Graco 311075C Reactor E-10 Instructions

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Graco 311075C Reactor E-10 Instructions | Manualzz

Instructions - Parts List

For spraying or dispensing 1:1 mix ratio materials, including epoxies, polyurethane foam, and polyurea coatings.

Not for use in explosive atmospheres.

Important Safety Instructions

Read all warnings and instructions in this manual.

Save these instructions.

See page 3 for a list of models and maximum working pressures.

Heated Package, with Fusion

Gun

Nonheated Package, with 2K Ultra-Lite

Gun and Cold Spray disposable mixer

311075C

TI6987b

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441

Copyright 2005, Graco Inc. is registered to I.S. EN ISO 9001

TI6989b

2

Related Manuals

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Isocyanate Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Foam Self-ignition . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Moisture Sensitivity of Isocyanates . . . . . . . . . . . . 7

Keep Components A and B Separate . . . . . . . . . . 7

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . . 7

Component Identification . . . . . . . . . . . . . . . . . . . . 8

Controls and Indicators . . . . . . . . . . . . . . . . . . . . 10

Motor/Pump Control Function Knob . . . . . . . . . 10

STATUS Indicator . . . . . . . . . . . . . . . . . . . . . . . 10

Motor Power Switch/Circuit Breaker . . . . . . . . . 10

Heater Power Switch/Circuit Breaker . . . . . . . . 11

Heater Temperature Controls . . . . . . . . . . . . . . 11

Fluid Temperature Sensors and Displays . . . . . 11

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Startup of Heated Units . . . . . . . . . . . . . . . . . . . . . 17

Heatup Guidelines . . . . . . . . . . . . . . . . . . . . . . 18

Heat Management Tips . . . . . . . . . . . . . . . . . . . 18

Heating Foam Resins with

245 fa Blowing Agents . . . . . . . . . . . . . . . . 19

Spraying/Dispensing . . . . . . . . . . . . . . . . . . . . . . . 20

Pause (Heated Units) . . . . . . . . . . . . . . . . . . . . . . . 21

Refilling Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 22

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . 28

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Before Beginning Repair . . . . . . . . . . . . . . . . . . 31

Removing Supply Tanks . . . . . . . . . . . . . . . . . . 31

Recirc/Spray Valves . . . . . . . . . . . . . . . . . . . . . . 32

Displacement Pump . . . . . . . . . . . . . . . . . . . . . 33

Control Module . . . . . . . . . . . . . . . . . . . . . . . . . 34

Fluid Heaters (if supplied) . . . . . . . . . . . . . . . . . 38

Pressure Transducers . . . . . . . . . . . . . . . . . . . . 38

Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Cycle Counter Switch Replacement . . . . . . . . . 39

Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Suggested Spare Replacement Parts . . . . . . . . . 54

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 58

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 58

Related Manuals

The following manuals are for Reactor E-10 components and accessories. Some are supplied with your package, depending on its configuration. Part No. 15G777 Compact Disk includes all Reactor E-10 manuals. Manuals are also available at www.graco.com.

Displacement Pump

Part No.

Description

311076 Instruction-Parts Manual (English)

Fluid Heater

Part No.

Description

311210 Instruction-Parts Manual (English)

Fusion Air Purge Spray Gun

Part No.

Description

309550 Instruction-Parts Manual (English)

Fusion Mechanical Purge Spray Gun

Part No.

Description

309856 Instruction-Parts Manual (English)

2K Ultra-Lite Dispense Valve

Part No.

Description

309000

311230

Instruction-Parts Manual (English)

2K Ultra-Lite Cold Spray and Joint Fill Kits

(English)

311075C

Models

Models

The model no., series letter, and serial no. are located on the back of the Reactor E-10. For faster assistance, please have that information ready before calling Customer Service.

Package

Part No.,

Series

249800,

A

Bare

Proportioner

Part No.,

Series

249570, A

Volts

120 V

249802,

A

249804,

A

249806,

A

249808,

A

249571, A

249572, A

249576, A

249577, A

240 V

240 V

120 V

240 V

* Electrical

Connection

15 A cord

(motor)

15 A cord

(heaters)

10 A cord

(motor)

10 A cord

(heaters)

20 A cord

(motor and heaters)

15 A cord

(motor only)

10 A cord

(motor only)

Package

Description

Heated Reactor E-10, insulated 5-hose bundle, Fusion

Air

Purge spray gun

Heated Reactor E-10, insulated 5-hose bundle, Fusion

Air

Purge spray gun

Heated Reactor E-10, insulated 5-hose bundle, Fusion

Air

Purge spray gun

Nonheated Reactor

E-10, 3-hose bundle,

2K Ultra-Lite

gun

Nonheated Reactor

E-10, 3-hose bundle,

2K Ultra-Lite

gun

Application

• Polyurethane

Foam

• Hot Polyureas

• Polyurethane

Foam

• Hot Polyureas

• Polyurethane

Foam

• Hot Polyureas

Self-leveling

Joint Fillers

Cold Polyureas

• Self-leveling

Joint Fillers

Cold Polyureas

Maximum

Working

Pressure, psi (MPa, bar)

2000 (14, 140)

2000 (14, 140)

2000 (14, 140)

2000 (14, 140)

2000 (14, 140)

* See page 13 for detailed electrical requirements.

311075C 3

4

Warnings

Warnings

The following general warnings are for the setup, use, grounding, maintenance, and repair of this equipment. Additional, more specific warnings may be found throughout the body of this manual where applicable. Symbols appearing in the body of the manual refer to these general warnings. When these symbols appear throughout the manual, refer back to these pages for a description of the specific hazard.

WARNING

ELECTRIC SHOCK HAZARD

Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power cord before servicing equipment.

• Use only grounded electrical outlets.

• Use only 3-wire extension cords.

• Ensure ground prongs are intact on sprayer 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 MSDS’s to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

• Gloves

• Hearing protection

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.

311075C

311075C

Warnings

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• 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 arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Ground all equipment in work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately.

Do not use equipment until you identify and correct the problem.

• Keep a fire extinguisher in the work area.

PRESSURIZED ALUMINUM PARTS HAZARD

Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical reaction and equipment rupture, and result in death, serious injury, and property damage.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco replacement parts only.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your Graco 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.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Comply with all applicable safety regulations.

MOVING PARTS HAZARD

Moving parts can pinch or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.

5

6

Overview

Overview

The Reactor E-10 is a portable, electric-powered, 1:1 mix ratio proportioner, for use with a wide variety of coatings, foams, sealants, and adhesives. Materials must be self-leveling and pourable, and may be applied with impingement mix spray guns, disposable mixer guns, or flush-type mix manifolds.

Reactor E-10 is gravity-fed from 7 gal. (26.5 liter) supply tanks mounted on the unit. The tanks are translucent to allow monitoring of fluid level.

Severe duty, positive displacement reciprocating piston pumps meter fluid flow to the gun for mixing and applying. When set to recirculation mode, Reactor E-10 will circulate fluids back to the supply tanks.

Heated models include separate thermostatically controlled heaters 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. Digital displays show the temperatures of the two fluids.

An electronic processor controls the motor, monitors fluid pressures, and alerts the operator if errors occur.

See STATUS Indicator , page 10, for further information.

Reactor E-10 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.

311075C

Isocyanate Hazard

Isocyanate Hazard

Read material manufacturer’s warnings and material

MSDS to know the specific hazards of isocyanates.

Use equipment in a well-ventilated area. Wear respirator, gloves, and protective clothing when using isocyanates.

Foam Self-ignition

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

• Never use solvent on one side if it has been contaminated from the other side.

• Always park pumps when you shutdown, see page

22.

• Always lubricate threaded parts with Part No.

217374 ISO pump oil or grease when reassembling.

Keep Components A and

B Separate

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

Moisture Sensitivity of

Isocyanates

Isocyanates (ISO) are catalysts used in two component foam and polyurea coatings. ISO will react with moisture

(such as humidity) to form small, hard, abrasive crystals, which become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts.

The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature.

To prevent exposing ISO to moisture:

• 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 felt washers in the pump wet-cups saturated with Graco ISO pump oil, Part No. 217374.

The lubricant creates a barrier between the ISO and the atmosphere.

• Use moisture-proof hoses specifically designed for

ISO, such as those supplied with your system (see

page 49).

CAUTION

To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (isocyanate) and component B (resin) parts.

Changing Materials

• When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.

• Always clean the fluid inlet strainers after flushing,

see page 23.

• Check with your material manufacturer for chemical compatibility.

• Most materials use ISO on the A side, but some use

ISO on the B side.

• Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the B (resin) side.

311075C 7

Component Identification

Component Identification

Key for F IG . 1

A Supply Tank A

B Supply Tank B

C Pump A

D Pump B

E Heater A

F Heater B

G Fluid Pressure Gauges

H Recirc/Spray and Overpressure Relief Valves

J

Control Panel; see F IG . 3, page 10

K Electric Motor and Drive Housings

L Insulated Hose Bundle (includes circulation return hoses)

M Fusion Air Purge Spray Gun

N Desiccant Dryer (mounts on supply tank A)

P Recirculation Tubes

Q Air Line Inlet (quick-disconnect fitting)

R Outlet Hose Connections

S Return Hose Connections

T Fluid Temperature Sensors

U Hose Rack and Control Shield

V Fluid Inlet Ball Valves (1 on each side)

W Fluid Inlet Strainers (1 on each side)

X Power Cord

Y Lift Ring

Z Air Filter/Moisture Separator

U Y

P

E

N

A

T

R

H

S

G

C

Q

Z

M

L

D

F

IG

. 1: Component Identification, Heated Packages (Part No. 249804 Shown)

8

J

P

B

F

T

K X

V

W

TI6987b

311075C

Component Identification

Key for F IG . 2

A Supply Tank A

B Supply Tank B

C Pump A

D Pump B

G Fluid Pressure Gauges

H Recirc/Spray and Overpressure Relief Valves

J

Control Panel; see F IG . 3, page 10

K Electric Motor and Drive Housings

L Hose Bundle

M 2K Ultra-Lite Spray Gun, with disposable static mixer

N Desiccant Dryer (mounts on supply tank A)

P Recirculation Tubes

Q Air Line Inlet (quick-disconnect fitting)

R Outlet Hose Connections

U Hose Rack and Control Shield

V Fluid Inlet Ball Valves (1 on each side)

W Fluid Inlet Strainers (1 on each side)

X Power Cord

Y Lift Ring

Z Air Filter/Moisture Separator

U Y

H

G

R

C

Q

P

N

A

J

P

B

K X

V

W

Z

M

L

D

F

IG

. 2: Component Identification, Nonheated Packages (Part No. 249808 Shown)

TI6989b

311075C 9

Controls and Indicators

Controls and Indicators

ST

CF

MP

HP

TD TD

TI7016a

F

IG

. 3. Controls and Indicators (heated unit shown)

Motor/Pump Control Function

Knob

Use knob (CF) to select desired function.

Icon Setting

Stop/Park

Function

Stops motor and automatically parks pumps.

Slow Recirc Slow recirculation speed.

Fast Recirc Fast recirculation speed.

Pressure

Adjust

Adjusts fluid pressure to gun in spray mode.

STATUS Indicator

• Indicator (ST) steady on: Motor Power switch is turned on and control board is working.

• Indicator (ST) blinking: If error occurs, STATUS indicator will blink 1 to 7 times to indicate status code,

pause, then repeat. See T ABLE 1 for a brief descrip-

tion of status codes. For more detailed information

and corrective action, see page 26.

Table 1: Status Codes

(see also the label on back of the control enclosure)

5

6

7

3

4

1

2

Code

No.

Code Name

Pressure imbalance between A and B sides

Unable to maintain pressure setpoint

Pressure transducer A failure

Pressure transducer B failure

Excessive current draw

High motor temperature

No cycle counter switch input

The default is to shut down if a status code indication occurs. Codes 1 and 2 may be set to disable automatic shutdown if desired; see page 26. The other codes are not settable.

Motor Power Switch/Circuit

Breaker

Switch (MP) turns power on to control board and function knob. The switch includes a 20 A circuit breaker.

10 311075C

Controls and Indicators

Heater Power Switch/Circuit

Breaker

See F IG . 3. Switch (HP) turns power on to heater ther-

mostats. The switch includes a 20 A circuit breaker.

Present on heated units only.

Heater Temperature Controls

See F IG . 4. Control knobs (HC) set temperature of com-

ponent A and B heaters. Indicator lights (HL) turn on when thermostats are heating, and off when heater reaches setpoint. Present on heated units only.

Fluid Temperature Sensors and

Displays

See F IG . 3. Fluid temperature sensors (T) monitor actual

temperature of component A and B fluid going to spray gun. Temperatures are then displayed (TD). Present on heated units only.

Unit is shipped set to °F. To change to °C, see page 34.

HL

HC

E

T

F IG . 4. Heater Temperature Controls

HL

HC

F

T

TI6984a

311075C 11

Setup

Setup

1.

Locate Reactor E-10

a.

Locate Reactor E-10 on a level surface. b.

Do not expose Reactor E-10 to rain.

2.

Electrical requirements

Improper wiring may cause electric shock or other serious injury if work is not performed properly. Have a qualified electrician perform any electrical work. Be sure your installation complies with all National, State and Local safety and fire codes.

Connect Reactor E-10 to the correct power source for

your model. See T ABLE 2. Models with two power cords

must be connected to two separate, dedicated circuits.

See F IG . 5.

Some models include cord adapters (55, 56) for use outside North America. Connect the appropriate adapter to the unit’s power cord before connecting to your power source.

3.

Ground system

The equipment must be grounded. Grounding reduces the risk of static and electric shock by providing an escape wire for the electrical current due to static build up or in the event of a short circuit.

a.

Reactor E-10: grounded through power cord. b.

Generator (if used): follow your local code. Start and stop generator with power cord(s) disconnected.

c.

Spray gun: grounded through the supplied fluid hoses, connected to a properly grounded Reactor E-10. Do not operate without at least one grounded fluid hose.

d.

Object being sprayed: follow your local code.

e.

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.

f.

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.

12 311075C

Model

120 V, 1 phase, 50/60 Hz, two 15 ft

(4.5 m) power cords, Heated

240 V, 1 phase, 50/60 Hz, two 15 ft

(4.5 m) power cords, Heated

Table 2: Electrical Requirements

Required Power Source

Two separate, dedicated circuits rated at minimum of 15 A each

Two separate, dedicated circuits rated at minimum of 10 A each

Power Cord Connector

Two NEMA 5-15T

Two IEC 320, with two local adapters:

Euro CEE74 Adapter

Australia/China Adapter

240 V, 1 phase, 50/60 Hz, one 15 ft

(4.5 m) power cord, Heated

120 V, 1 phase, 50/60 Hz, one 15 ft

(4.5 m) power cord, Nonheated

240 V, 1 phase, 50/60 Hz, one 15 ft

(4.5 m) power cord, Nonheated

Single dedicated circuit rated at minimum of 16 A

Single dedicated circuit rated at minimum of 15 A

Single dedicated circuit rated at minimum of 8 A

One NEMA 6-20P

One NEMA 5-15T

One NEMA 6-20P

Table 3: Extension Cord Requirements

Model

Nonheated and two cord heated models

Single cord heated model

Required Wire Size

Up to 50 ft (15 m)

AWG 14

AWG 12

Up to 100 ft (30 m)

AWG 12

AWG 10

Cords must be 3-conductor grounded, rated for your environment.

Setup

To avoid electric shock, always unplug both cords before servicing Reactor E-10.

1 Ensure no other high amp loads are connected while running Reactor E-10.

2 To verify separate circuits, plug in Reactor E-10 or a worklight and cycle breakers on and off.

1

Heater Power

Motor Power

F IG . 5. Use Two Separate Circuits for Two Cord Models

311075C

1

2

TI7061a

13

Setup

4.

Connect fluid hoses

Connect fluid supply hoses to outlet hose con-

nections (R, F IG . 6). Red hoses for component A

(ISO), blue for component B (RES). Fittings are sized to prevent connection errors. Connect other end of hoses to A and B inputs of gun.

Heated units only: connect recirculation hoses from gun recirculation ports to connections (S).

6.

Connect main air supply

Connect the main air supply to the quick disconnect fitting (Q) on the unit. 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).

Air Filter/Moisture Separator (Z) is equipped with an automatic moisture drain.

5.

Connect gun air hose

Connect 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 (305) provided with the hose bundle.

On heated 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.

7.

Flush before first use

The Reactor E-10 is tested with a plasticizer oil at the factory. Flush out the oil with a compatible

solvent before spraying. See page 24.

S

R

Heated Units

B (RES)

A (ISO)

Q

Z

TI6988b

AIR

A (ISO)

Q

B (RES)

AIR

Nonheated Units

Z

R

F IG . 6. Hose Connections

14

TI6990b

311075C

Setup

8.

Fill wet-cups

Keep the felt washers in the pump wet-cups saturated with Graco ISO pump oil, Part No.

217374. The lubricant creates a barrier between the ISO and the atmosphere.

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.

a.

Lift hose rack. Remove tank A cover and pour ISO into tank A (red side, with desiccant filter in cover). Replace cover.

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 wet-cup.

Fill wet-cups through slots in plate, or loosen screws and swing plate aside.

TI7017a

Desiccant filter is blue when fresh, and turns pink when saturated. Be sure shipping plugs are removed from openings on desiccant filter.

b.

Remove tank B cover and pour resin into tank B (blue side). Replace cover.

TI6985a

9.

Fill fluid tanks

TI7018a

CAUTION

To prevent cross-contamination of fluids and equipment parts, never interchange component A (isocyanate) and component B (resin) parts or containers.

Have at least two 5 gal. (19 liter) pails to transfer fluid from drums to supply tanks. Label one pail “A” and the other “B”, using the red and blue labels provided.

Always doublecheck 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.

311075C 15

f.

Set Recirc/Spray valves to Recirc.

Setup

10.

Purge air and flush fluid from lines

a.

Remove both recirculation tubes (P) from the tanks and secure each one in a dedicated waste container.

P

TI7022a b.

Set function knob to Stop/Park . g.

Set function knob to Slow Recirc or

Fast Recirc .

OR h.

When clean fluids exit both recirculation tubes (P), set function knob to

Stop/Park . c.

Plug in power cord(s). See T

ABLE

2, page 13.

d.

Open both pump fluid inlet valves (V, shown in open position).

V

TI7019a i.

Replace recirculation tubes in supply tanks. j.

On nonheated units, purge the hoses through the gun without a static mixer installed.

For heated units, continue with

Startup of Heated

Units , page 17.

Nonheated units are ready to spray/dispense. Go to

Spraying/Dispensing , page 20.

e.

Turn on Motor Power.

16 311075C

Startup of Heated Units

Startup of Heated Units

3.

Turn on Heater Power.

Some models heat the fluid, which can cause equipment surfaces to become very hot. To avoid severe burns:

• Do not operate Reactor E-10 without all covers and shrouds in place.

• Do not touch hot fluid or equipment.

• Allow equipment to cool completely before touching it.

• Wear gloves if fluid temperature exceeds 110°F

(43°C).

1.

Perform Setup

, pages 12-16.

4.

Temporarily set heater control knobs to maximum setting.

2.

Set function knob to Slow Recirc or Fast

See , page 18,

then continue with steps 3-6.

5.

Circulate through heaters until temperature readouts display desired temperature. See

T ABLE 4 below.

6.

Adjust heater control knobs as necessary for a stable spray temperature.

OR

Table 4: Heatup Time Guidelines for starting a cold machine with 5 gal. (19 l) per side (see Notes below)

Fluid Spray Target

Temperature

125°F (52°C)

150°F (65°C)

35 ft (10.7 m) Hose

(1 bundle)

20 minutes

40 minutes

70 ft (21 m) Hose

(2 bundles)

25 minutes

50 minutes

Use fast circulation until temperature is within 20°F

(11°C) of target, then use slow circulation to reach final temperature.

Different fluids will absorb heat at different rates.

When refilling a warm machine, heatup times will be less.

311075C 17

Startup of Heated Units

Heatup Guidelines

The fluids must be circulated from the pumps through the heaters, 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.

• 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.

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 does not allow enough heating time, and cold material will enter the hose.

• If temperature displays fall below acceptable limits, set function knob to Slow Recirc again to bring temperatures back up.

and circulate

• Each 35 ft (10.7 m) hose bundle adds about 5 minutes to heatup time, with most materials.

Water-based materials take longer to heat up. Maximum recommended hose length is 105 ft (32 m).

Fast Recirculation

• Fast Recirc keeps heaters on fulltime to bring fluid tanks up to temperature. The higher your usage rate, the more heat needed in the tanks before spraying.

• For normal usage rates: Use Fast Recirc to get tanks to approximately 50°F (28°C) below desired spray temperature, then use Slow

Recirc to raise hose and gun to desired temperature.

• For higher flow rates or continuous spraying:

Use Fast Recirc to bring temperature of tanks to approximately 20°F (11°C) below desired spray temperature, then use Slow Recirc to raise hose and gun to desired 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.

• Use Fast Recirc until tanks are warm to the touch, then use Slow Recirc desired temperature.

until displays read

• For a quicker start, do initial heatup circulation with the tanks 1/4 to 1/3 filled, then add more material.

18 311075C

Startup of Heated Units

Heating Foam Resins with 245 fa

Blowing Agents

New foam blowing agents will froth at temperatures above 90°F (33°C) when not under pressure, especially if agitated.

Never fill the 7 gal. (26 l) supply tanks beyond the 5 gal.

(19 l) line on the tanks, to leave room for some frothing.

At High Ambient Temperature (above

75°F/24°C)

• Pour resins slowly to avoid frothing.

At Cool Ambient Temperature (below

75°F/24°C)

• Use Fast Recirc to heat tanks to 75-90°F.

(24-32°C), then use Slow Recirc to raise hose and gun to desired spray temperature.

• If the top of the resin in tank starts frothing, do not use Fast Recirc any more.

• Only use Slow Recirc , to avoid heating and agitating the tank. If temperature doesn’t keep up, set function knob to Stop/Park , then set to Slow

• When you stop to refill the tanks, avoid boiling off fluid in the heaters by following these steps: a.

Shut off Heater Power. b.

Leave hoses under pressure.

c.

Fill tanks, page 15.

d.

Set Recirc/Spray valves to Recirc. e.

Set function knob to Slow Recirc .

f.

Turn on Heater Power.

311075C 19

Spraying/Dispensing

Spraying/Dispensing

Air is supplied to spray gun with gun piston safety lock or trigger safety lock engaged and gun fluid manifold valves A and B 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 sec after entering spray pressure mode, to allow time to balance pressures.

In this example, B side pressure is higher, so use the B side valve to balance pressures.

Fusion Gun 2K Ultra-Lite Gun TI7069a

1.

Set function knob to Stop/Park .

Watch gauges for 10 sec to be sure pressure holds on both sides and pumps are not moving.

5.

Open gun fluid manifold valves A and B

(impingement mix guns only).

2.

Set Recirc/Spray valves to Spray.

On impingement guns, never open fluid manifold valves or trigger gun if pressures are imbalanced.

3.

Turn function knob to Pressure Adjust .

Keep turning to the right until fluid pressure gauges show desired pressure.

20 311075C

Pause (Heated Units)

6.

Disengage piston safety lock or trigger safety lock.

3.

Set Recirc/Spray valves to Recirc until temperature readouts come back up.

Fusion Gun 2K Ultra-Lite Gun TI7070a

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.

4.

If you stop spraying for more than 2 minutes when using an impingement mix gun, close gun fluid valves A and B. Doing this will keep the internal parts of the gun cleaner and prevent crossover.

Pause (Heated Units)

Refilling Tanks

Material can be added to the tanks at any time. See

page 15.

To bring the hose and gun back to spray temperature after a brief break, use the following procedure.

1.

Engage piston safety lock or trigger safety lock.

Fusion Gun 2K Ultra-Lite Gun TI7069a

2.

Set function knob to Slow Recirc .

If you are operating at high temperatures or flow

rates, follow instructions under Pause (Heated

Units) to bring tanks up to temperature.

CAUTION

To prevent cross-contamination of fluids and equipment parts, never interchange component A (isocyanate) and component B (resin) parts or containers.

Have at least two 5 gal. (19 liter) pails to transfer fluid from drums to supply tanks. Label one pail “A” and the other “B”, using the red and blue labels provided.

Always doublecheck 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.

311075C 21

Pressure Relief Procedure

Pressure Relief

Procedure

Shutdown

For longer breaks (more than 10 minutes), use the following procedure. If you will be shut down for

more than 3 days, first see Flushing , page 24.

1.

Engage piston safety lock or trigger safety lock.

1.

Follow all steps of

Pressure Relief Procedure

, at left.

Fusion Gun 2K Ultra-Lite Gun TI7069a

2.

Set function knob to Stop/Park .

2.

If using an impingement mix gun, close gun fluid valves A and B. Doing this will keep the internal parts of the gun cleaner and prevent crossover.

3.

Shut off Heater Power (heated units only).

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.

4.

Shut off Motor Power.

5.

Refer to your separate gun manual and perform the Shutdown procedure.

22 311075C

Maintenance

Maintenance

• Check pump wet-cups fluid level daily, page 15.

• Do not overtighten packing nut/wet-cup. Throat u-cup is not adjustable.

• Keep component A from exposure to moisture in atmosphere, to prevent crystallization.

• Wipe supply tank lid o-ring and inner rim 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 (51a) as needed. Always clean the fluid inlet strainers after flushing.

• If using an impingement mix gun, close gun fluid valves A and B 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.

• 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. Use Part

No. 117773 Grease. See gun manual 309550.

X

51a

TI7021a

311075C 23

Flushing

Flushing

3.

Shut off Heater Power (heated units only). Allow system to cool.

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

• Generally, 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.

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

• Use the lowest possible pressure when flushing.

• Always leave some type of fluid in system. Do not use water.

• For long term storage, flush out the solvent with a storage fluid such as Bayer Mesamoll plasticizer or, at minimum, clean motor oil.

4.

Remove recirculation tubes (31) from supply tanks and place in original containers or waste containers.

31

5.

Turn Recirc/Spray valves to Recirc.

TI7022a

1.

Engage piston safety lock or trigger safety lock.

Close fluid valves A and B. Leave air on.

Fusion Gun 2K Ultra-Lite Gun TI7069a

2.

Set function knob to Stop/Park .

6.

Set function knob to Fast Recirc . Pump material from supply tanks until no more comes out.

7.

Set function knob to Stop/Park .

24 311075C

Flushing

8.

Wipe out any remaining material from the supply tanks. Fill each supply tank with 1-2 gal. (3.8-7.6 l) of solvent recommended by your material manufacturer.

9.

Set function knob to Fast Recirc . Pump solvent through system to waste containers.

To flush gun, refer to gun instruction manual.

Purge Gun Hoses (Nonheated Units Only)

Disconnect hoses from gun and secure back into the tanks for thorough cleaning with solvent.

• Turn Recirc/Spray valve A to Spray.

10.

When nearly clear solvent comes from recirculation tubes, set function knob to Stop/Park

Return recirculation tubes to supply tanks.

.

• Open gun into waste container A.

• Set function knob to Slow Recirc hose is flushed.

• Set function knob to Stop/Park

• Repeat for B side.

.

until

12.

Set function knob to Stop/Park .

11.

Set function knob to Fast Recirc . Circulate solvent through system for 10-20 minutes to ensure thorough cleaning.

13.

Solvent flushing is a two step process. Go back

to step 4, drain solvent, and flush again with

fresh solvent.

14.

Leave unit filled with solvent, plasticizer, clean motor oil, or refill supply tanks with new material and reprime.

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.

311075C 25

Troubleshooting

Troubleshooting

Status Codes

Determine the status code by counting the number of times the status indicator (ST) blinks.

ST

3.

Check fluid inlet strainers (51a, page 23) and fluid

filters at gun.

4.

Clean or change restrictor at mixer manifold if using disposable mixer gun kit.

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).

Status Code 1: Pressure Imbalance

TI7016a

Unit senses pressure deviation from setpoint, and warns or shuts down, depending on settings of DIP switches 3 and 4. If 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 tighten pressure tolerances for status code 2, see Status Code 1 and 2

Settings , below.

The unit does not check for pressure imbalance at setpoints less than 250 psi (1.75 MPa, 17.5 bar).

The unit does not check for pressure imbalance for

10 sec after entering pressure mode.

Status Code 1 and 2 Settings

1.

Locate switch SW2 on the control board, page 37.

2.

Set the four DIP switches to the desired positions.

See F IG . 7 and T ABLE 5 on page 27.

Unit senses pressure imbalance between components

A and B, 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 Status Code 1 and 2 Settings , below.

1.

Check fluid supply of lower pressure component and refill if necessary.

2.

Reduce pressure of higher component by slightly turning Recirc/Spray valve for that component toward Recirc, until gauges show balanced pressures.

In this example, B side pressure is higher, so use the B side valve to balance pressures.

Turn Recirc/Spray valve only enough to balance pressure. If turned completely, all pressure will bleed off.

OFF

3

4

1

2

TI7023a

3

4

1

2

F IG . 7. DIP Switch (SW2) Settings

ON

(Default)

TI7024a

26 311075C

Troubleshooting

Table 5: Status Code 1 and 2 Settings

DIP Switch and Function

DIP Switch 1

Enables shutdown due to A and B pressure imbalance

Left Right (default setting)

OFF ON

DIP Switch 2

Causes shutdown if A and B pressure imbalance is greater than 500 psi (3.5 MPa, 35 bar)

(60% if < 800 psi [5.6 MPa,

56 bar] running)

800 psi (5.6 MPa, 56 bar)

(70% if < 800 psi [5.6 MPa,

56 bar] running)

Causes warning if A and B pressure imbalance is greater than 300 psi (2.1 MPa, 21 bar)

(50% if < 800 psi [5.6 MPa,

56 bar] running)

500 psi (3.5 MPa, 35 bar)

(60% if < 800 psi [5.6 MPa,

56 bar] running)

DIP Switch 3

Enables shutdown due to deviation of pressure from setpoint OFF ON

DIP Switch 4

Causes warning if deviation of pressure from setpoint is greater than 300 psi (2.1 MPa, 21 bar)

(25% if < 800 psi [5.6 MPa,

56 bar])

500 psi (3.5 MPa, 35 bar)

(40% if < 800 psi [5.6 MPa,

56 bar])

Status Code 3: Transducer A Failure

1.

Check transducer A electrical connection (J3) at board, page 37.

2.

Reverse A and B transducer electrical connections at board, page 37. If error moves to transducer B

(Status Code 4), replace transducer A, page 38.

Status Code 4: Transducer B Failure

1.

Check transducer B electrical connection (J8) at board, page 37.

2.

Reverse A and B transducer electrical connections at board, page 37. If error moves to transducer A

(Status Code 3), replace transducer B, page 38.

Status Code 5: Excessive Current Draw

Shut off unit and contact distributor before resuming operation.

1.

Locked rotor; motor unable to turn. Replace motor,

page 40.

2.

Short on control board. Replace board, page 36.

3.

Worn or hung up motor brush causing arcing of

brush at commutator. Replace brushes, page 41.

Status Code 6: High Motor Temperature

Motor is running too hot.

1.

Motor temperature too high. Reduce pressure duty cycle, gun tip size, or move Reactor E-10 to a cooler location. Allow 1 hour for cooling.

2.

Check fan operation. Clean fan and motor housing.

Status Code 7: No Cycle Counter Switch

Input

Have not received input from cycle counter switch for 10 seconds after selecting Recirc mode.

1.

Check cycle counter switch connection to board

(J10, pins 5, 6), page 37.

2.

Check that magnet (224) and cycle counter switch

(223) are in place under B side motor end cover

(227). Replace if necessary.

311075C 27

Troubleshooting

Troubleshooting Chart

PROBLEM

Reactor E-10 does not operate.

No power.

CAUSE SOLUTION

Plug in power cord.

Cycle Motor Power off , then on to reset breaker.

Motor does not operate.

Fan not working.

Power turned on with function knob set to a run position.

Set function knob to Stop/Park , then select desired function.

Loose connection on control board.

Check connection at J4 (120 V) or

J11 (240 V). See page 36.

Worn brushes.

Check both sides. Replace brushes worn to less than 1/2 in. (13 mm), see

page 41.

Broken or misaligned brush springs.

Realign or replace, page 41.

Brushes or springs binding in brush holder.

Clean brush holder and align brush leads for free movement.

Shorted armature.

Check motor commutator for burn spots, black pitting, or other damage.

Replace motor, page 40.

Remove motor. Have motor shop resurface commutator, or replace

motor, page 40.

Failed control board.

Loose fan cable.

Replace board. See page 36.

Check that cable is connected at fan and at J9 on control board. See

pages 41 and 36.

Pump output low.

Defective fan.

Plugged fluid inlet strainer.

Plugged disposable mixer.

Leaking or plugged piston valve or intake valve in displacement pump.

Test and replace if necessary, page

41.

Clear, see page 23.

Clean or replace.

Check valves. See pump manual.

Dirty or damaged Recirc/Spray valve. Clean or repair, page 32.

One side doesn’t come up to pressure in spray mode.

Pressure is higher on one side when setting pressure with function knob.

Plugged fluid inlet strainer.

Clear, see page 23.

Pump intake valve plugged or stuck open.

Clean pump intake valve. See page

33.

Pump intake valve partially plugged.

Clean pump intake valve. See page

33.

Air in hose. Fluid is compressible.

Unequal size hoses or unequal hose construction.

Purge air from hose.

Use matching hoses, or balance pressures before spraying.

28 311075C

Troubleshooting

PROBLEM CAUSE SOLUTION

Pressures are not balanced when running, but pressure is generated and holds on both strokes.

Unequal viscosities.

Change temperature setting to balance viscosities.

Restriction on one side.

Change restrictor at mix point to balance back pressure.

Clean mix module or restrictor at mix manifold.

Clean gun check valve screens.

Replace. See pump manual.

Repair, page 32.

Fluid leak in pump packing nut area.

Worn throat seals.

Pressure doesn’t hold when stalled against gun in spray mode.

Leaking Recirc/Spray valve.

Leaking piston valve or intake valve in displacement pump.

Leaking gun shutoff.

Repair. See pump manual.

One gauge shows half as many pulses as the other when pumps are cycling.

Loss of pressure on downstoke.

Loss of pressure on upstoke.

Repair. See gun manual.

Pressure is higher on B side during startup of recirculation, especially in

High Recirc mode.

Resin froths and overflows tank after refilling hot equipment.

This is normal. Component B is typically higher viscosity than component

A until the material is heated during recirculation.

No action required.

Agitation from pouring. Hot material in heaters and hoses froths when not under pressure.

Turn heaters off before refilling.

Leave hoses pressurized. See page

19.

Intake valve is leaking or not closing.

Clean or replace valve; see page 33.

Piston valve is leaking or not closing.

Clean or replace valve or packings;

see page 33.

Status indicator (red LED) not lit.

Motor Power switch off.

Cycle Motor Power off , then

A side rich; lack of B side.

B side rich; lack of A side.

Loose indicator cable.

Failed control board.

A side gauge is low.

B side gauge is low.

A side gauge is low.

B side gauge is low.

on to reset breaker.

Check that cable is connected at J10 pins 1 (red) and 2 (black) on control board. See page 36.

Replace board. See page 36.

B side restriction downstream of gauge. Check gun check valve screen, mix module, or mix manifold restrictor.

B side material supply problem.

Check B side inlet strainer and pump intake valve.

A side material supply problem.

Check A side inlet strainer and pump intake valve.

A side restriction downstream of gauge. Check gun check valve screen, mix module, or mix manifold restrictor.

311075C 29

Troubleshooting

PROBLEM CAUSE SOLUTION

No temperature display (heated units only).

Loose display cables on control board.

Failed control board (displays get power from control board).

Check cable connections to each display, page 36.

Remove access panel. Check if board LED is lighted. If not, replace board, page 36.

Inadequate power to control board.

Check that power supply meets requirements.

Loose power cable.

Check cable connections, page 36.

Motor Power switch circuit breaker tripped.

Display is powered from Motor Power circuit breaker. Cycle Motor Power off

Wrong temperature displayed.

Temperature displays do not match at ambient temperature.

°F/°C switch in wrong position.

Displays need calibration.

, then on to reset breaker.

Set switch, see page 34.

Turn calibration screw on back of displays to correct reading, see page

34.

No heat, and heater indicator light is off.

Heater Power shut off, or circuit breaker tripped.

Cycle Heater Power off , then on to reset circuit breaker.

No heat, but heater indicator light is on.

Bad thermostat.

Bad overtemperature sensor (this is a high temperature limit fuse and must be replaced if blown).

Loose heater cable connections.

Bad heater cartridge.

Heater on one side shuts off early or continuously during recirculation.

Y-strainer is plugged on that side.

Fluid inlet valve (52) closed.

With power on, check for continuity at clicks of heater control knob. To replace thermostat, see 311210.

With power on, check for continuity at overtemperature sensor. To replace sensor, see 311210.

Check connections at Heater Power switch. See F IG . 12, page 37.

Check for continuity at heater cartridge connections: 16-18.6 ohms for

120 V, 64-75 ohms for 240 V.

Clean or replace strainer, page 23.

Open valve.

30 311075C

Repair

Repair

Before Beginning Repair Removing Supply Tanks

Displacement pump repair and parts information is included in manual 311076, which is supplied with your unit.

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 12. Be sure to shut

off all power to the equipment before repairing.

1.

See

Before Beginning Repair

pressure, page 22.

, page 31. Relieve

1.

Flush if possible, see page 24. If not possible, clean

all parts with solvent immediately after removal, to prevent isocyanate from crystallizing due to moisture in the atmosphere.

2.

Close both fluid inlet ball valves (52).

52

2.

Set function knob to Stop/Park .

3.

Shut off Motor Power. Disconnect power supply.

4.

Shut off Heater Power. Allow equipment to cool before repairing.

5.

Relieve pressure, page 22.

50

51

TI7020a

Use dropcloth or rags to protect Reactor E-10 and surrounding area from spills.

3.

Open filter drain plug on Y-strainer (51).

4.

Disconnect swivel elbow (50) at pump fluid inlet.

5.

Remove screws (4) holding tank to cart frame.

6.

Pivot top of tank to side and lift it and fluid inlet fittings off cart.

311075C 31

Repair

Recirc/Spray Valves

1.

See

Before Beginning Repair , page 31. Relieve

pressure, page 22.

2.

See F IG . 8. Disassemble Recirc/Spray valves. Clean and inspect all parts for damage. Ensure that the seat (503a) and gasket (503b) are positioned inside each valve cartridge (503).

3.

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

4.

Reassemble in reverse order, following all notes in

F IG . 8.

508

510

Heated Models

506

509

Nonheated Models

505

504

503

1 2

503a

503b

3

3

501

502

507

506

507 510

TI6977a 511

1

2

Torque to 250 in-lb (28 N•m).

Use blue threadlocker on valve cartridge threads into manifold.

3 Part of item 503.

508

509

TI6982a

505

504

503

1 2

503a

503b

3

3

501

502

F IG . 8. Recirc/Spray Valves

32 311075C

Repair

Displacement Pump

To Remove Entire Pump Assembly

5.

Disconnect fluid inlet (C) and outlet (D) lines. Also disconnect steel outlet tube (16) from heater inlet.

Displacement pump repair and parts information is included in manual 311076, which is supplied with your unit.

Use dropcloth or rags to protect Reactor E-10 and surrounding area from spills.

6.

Remove pump rod cover (222). Push clip up in back and push pin (217) out. Loosen locknut (218) by hitting firmly right-to-left with a non-sparking hammer.

Unscrew pump. See manual 311076 for pump repair and parts.

1.

See Before Beginning Repair , page 31. Relieve

pressure, page 22.

2.

Close both fluid inlet ball valves (52). Open filter drain plug on Y-strainer (51).

52

7.

Install pump in reverse order of disassembly, following all notes in F IG . 9. Clean strainer (51). Reconnect fluid inlet (C) and outlet (D) lines.

8.

Tighten fluid outlet fitting (D), then tighten locknut

(218) by hitting firmly with a non-sparking hammer.

9.

Open fluid inlet valve (52). Set function knob to Slow

Recirc

. Purge air and prime. See page 16.

51

TI7020a

To Remove Intake Valve Only

If 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.

217

E

16

222

D

2

3.

Disconnect fluid inlet (C) and swing it aside.

2

C

4.

Remove intake valve by hitting ears (E) firmly right-to-left with a non-sparking hammer. Unscrew from pump. See manual 311076 for repair and parts.

51

1 Flat side faces up. Tighten by hitting firmly with non-sparking hammer.

2 Lubricate threads with ISO oil or grease.

F IG . 9. Displacement Pump

218 1 2

TI7025a

311075C 33

Repair

Control Module

Change Display Temperature Units (°F/°C)

Unit is shipped with temperature displays set to °F.

1.

Shut off Motor Power. Disconnect power supply.

2.

Remove access cover (39) from back of control module.

3.

See F

IG

. 11. Locate slide switch (FC) at right edge of each temperature display board. Unit is shipped set to °F (down). To change to °C, move both switches to up position.

Calibrate Temperature Displays

a.

Loosen setscrew (22) on thermowell housing

(21). See F IG . 10.

b.

Pull sensor (424) out of thermowell housing.

c.

Work sensor and wire out of cable channel between tanks. It may be easier to remove one

tank. See page 31.

3.

Remove access cover (39) from back of control module.

4.

Disconnect temperature display power cable from

J14 or J15 at bottom left of control board (406).

5.

Remove four screws from rear panel studs and remove temperature display (403) from front plate

(401).

6.

Remove screw and nut (409) holding display to plate (403).

7.

Pull sensor cable through split in bushing (411).

8.

Reassemble in reverse order. Mount temperature display so Heater Power switch off (0) position is at left when facing control panel.

1.

Remove access cover (39) from back of control module.

2.

See F IG . 11. Locate calibration screw (CS) at upper right corner of each temperature display board. Turn screw slightly to correct temperature display.

Temperature displays do not read lower than 50°F

(10°C).

Replace Temperature Display and Sensor

(Heated Units Only)

22

424

F IG . 10. Temperature Sensor

1.

See

Before Beginning Repair , page 31. Relieve

pressure, page 22.

2.

Remove temperature sensor (424):

34

21

TI7067a

311075C

Repair

Replace Function Knob/Potentiometer

1.

See Before Beginning Repair , page 31. Relieve

pressure, page 22.

2.

Remove access cover (39) from back of control module.

3.

Disconnect potentiometer wires from J2 on control board (406). See F IG . 12.

Detail of Function Knob/Potentiometer

415

P

N

404

S

404

4.

See F IG . 11. Remove two setscrews (416a) and pull function knob (416) off potentiometer (404) shaft.

5.

Remove nut (N, part of 404) and detent plate (415).

6.

Install new potentiometer (404) in reverse order.

Position potentiometer so slot (S) is horizontal. Position knob (416) so pointer (P) faces up. Install knob on shaft so slot (S) engages alignment pin in knob.

Push knob onto shaft against detent spring before tightening setscrews (416a).

7.

Reconnect potentiometer wires to J2 as shown in

F IG . 12.

402 405

416a

416

416a

401

TI7076a

416a

416

416a

421

*403

*402

N

415

417

409

*424

FC

CS

CS

FC

424*

410 410*

408

407

406

412

411

413

* These items are not included on the nonheated display.

TI6979a

F IG . 11. Control Module (Heated Model Shown)

311075C 35

Repair

Control Board

Power Bootup Check

There is one red LED (D11) on the board. Power must be on to check. See F IG . 12 for location.

Function is:

• Startup: 1 blink for 60 Hz, 2 blinks for 50 Hz.

• Motor running: LED on.

• Motor not running: LED off.

• Status code (motor not running): LED blinks status code.

Control Board Replacement

1.

See

Before Beginning Repair , page 31. Relieve

pressure, page 22.

2.

Remove access cover (39) at back of control module to expose control board (406).

3.

Disconnect all cables and connectors from board.

Remove two jumper wires (413) from J10 pins 7-8 and 9-10.

4.

Remove screws (408) and remove board from control module.

5.

Install new board in reverse order.

Apply thermal compound between the square steel piece on the back of the board and the main aluminum plate. Order Part No. 110009 Thermal

Compound.

Table 6: Control Board Connectors (see F IG . 12)

Board

Jack

J7

J8

J9

J10

J1

J2

J3

J4

J11

J14

J15

Pin Description n/a Main power from breaker n/a Function knob n/a Transducer A n/a Motor power (230 V units)

1, 2 Motor thermal overload signal n/a Transducer B n/a Fan

1, 2 Status indicator

3, 4 Not used

5, 6 Cycle switch signal

7-8 Jumpered

9-10 Jumpered n/a Motor power (120 V) n/a B temperature display n/a A temperature display

36 311075C

Repair

Motor

Cycle

Counter

LINE

P1

P2

Heated Models Only

LINE

P1

P2

Heater Power

On/Off

(20 A

Breaker)

Single Cord Models Only

Heater

A

Heater

B

J9

J1

Fan

Black Twin Flat Cable

Red

Black

J11 (120 V Board)

J4 (240 V Board)

Yellow

J7

CONTROL BOARD

249434 (120 V)

249432 (240 V)

Yellow

Red

Black

Status

Indicator

Black Sheath

Black

Jumper

White

Jumper

1

4

5

2

3

6

7

8

9

10

2 pin red connectors

Gray Sheath

J10

OFF

1

2

3

4

D11

J14 J15

ON

SW2 (see page 26 to adjust settings) not used

Black

Red

White

J2

J8 J3

2 pin red connectors

Gray Sheath

Function

Knob

Black Sheath

Pressure Transducer A

Calibration

Screw

Temperature

°F

Display B

°C

Calibration

Screw

Temperature

Display A

°C

°F Black Phone Cable and Plug

Pressure Transducer B

Gray Sheath

Temperature

Sensor B

Temperature

Sensor A

Heated Models Only

F IG . 12. Control Module Wiring Connections

311075C 37

Repair

Fluid Heaters (if supplied)

Fluid heater repair and parts information is included in manual 311210, which is supplied with heated units.

Pressure Transducers

1.

To replace a pressure transducer, see at right.

See

Before Beginning Repair

pressure, page 22.

, page 31. Relieve

2.

Control section of heater can be repaired in place.

Remove heater to clean fluid section. See manual

311210 for heater repair and parts.

1.

See Before Beginning Repair , page 31. Relieve

pressure, page 22.

2.

Remove access cover (39) at back of control module to expose control board (406).

3.

Disconnect transducer cables from J3 and J8 at board; see F IG . 12, page 37. Reverse A and B connections and check if status code follows the bad transducer, page 27.

4.

Reconnect good transducer to proper connector.

Disconnect failed transducer from board, and unscrew from base of fluid heater (heated units) or transducer manifold (nonheated units).

5.

Install o-ring (60) on new transducer (58), F IG . 13.

6.

Install transducer in heater or manifold. Mark board end of cable with tape (red=transducer A, blue=transducer B).

7.

Route cable through channel to control module.

8.

Connect transducer cable at board; see F IG . 12, page 37.

58 60 58 60

Nonheated Units

TI7027a

F IG . 13. Transducers

Heated Units

TI7026a

38 311075C

Repair

Drive Housing

Removal

3.

Install bronze bearings (209, 211) and steel washer

(208) on crankshaft (210). Install bronze bearing

(213) and steel washer (212) on gear reducer (214).

4.

Install gear reducer (214) and crankshaft (210) into motor end bell (MB).

1.

See Before Beginning Repair , page 31. Relieve

pressure, page 22.

2.

Remove screws (207) and end covers (221, 227),

F IG . 14.

Examine connecting rod (216). If rod needs

replacing, first remove the pump (219), page 33.

CAUTION

Do not drop gear reducer (214) and crankshaft (210) when removing drive housing (215). These parts may stay engaged in motor end bell (MB) or may pull away with 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 washers (208, 212), bearings (209, 211, 213), gear reducer (214), crankshaft

(210), and inside drive housing (215). Grease is supplied with replacement parts kits.

B side crankshaft (210) includes the cycle counter magnet (224). When reassembling, be sure to install crankshaft with magnet on B side.

If replacing crankshaft, remove magnet (224).

Reinstall magnet in center of offset shaft on new crankshaft. Position shaft in Park position.

2.

Install bronze bearings (211, 213) in drive housing

(215), as shown.

Crankshaft (210) must be in line with crankshaft at other end of motor. Pumps will move up and down together.

If connecting rod (216) or pump (219) were removed, reassemble rod in housing and install

pump, page 33.

5.

Push drive housing (215) onto motor (201). Install screws (220).

6.

Install drive housing covers (221 on A side, 227 on

B side) and screws (207). Pumps must be in phase

(both at same position in stroke).

Cycle Counter Switch

Replacement

B side drive housing cover (227) includes the cycle counter switch (223), mounted in the cover.

When reassembling, be sure to install cover with switch on B side.

223

0.6 in. (15.2 mm) from inside edge

1.0 in. (25.4 mm) from inside bottom edge

TI7028a

311075C 39

Repair

206

207

221

MB

208

(steel)

209

(bronze)

210

1

211

(bronze)

215

220

227

207

201

212

(steel)

213

(bronze)

214

213

(bronze)

224

216

1 Crankshaft must be in line with crankshaft at other end of motor, so pumps move up and down in unison.

F IG . 14. Drive Housing

219

TI7029a

Electric Motor

Test Motor

If motor is not locked up by pumps, it can be tested using a 9 V battery. Disconnect J4 or J11 from control board, see F IG . 12, page 37. Touch jumpers from battery to motor connections. Motor should turn slowly.

Removal

If replacing a component with electrical cabling,

remove one supply tank, page 31.

1.

See Before Beginning Repair , page 31. Relieve

pressure, page 22.

2.

Remove four screws (207) and shroud (206). See

F IG . 14.

3.

Remove drive housing/pump assemblies, page 39.

40 311075C

Repair

4.

Disconnect motor cables as follows: a.

Find control board at back of control module, see F IG . 12, page 37. b.

Unplug motor power connector from J4 (240 V units) or J11 (120 V units).

c.

Unplug motor temp switch harness from connector J7. d.

Unplug cable (37) from fan (202). See F IG . 15.

e.

Thread motor power switch harness out bottom of control module and cable channel, to free motor.

Motor Brushes

Replace brushes worn to less than 1/2 in. (13 mm). Brushes wear differently on each side of motor; check both sides. Brush Repair Kit 248186 is available; kit includes instruction sheet 406582.

Motor commutator should be smooth. If not, resurface commutator or replace motor.

1.

See

Before Beginning Repair , page 31. Relieve

pressure, page 22.

CAUTION

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

2.

See instruction sheet 406582, included with Brush

Repair Kit 248186. Remove old brushes and install new ones supplied in kit.

5.

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

Installation

1.

If replacing motor, install fan assembly and fan mount threaded bushing on new motor.

2.

Place motor and fan on unit. Thread motor switch harness into control module.

3.

Fasten motor with screws underneath. Do not tighten yet.

4.

Plug 3-pin connector J7 to board.

5.

Plug Motor Power switch harness to connector J4

(240 V units) or J11 (120 V units).

6.

Install drive housing/pump assemblies, page 39.

Reconnect inlet assemblies to pumps.

7.

Tighten motor mounting screws.

8.

Return to service.

Fan

1.

Disconnect fan cable (37) from fan (202). With

Motor Power on, test cable connector for line voltage (120 V or 240 V).

2.

If voltage is correct, fan is defective. Remove screws holding fan to shield (206). Install new fan in reverse order.

3.

If voltage is not correct, check fan cable connection at J9 on control board; see F IG . 12, page 37.

37

202

TI7030a

F IG . 15. Fan

311075C 41

Parts

Parts

Part No. 249800, 120 V, 15 A, Heated Package

Part No. 249802, 240 V, 10 A, Heated Package

Part No. 249804, 240 V, 20 A, Heated Package

61

61

101

103

102

TI6988b

Ref.

No.

Part No. Description

101 249570 PROPORTIONER, heated, 120 V,

15 A; see page 44; 249800 only

249571 PROPORTIONER, heated, 240 V,

10 A; see page 44; 249802 only

249572 PROPORTIONER, heated, 240 V,

20 A; see page 44; 249804 only

Qty

1

1

1

Ref.

No.

Part No. Description

102 249499 HOSE BUNDLE, insulated; see

page 49

103 249810 GUN, Fusion, air purge; see

309550

Qty

1

1

42 311075C

Parts

Part No. 249806, 120 V, 15 A, Nonheated Package

Part No. 249808, 240 V, 10 A, Nonheated Package

61

103

61

101

102

TI6990b

Ref.

No.

Part No. Description

101 249576 PROPORTIONER, nonheated, 120

V, 15 A; see page 46; 249806 only

249577 PROPORTIONER, heated, 240 V,

10 A; see page 46; 249808 only

Qty

1

1

Ref.

No.

Part No. Description

102 249633 HOSE BUNDLE, non-insulated;

see page 49

103 249834 GUN, 2K Ultra-Lite; see 309000 and 311230

Qty

1

1

311075C 43

Parts

Part No. 249570, 120 V, 15 A, Heated Proportioner

Part No. 249571, 240 V, 10 A, Heated Proportioner

Part No. 249572, 240 V, 20 A, Heated Proportioner

5 8

11

32

2a

2

57

56

55

31

30

41

34

31

47

38

36

35

6

11

7

8

45

2

2a

33

24

20

23

19

1 (Ref)

18

17

1 (Ref)

12

28

25

23

26

22

21

41

16

58

60

27

63

64

424 (Ref)

62

14

54*

65 29

13 50*

51*

53*

52*

15

50*

4

1 (Ref)

46

49

44

1

TI7068a

TI6975b

41

39

41

40 ▲

44 311075C

Parts

Heated Proportioners

13

14

15

16

17

26

27

28

29

30

31

32

18

19

20

21

22

23

24

25

1

2

Ref.

No.

Part No. Description

2a

4

5

6

7

8

11

12

Qty npt(m)

116704 ADAPTER, B side; 9/16 JIC x 1/4 npt(m)

104641 BULKHEAD FITTING

169970 FITTING, air line; 1/4 npt(m)

162453 NIPPLE; 1/4 npt x 1/4 npsm

287712 MANIFOLD, recirculation, with

valves; see page 52

15G097 TUBE, recirculation; 3/8 (10 mm)

OD; sst

249629 HOSE, component A (ISO); 1/4 in.

(6 mm) ID; thermoplastic hose with moisture guard; 1/4 npsm(f) x 48 in.

(1219 mm)

1

1

1

1

1

1

2

2

2

1

1

1

1

Ref.

No.

Part No. Description Qty

33

34

249630 HOSE, component B (RES); 1/4 in.

(6 mm) ID; thermoplastic hose; 1/4 npsm(f) x 48 in. (1219 mm)

249556 DISPLAY, heated, 120 V; Model

249570; see page 50

249557 DISPLAY, heated, 240 V; Models

1

1

1

35

36

249571 and 249572; see page 50

117623 NUT, cap; 3/8-16

15B382 CORD, 120 V; Model 249570

15G220 CORD, 240 V; Model 249571

37

15G219 CORD, 240 V; Model 249572

15G458 CABLE, fan; see page 48

38 CONDUIT, flexible; non-metallic

39 15G385 COVER, access, display

40

15G280 LABEL, warning

41 108296 SCREW, machine, hex washer hd;

43

44

45

46

1/4-20 x 5/8 in. (16 mm)

217374 LUBRICANT, ISO pump; not shown

BOLT; 10-24 x 1 in. (25 mm)

47

48

15G119 GUARD, splash

15G461 RACK, hose

PLUG

109510 STRAP, bungee; 25 in. (635 mm)

49 WASHER, flat; 1/4 in.; nylon

50* 160327 ELBOW, swivel; 3/4 npt(m) x 3/4

1

2

4

2

4

2

1

1

1

10

1

1

1

1

4

2

2 npsm(f)

51* 101078 Y-STRAINER; includes item 51a

51a 180199 . ELEMENT, 20 mesh; not shown

52* 109077 VALVE, ball; 3/4 npt (fbe)

53* C20487 NIPPLE; 3/4 npt

54* 157785 UNION, swivel; 3/4 npt(m) x 3/4

55

56

57 npsm(f)

242001 ADAPTER, cord; Europe; Model

249571 only

242005 ADAPTER, cord; Australia; Model

249571 only

195551 RETAINER, plug, adapter; Model

58

60

61

2

2

2

249571 only

246123 TRANSDUCER, pressure; included 2 with item 17

111457 O-RING; ptfe; included with item 17 2

15G476 LABEL, components A and B; see 2

2

2

2

1

2

62

63

64 page 42

119992 NIPPLE, pump inlet; 3/4 npt

157350 NIPPLE; 1/4 npt x 3/8 npt

117629 AIR FILTER/SEPARATOR, with 3/8 npt auto drain; includes item 2a

64a 114228 . ELEMENT, 5 micron; polypropy-

65 lene; not shown

100176 BUSHING; 3/8 npt(m) x 1/4 npt(f)

1

1

2

1

1

* Included in 287718 Pump Inlet Kit (one side).

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

311075C 45

Parts

Part No. 249576, 120 V, Nonheated Proportioner

Part No. 249577, 240 V, Nonheated Proportioner

5 8

31

32

57

56

55

30 1 (Ref) 31

34

47

38

36

45

35

7

8

6

11

2

2a

11

2a

2

33

16

30 (Ref)

15

59

60

58

23

12

28

62

29

27

63

64 65 29

13

50*

51*

53*

50*

54*

52*

1 (Ref)

4

1

46

49

44

41

39

41

40

1 (Ref)

TI7068a

TI6981b

46 311075C

Parts

Nonheated Proportioners

27

28

29

30

5

6

7

8

11

12

Ref.

No.

1

2

2a

4

13

15

16

23

25

26

31

32

33

34

35

Part No. Description

249582 CART; see page 53

249438 TANK, with lid and outlet fitting;

LDPE; includes item 2a

15F895 . O-RING, lid, tank

111800 SCREW, cap, hex hd; 5/16-18 x 5/8 in. (16 mm)

119974 DRYER, desiccant; package of 2

113037 MUFFLER, vent

101044 WASHER, plain; 1/2 in. (13 mm)

119973 LANYARD; 14 in. (356 mm); sst

119993 PLUG

287655 PROPORTIONER, bare, 120 V;

Model 249576; see page 48

287656 PROPORTIONER, bare, 240 V;

Model 249577; see page 48

117493 SCREW, machine, hex washer hd;

1/4-20 x 1-1/2 in. (38 mm)

119983 UNION; 1/4 npt(m) x 3/8 (10 mm)

OD tube

15G296 TUBE, fluid, with ferrule and nuts;

3/8 in. (10 mm) OD; sst

155541 ELBOW, swivel; 1/4 npt(m) x 1/4 npsm(f)

119998 ADAPTER, A side; 1/2 JIC x 1/4 npt(m)

116704 ADAPTER, B side; 9/16 JIC x 1/4 npt(m)

104641 BULKHEAD FITTING

169970 FITTING, air line; 1/4 npt(m)

162453 NIPPLE; 1/4 npt x 1/4 npsm

287755 MANIFOLD, recirculation, with

valves; see page 52

15G097 TUBE, recirculation; 3/8 (10 mm)

OD; sst

249629 HOSE, component A (ISO); 1/4 in.

(6 mm) ID; thermoplastic hose with moisture guard; 1/4 npsm(f) x 48 in.

(1219 mm)

249630 HOSE, component B (RES); 1/4 in.

(6 mm) ID; thermoplastic hose; 1/4 npsm(f) x 48 in. (1219 mm)

249537 DISPLAY, nonheated, 120 V; Model

249576; see page 51

249538 DISPLAY, nonheated, 240 V; Model

249577; see page 51

117623 NUT, cap; 3/8-16

Qty

1

2

1

12

3

1

1

1

2

2

1

1

1

1

1

4

2

2

2

1

1

2

1

1

1

1

4

Ref.

No.

Part No. Description Qty

58

59

60

61

36 15B382 CORD, 120 V; Model 249576

15G220 CORD, 240 V; Model 249577

37

38

15G458 CABLE, fan; see page 48

CONDUIT, flexible; non-metallic

39 15G385 COVER, access, display

40 ▲ 15G280 LABEL, warning

41 108296 SCREW, machine, hex washer hd;

43

44

45

1/4-20 x 5/8 in. (16 mm)

217374 LUBRICANT, ISO pump; not shown 1

BOLT; 10-24 x 1 in. (25 mm)

15G119 GUARD, splash

2

1

46

47

48

49

15G461 RACK, hose

PLUG

109510 STRAP, bungee; 25 in. (635 mm)

WASHER, flat; 1/4 in.; nylon

50* 160327 ELBOW, swivel; 3/4 npt(m) x 3/4

2

4

1

4

2

1

1

6

1

1

1

1 npsm(f)

51* 101078 Y-STRAINER; includes item 51a

51a 180199 . ELEMENT, 20 mesh; not shown

52* 109077 VALVE, ball; 3/4 npt (fbe)

53* C20487 NIPPLE; 3/4 npt

54* 157785 UNION, swivel; 3/4 npt(m) x 3/4

55

56 npsm(f)

242001 ADAPTER, cord; Europe; Model

249577 only

242005 ADAPTER, cord; Australia; Model

57

249577 only

195551 RETAINER, plug, adapter; Model

249577 only

246123 TRANSDUCER, pressure

15G292 MANIFOLD, pressure transducer

111457 O-RING; ptfe

15G476 LABEL, components A and B; see

1

1

1

2

2

2

2

2

1

2

2

2

62

63

64

page 43

119992 NIPPLE; 3/4 npt

157350 NIPPLE; 1/4 npt x 3/8 npt

117629 AIR FILTER/SEPARATOR, with 3/8 npt auto drain; includes item 2a

64a 114228 . ELEMENT, 5 micron; polypropy-

65 lene; not shown

100176 BUSHING; 3/8 npt(m) x 1/4 npt(f)

1

1

2

1

1

* Included in 287718 Pump Inlet Kit (one side).

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

311075C 47

Parts

Part No. 287655, 120 V Bare Proportioner

Part No. 287656, 240 V Bare Proportioner

207

201 (Ref)

206

207

205

203

‡221

208* 209* 210*

224

211*

223

227

204

202

37

215‡

220‡

207‡

201

†212

†213

†214

†213

216

218

222‡

219

Ref.

No.

Part No. Description

201 287650 MOTOR, electric; 120 V

287651 MOTOR, electric; 240 V

202 119994 FAN, cooling; 120 V

119995 FAN, cooling; 240 V

203 115836 GUARD, finger

204

205

RIVET, blind; 5/32 x 3/8 grip

SCREW, machine, slotted hd; 8-32 x 2 in. (51 mm)

206 249518 SHIELD, proportioner

207‡ 115492 SCREW, machine, hex washer hd;

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

208* 116074 WASHER, thrust; steel

209* 107434 BEARING, thrust; bronze

210* 248231 CRANKSHAFT KIT

211* 180131 BEARING, thrust; bronze

212† 116073 WASHER, thrust; steel

213† 116079 BEARING, thrust; bronze

214† 287057 GEAR REDUCER KIT

215‡ 287055 DRIVE HOUSING KIT

216

287053 CONNECTING ROD KIT

Qty

1

1

1

1

1

3

1

12

2

2

2

4

2

2

2

2

2

220‡

217

207‡

TI6978a

Ref.

No.

Part No. Description

217

196762 PIN, straight

218 195150 NUT, jam, pump

219 287657 PUMP, displacement; see 311076

220‡ 117493 SCREW, machine, hex washer hd;

1/4-20 x 1-1/2 in. (38 mm)

221‡ 15B254 COVER, drive housing, A side

222‡ 15B589 COVER, pump rod

223 117770 SWITCH, reed, w/cable

224 119875 MAGNET

227 249854 COVER, drive housing, B side; includes item 223 and 228

228 115711 TAPE, mounting, reed switch; not shown

Qty

2

8

2

2

1

1

1

1

2

1

* Included in 248231 Crankshaft Kit.

† Included in 287057 Gear Reducer Kit.

‡ Included in 287055 Drive Housing Kit.

Included in 287053 Connecting Rod Kit.

48 311075C

Parts

Part No. 249499, Insulated Hose Bundle with recirculation lines

301 302 (Ref)

302

304

303 (Ref)

305 303

Ref.

No.

Part No. Description

301 249508 HOSE, fluid (component A), moisture guard; 1/4 in. (6 mm) ID; no. 5

JIC fittings (mxf); 35 ft (10.7 m)

302 249509 HOSE, fluid (component B); 1/4 in.

(6 mm) ID; no. 6 JIC fittings (mxf);

35 ft (10.7 m)

Qty

2

2

TI6991a

Ref.

No.

Part No. Description

303 15G342 HOSE, air; 1/4 in. (6 mm) ID; 1/4

304 buy npsm (fbe); 35 ft (10.7 m)

TUBE, foam, insulated; 1-3/8 in. (35 locally mm) ID; 31 ft (9.5 m)

305 156971 NIPPLE; 1/4 npt; for joining air line to another hose bundle

Qty

1

1

1

Part No. 249633, Non-insulated Hose Bundle without recirculation lines

301

302

305

302 (Ref)

303

Ref.

No.

Part No. Description

301 249508 HOSE, fluid (component A), moisture guard; 1/4 in. (6 mm) ID; no. 5

JIC fittings (mxf); 35 ft (10.7 m)

302 249509 HOSE, fluid (component B); 1/4 in.

(6 mm) ID; no. 6 JIC fittings (mxf);

35 ft (10.7 m)

Qty

1

1

TI6992a

Ref.

No.

Part No. Description

303 15G342 HOSE, air; 1/4 in. (6 mm) ID; 1/4 npsm (fbe); 35 ft (10.7 m)

305 156971 NIPPLE; 1/4 npt; for joining air line to another hose bundle

Qty

1

1

311075C 49

Parts

Part No. 249556, 120 V Heated Display

Part No. 249557, 240 V Heated Display

404 414 402

421

401

405 416a

416

416a

404 (Ref)

415

417

403

402

409

411

408

407

412

413

406

424

410 410

Ref.

No.

Part No. Description

401 15F984 PLATE

402 119927 SWITCH, motor or heater power, with circuit breaker

403 249567 MODULE, display, temperature; includes (1) item 402 and (2) item

424

404 249494 POTENTIOMETER

405 119930 INDICATOR, status, LED

406 249434 BOARD, control; 120 V units only

249432 BOARD, control; 240 V units only

407 15G230 CABLE, harness

408 107156 SCREW, machine, pan hd

409 113505 NUT, keps, hex hd

410 119898 BULKHEAD FITTING, cable

Qty

1

2

1

7

10

1

1

2

1

1

1

TI6979a

Ref.

No.

Part No. Description Qty

411 101765 GROMMET

412 116773 CONNECTOR, plug

413 15C866 WIRE, jumper

414 15G279 LABEL, display

415 15G053 PLATE, detent

416 249453 KNOB, function; includes item 416a 1

416a 101118 . SCREW, set; no. 10 x 1/4 in. (6 2

1

1

1

1

2

417

421 mm)

15G454 LABEL, startup, heated

15G384 ENCLOSURE

424 119869 DISPLAY, temperature, with sensor 2

425 DUAL TERMINAL; not shown 2

1

1

50 311075C

Parts

Part No. 249537, 120 V Nonheated Display

Part No. 249538, 240 V Nonheated Display

403

404

414

402

401

421

409

405

416a

416

416a

404 (Ref)

415

417

410

408

407

406

423

411

Ref.

No.

Part No. Description

401 15F984 PLATE

402 119927 SWITCH, motor power, with circuit breaker

403 15G408 COVER, display

404 249494 POTENTIOMETER

405 119930 INDICATOR, status, LED

406 249434 BOARD, control; 120 V units only

249432 BOARD, control; 240 V units only

407 15G230 CABLE, harness

408 107156 SCREW, machine, pan hd

409 113505 NUT, keps, hex hd

410 119897 BULKHEAD FITTING, cable

411 101765 GROMMET

412 116773 CONNECTOR, plug

413 WIRE, jumper

Qty

1

1

7

10

1

1

1

1

1

1

1

2

1

1

412

413

TI6983a

Ref.

No.

Part No. Description Qty

414 15G279 LABEL, display 1

415 15G053 PLATE, detent 1

416 249453 KNOB, function; includes item 416a 1

416a 101118 . SCREW, set; no. 10 x 1/4 in. (6 2 mm)

417 15G281 LABEL, startup, unheated

421 15G384 ENCLOSURE

423 PLUG

1

1

1

311075C 51

Parts

Part No. 287712 Recirculation Manifold, Heated Models

▲ 512

508

506

505

504

503

503a

503b

501

502

507

Ref.

No.

Part No. Description Qty

501 15F870 MANIFOLD, recirculation

502 111763 ELBOW; 1/4 npt (mbe)

503 239914 VALVE, recirc/spray; includes items

505

506

507

508

503a, 503b

503a 15E022 . SEAT

503b 111699 . GASKET

504 224807 BASE, valve

187625 HANDLE, valve, drain

111600 PIN, grooved

100721 PLUG, pipe; 1/4 npt(m)

100840 ELBOW, street; 1/4 npt(m) x 1/4 npsm(f)

509 116704 ADAPTER; 9/16-18 JIC x 1/4 1 npt(m)

510 119998 ADAPTER; 1/2-18 JIC x 1/4 npt(m) 1

512 ▲ 189285 LABEL, warning 1

2

2

2

2

2

1

1

1

2

2

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

510 509 TI6977a

Part No. 287755 Recirculation Manifold, Nonheated Models

507

506

505

504

503

503a

503b

501

502

Ref.

No.

Part No. Description Qty

501 15F870 MANIFOLD, recirculation

502 111763 ELBOW; 1/4 npt (mbe)

503 239914 VALVE, recirc/spray; includes items

503a 15E022 . SEAT

505

506

507

508

503a, 503b

503b 111699 . GASKET

504 224807 BASE, valve

187625 HANDLE, valve, drain

111600 PIN, grooved

113641 GAUGE, pressure, fluid

116504 TEE; 1/4 npt(m) x 1/4 npt(f) run; 1/4 npt(f) branch

509 116704 ADAPTER; 9/16-18 JIC x 1/4 1 npt(m)

510 119998 ADAPTER; 1/2-18 JIC x 1/4 npt(m) 1

511 ELBOW, tube; 1/4 npt(m) x 3/8 in. 2

(10 mm) OD tube

2

2

2

2

1

1

2

1

4

2

510

511

508

509

TI6982a

52 311075C

Parts

Part No. 249582, Cart

Ref.

No.

Part No. Description

602 154636 WASHER, flat

603 116411 SPRING

604 116477 WASHER, flat; nylon

605 116478 WHEEL, pneumatic

606 101242 RING, retaining

607 GRIP, handle

Qty

4

2

4

2

2

2

607

602

603

602

604 605

604

606

TI6976a

311075C 53

Suggested Spare Replacement Parts

Suggested Spare Replacement Parts

Keep the following spare parts on hand to reduce downtime.

All Units Heated Units Only

Part No. Description

119974 DRYER, desiccant; package of 2

15F895 O-RING, lid, tank

119927 SWITCH, motor or heater power, with circuit breaker

113641 GAUGE, pressure, fluid; sst

101078 Y-STRAINER; includes 180199 element

180199 ELEMENT, Y-strainer, 20 mesh

114228 ELEMENT, air filter, 5 micron; polypropylene

239914 VALVE, recirc/spray; includes seat and gasket

249494 POTENTIOMETER, control knob

249434 BOARD, control; 120 V units only

249432 BOARD, control; 240 V units only

246123 TRANSDUCER, pressure

287657 PUMP, displacement; fits either side

287718 INLET KIT, tank to pump

249855 REPAIR KIT, displacement pump; includes seals, balls, bearings, intake valve seat)

Part No. Description

119869 DISPLAY, temperature, with sensor

119857 FUSE, heater over-temperature

119797 THERMOSTAT, heater

15F770 HEATER ELEMENT; 120 V units only

15F771 HEATER ELEMENT; 240 V units only

54 311075C

Dimensions

Dimensions

All Models

26.5 in.

(673 mm)

44 in.

(1118 mm)

30 in.

(762 mm)

TI6974a

311075C 55

Technical Data

Technical Data

Maximum fluid working pressure

Electrical requirements

2000 psi (14 MPa, 140 bar)

Model 249800: 120 Vac, 1 phase, 50/60 Hz, 3500 W; requires two separate, dedicated 15 A circuits

Model 249802: 240 Vac, 1 phase, 50/60 Hz, 3800 W; requires two separate, dedicated 10 A circuits

Model 249804: 240 Vac, 1 phase, 50/60 Hz, 3800 W; requires a single dedicated

16 A circuit

Model 249806: 120 Vac, 1 phase, 50/60 Hz, 1800 W; requires a single dedicated

15 A circuit

Generator Size (for Reactor

E-10 only)

Model 249808: 240 Vac, 1 phase, 50/60 Hz, 1800 W; requires a single dedicated

8 A circuit

Heated: 5000 W minimum

Nonheated: 2500 W minimum

160°F (71°C)

110°F (43°C)

Maximum Fluid Temperature

Maximum Ambient Temperature

Maximum Output

Output per Cycle (A and B)

Overpressure Relief

Heater Power

Sound Pressure

12 lb/min (5.4 kg/min) at 340 cycles/min

.00352 gal. (.0133 liter)

Recirc/Spray valves automatically relieve excessive fluid pressure back to supply tanks

120V models: 850 W each; 1700 W total

240V models: 1000 W each; 2000 W total

78.7 dB(A) in fast circulation mode

84.5 dB(A) at 2000 psi (14 MPa, 140 bar), 0.72 gpm (2.7 lpm)

Sound Power, per ISO 9614-2 88.6 dB(A) in fast circulation mode

94.4 dB(A) at 2000 psi (14 MPa, 140 bar), 0.72 gpm (2.7 lpm)

56 311075C

Technical Data

Tank Capacity

Fluid Outlets

Fluid Circulation Returns

Air Inlet

Air Outlet

Gun Compressed Air Requirements

Hose Markings

Weight (empty)

Wetted Parts

7 gal. (26.5 liters) each (nominal)

Component A (ISO): #5 JIC (1/2-18) male

Component B (RES): #6 JIC (9/16-18) male

Component A (ISO): #5 JIC (1/2-18) male

Component B (RES): #6 JIC (9/16-18) male

1/4 in. quick-disconnect industrial type pin fitting

1/4 npsm(m)

Fusion Gun (purge air and operating air): 4 scfm (0.112 m

3

/min)

2K Ultra-Lite Gun with disposable mixer kit: 14 scfm (0.392 m

3

/min), with air spray valve fully open

2K Ultra-Lite Gun with joint fill kit: 2 scfm (.056 m

3

/min)

A Side: Red

B Side: Blue approximately 160 lb (72 kg), depending on model

Aluminum, stainless steel, carbon steel, brass, carbide, chrome, chemically resistant o-rings, PTFE, ultra-high molecular weight polyethylene

All other brand names or marks are used for identification purposes and are trademarks of their respective owners.

311075C 57

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

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.

MM 311075

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441 www.graco.com

Printed in USA 311075C

8/2005 Rev. 10/2005

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