4 npsm x 1/4 npt
457
5
Qty.
1
2
1
2
2
1
2
2
1
1
2
2 ti21838a
Ref. Part Description
460 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.
332144H 69
Parts
25R000, Insulated Hose Bundle with Recirculation Lines
501 502 (Ref)
502
304
503 (Ref)
505 503
TI6991a
Ref. Part Description
501 24R996 HOSE, fluid (component ISO), 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 in. (6 mm) ID; number 6 JIC fittings (mxf); 35 ft (10.7 m)
Qty.
2
2
Ref. Part Description
503 15G342 HOSE, air; 1/4 in. (6 mm) ID; 1/4
504 buy npsm (fbe); 35 ft (10.7 m)
TUBE, foam, insulated; 1-3/8 in. locally (35 mm) ID; 31 ft (9.5 m)
505 156971 NIPPLE; 1/4 npt; for joining air line to another hose bundle
Qty.
1
1
1
Outlet Manifold
554
553
1
551
2
552 ti21846a
1
2
Apply lubricant to o-rings.
Orient housing with exhaust hole pointing down.
Ref. Part Description
551 24T976 MANIFOLD, fluid, pump, outlet
552 247520 HOUSING, rupture disc
553 111457 PACKING, o-ring
554 24K999 TRANSDUCER, pressure, control
Qty.
1
1
1
1
70 332144H
Parts
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
6 5( 67 %22
+
+
+
+
+
+
+
+
+
(6 5 0$,1
+
+
+
+
2 ,6 67 %22
+
+
F IG . 23 Power Harness (78) Wire Identification
332144H
+
+
&
&
&
&
&
&
71
Parts
+
%/8(
+
%/$&.
%/8(
%/$&.
*5((1
F IG . 24
72
%/$&.
7$1
%/$&.
7$1
*5((1
*5((1
+
+
%/8(
%52:1
%/8(
%52:1
%/$&.
7$1
+ +
332144H
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
Dimensions
Accessories
Part Description
24E727 Probler Recirc Kit
24U342 Lift Ring Kit
Suggested Replacement Parts
46 in.
(116.8 cm)
36 in.
(91.4 cm)
29 in.
(73.6 cm) ti21488a
332144H 73
Technical Specifications
Technical Specifications
Reactor E-10hp
Maximum fluid working pressure
Maximum spray pressure: 120 V
Maximum spray pressure: 230 V
Maximum fluid temperature
Maximum ambient temperature
Maximum output
Output per cycle (ISO and RES)
Air inlet
Air outlet
Overpressure relief
3000 psi
2200 psi
2500 psi
170°F
120°F
1 gal./min
US
0.0038 gallons/cycle
Metric
20.6 MPa, 206 bar
15.2 MPa, 152 bar
17.2 MPa, 172 bar
77°C
48°C
3.8 liters/min
0.014 liters/cycle
1/4 in. quick-disconnect industrial type pin fitting
1/4 npsm(m)
Spray valves automatically relieve excessive fluid pressure back to supply tanks
Gun compressed air requirements
Maximum hose length
Tank capacity each (nominal)
Fusion ® Air Purge
Fusion Gun (purge air and operating air): 4 scfm (0.112 m 3 /min)
105 ft
6 gal.
Weight (empty)
Recommended Mix Chamber Sizes
239 lb
32 m
22.7 liters
108 kg
000, AW2222 (00 and 01 at reduced spray pressure)
AA (00 and 01 at reduced spray pressure)
Probler ® P2
Electrical Requirements
120 V
230 V
100-120VAC, 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.
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)
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)
74 332144H
Technical Specifications
Reactor E-10hp
US Metric
Sound Power*
In fast recirculation mode
Measure at 2500 psi (17 MPa, 172 bar), 1 gpm (3.8 lpm)
Fluid Outlets
ISO Side
RES Side
Fluid Circulation Returns
79.9 dB(A)
93.3 dB(A)
-5 JIC male
-6 JIC male
ISO side
RES side
Hose Markings
ISO side
-5 JIC male
-6 JIC male
RES side
Wetted Parts
Wetted parts on all models
Red
Blue
Aluminum, stainless steel, carbon steel, brass, carbide, chrome, chemically resistant o-rings, PTFE, ultra-high molecular weight polyethylene
Notes
* Sound power measured per ISO-9614-2.
All trademarks or registered trademarks are the property of their respective owners.
332144H 75
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 2018, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision H , July 2019
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