Repair - Parts R EN

Transcription

1 Repair - Parts R EN Hydraulic, Heated, Plural Component Proportioner. For spraying polyurethane foam and polyurea coatings. For professional use only. Not for use in explosive atmospheres. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. See page 3 for model information, including maximum working pressure and approvals. For patent information, see Model H-40 Shown TI9830a

2 Contents Models Supplied Manuals Related Manuals Warnings Temperature Control Diagnostic Codes E01: High fluid temperature E02: High zone current E03: No zone current E04: Fluid Temperature Sensor (FTS) or thermocouple disconnected E05: Circuit board overheated E06: Communication cable unplugged Motor Control Diagnostic Codes Alarms Warnings E21: No component A transducer E22: No component B transducer E23: High fluid pressure E24: Pressure imbalance E27: High motor temperature E30: Momentary loss of communication E31: Pumpline reversing switch failure/high cycle rate E99: Loss of communication Troubleshooting Reactor Electronics Primary Heaters (A and B) Hose Heat System Hydraulic Drive System Proportioning System Repair Pressure Relief Procedure Flushing Proportioning Pumps Circuit Breaker Module Electric Motor Motor Control Board Transducers Electric Fan Temperature Control Module Primary Heaters Heated Hose Fluid Temperature Sensor (FTS) Display Module Inlet Fluid Strainer Screen Pump Lubrication System Change Hydraulic Fluid and Filter Parts Parts Used on All Models Parts that Vary by Model Sub Assemblies Proportioner Assembly kw and 6.0 kw Heaters kw Dual Zone Heater kw Single Zone Heater Hydraulic Cylinder Display Temperature Control Fluid Manifold Circuit Breaker Modules Dimensions Technical Data Graco Standard Warranty Graco Information R

3 Models Models H-25 SERIES Part, Series H-40 SERIES Part, Series H-50 SERIES Full Load Peak Amps* Per Phase Voltage (phase) System Watts Primary Heater Watts Max Flow Rate lb/min (kg/min) Approximate Output per Cycle (A+B) gal. (liter) Hydraulic Pressure Ratio Maximum Fluid Working Pressure psi (MPa, bar) , F V (1) 15,960 8, (10) (0.24) 1.91: (13.8, 138) , F V (3) 15,960 8, (10) (0.24) 1.91: (13.8, 138) , F V (3) 15,960 8, (10) (0.24) 1.91: (13.8, 138) , F V (1) 23,260 15, (10) (0.24) 1.91: (13.8, 138) , F V (3) 23,260 15, (10) (0.24) 1.91: (13.8, 138) , F V (3) 23,260 15, (10) (0.24) 1.91: (13.8, 138) Full Load Peak Amps* Per Phase Voltage (phase) System Watts Primary Heater Watts Max Flow Rate lb/min (kg/min) Approximate Output per Cycle (A+B) gal. (liter) Hydraulic Pressure Ratio Maximum Fluid Working Pressure psi (MPa, bar) , E V (1) 23,100 12, (20) (0.24) 1.91: (13.8, 138) , E V (3) 26,600 15, (20) (0.24) 1.91: (13.8, 138) , E V (3) 26,600 15, (20) (0.24) 1.91: (13.8, 138) , E V (3) 31,700 20, (20) (0.24) 1.91: (13.8, 138) , E V (3) 31,700 20, (20) (0.24) 1.91: (13.8, 138) Part, Series Full Load Peak Amps* Per Phase Voltage (phase) System Watts Primary Heater Watts Max Flow Rate lb/min (kg/min) Approximate Output per Cycle (A+B) gal. (liter) Hydraulic Pressure Ratio Maximum Fluid Working Pressure psi (MPa, bar) , E V (1) 23,100 12, (24) (0.28) 1.64: (11.7, 117) , E V (3) 26,600 15, (24) (0.28) 1.64: (13.8, 138) , E V (3) 26,600 15, (24) (0.28) 1.64: (13.8, 138) , E V (3) 31,700 20, (24) (0.28) 1.64: (13.8, 138) , E V (3) 31,700 20, (24) (0.28) 1.64: (13.8, 138) R 3

4 Models H-XP2 SERIES Part, Series H-XP3 SERIES Part, Series Full Load Peak Amps* Per Phase Voltage (phase) System Watts Primary Heater Watts Max Flow Rate gpm (lpm) Approximate Output per Cycle (A+B) gal. (liter) Hydraulic Pressure Ratio Maximum Fluid Working Pressure psi (MPa, bar) , F V (1) 23,260 15, (5.7) (0.16) 2.79: (24.1, 241) , F V (3) 23,260 15, (5.7) (0.16) 2.79: (24.1, 241) , F V (3) 23,260 15, (5.7) (0.16) 2.79: (24.1, 241) Full Load Peak Amps* Per Phase Voltage (phase) System Watts Primary Heater Watts Max Flow Rate gpm (lpm) Approximate Output per Cycle (A+B) gal. (liter) Hydraulic Pressure Ratio Maximum Fluid Working Pressure psi (MPa, bar) , E V (1) 23,100 12, (10.6) (0.16) 2.79: (24.1, 241) , E V (3) 31,700 20, (10.6) (0.16) 2.79: (24.1, 241) , E V (3) 31,700 20, (10.6) (0.16) 2.79: (24.1, 241) * Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less. Total system watts, based on maximum hose length for each unit: Parts through , 310 ft (94.6 m) maximum heated hose length, including whip hose. Parts through , through 25372, , and , 410 ft (125 m) maximum heated hose length, including whip hose. Maximum flow rate given for 60 Hz operation. For 50 Hz operation, maximum flow rate is 5/6 of 60 Hz maximum flow. CE approval does not apply R

5 Supplied Manuals Supplied Manuals The following manuals are shipped with the Reactor Proportioner. Refer to these manuals for detailed equipment information. Order Part 15M334 for a compact disk of Reactor manuals translated in several languages. Manuals are also available at Reactor Hydraulic Proportioner Part Description Reactor Hydraulic Proportioner, Operation Manual (English) Reactor Electrical Diagrams Part Description Reactor Hydraulic Proportioner, Electrical Diagrams (English) Proportioning Pump Part Description Proportioning Pump Repair-Parts Manual (English) Translations The Reactor Repair-Parts manual is available in the following languages. See the following chart for specific languages and corresponding part numbers. Part Language English Chinese Dutch French German Italian Japanese Korean Russian Spanish Order Part 15M334 for a compact disk of Reactor manuals translated in several languages. Order Part 15B381 for a compact disk of Fusion manual translated in several languages. Feed Pump Kits Part Description Instruction-Parts Manual (English) Air Supply Kit Part Description Instruction-Parts Manual (English) for Feed Pump Air Supply Kit Circulation and Return Tube Kits Part Description Instruction-Parts Manual (English) Heated Hose Part Description Instruction-Parts Manual (English) Circulation Kit Part Description Instruction-Parts Manual (English) Circulation Valve Kit Part Description Instruction-Parts Manual (English) Data Reporting Kit Part Description Instruction-Parts Manual (English) Rupture Disk Assembly Kit Part Description Instruction-Parts Manual (English) Proportioning Pump Repair Kits Part Description Seal Kits Instruction-Parts Manual (English) Related Manuals The following manuals are for accessories used with the Reactor R 5

6 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 symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable. 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. Always wear impervious gloves when spraying or cleaning equipment. 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. 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. Do not spray without tip guard and trigger guard installed. Follow Pressure Relief Procedure in this manual, 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 R

7 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 and clean 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 lights on or off when flammable fumes are present. Ground equipment, personnel, object being sprayed, and conductive objects in work area. See Grounding instructions. Use only Graco grounded hoses. Check gun resistance daily. If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem. Do not flush with gun electrostatics on. Do not turn on electrostatics until all solvent is removed from system. Keep a working fire extinguisher in the work area. THERMAL EXPANSION HAZARD Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure due to the thermal expansion. Over-pressurization can result in equipment rupture and serious injury. Open a valve to relieve the fluid expansion during heating. Replace hoses proactively at regular intervals based on your operating conditions. PRESSURIZED ALUMINUM PARTS HAZARD 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. This equipment is for professional use only. Do not leave the work are while the equipment is energized or under pressure. Turn off all equipment and follow the Pressure Relief Procedure in this manual when the equipment is not in use. 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 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 forms from distributor or retailer. Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer s replacement parts only. Do not alter or modify equipment. Use equipment only for its intended purpose. Call your distributor for information. Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not kink or over bend hoses or use hoses to pull equipment. Keep children and animals away from work area. Comply with all applicable safety regulations. 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 R 7

8 Warnings WARNING 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 R

9 Temperature Control Diagnostic Codes Temperature Control Diagnostic Codes NOTICE To prevent damage to soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails. Temperature control diagnostic codes appear on temperature display. These alarms turn off heat. E99 clears automatically when communication is regained. Codes E03 through E06 can be cleared by pressing. For other codes, Code Code Name Alarm Zone Corrective Action page 01 High fluid temperature Individual 9 02 High zone current Individual No zone current with hose heater on Individual FTS not connected Individual Board overtemperature Individual Communication cable unplugged from module Individual Loss of communication A 16 turn main power OFF then ON to clear. For hose zone only, if FTS is disconnected at startup, display will show hose current 0A. E01: High fluid temperature Causes of E01 Errors Thermocouple A or B (310) senses a fluid temperature above 230 F (110 C). Fluid temperature sensor (FTS) senses a fluid temperature above 230 F (110 C). Overtemperature switch A or B (308) senses a fluid temperature above 230 F (110 C) and opens. At 190 F (87 C) the switch closes again. Thermocouple A or B (310) fails, is damaged, is not touching the heater element (307), or has a poor connection to the temperature control board. Overtemperature switch A or B (308) fails in the open position. The temperature control board fails to turn off any heat zone. Zone power wires or thermocouples are switched from one zone to another. Failed heater element where thermocouple is installed. Loose wire On 8 kw heater models only: Jumper wire on J1 connector, between module (3) and display (4), is loose or incorrectly wired. Checks Troubleshooting this equipment requires access to parts that may cause electric shock or other serious injury if work is not performed properly. Have a qualified electrician perform all electrical troubleshooting. Be sure to shut off all power to the equipment before repairing. Check which zone is displaying the E01 error. 1. Check that connector B is firmly plugged into temperature control module (see FIG. 8, page 36). 2. Clean and re-plug connections. 3. Check connections between the temperature control module and overtemperature switches A and B (308), and between temperature control module and thermocouples A and B (310) or FTS (21) [depending on which zone is displaying E01]. See TABLE 6, page 36. Ensure that all wires are securely connected to connector B R 9

10 Temperature Control Diagnostic Codes 4. Remove connector B from temperature control module, and check continuity of overtemperature switches A and B, thermocouples A and B, or FTS by measuring resistance across the pins on the plug end; see TABLE 1. Before doing the following checks, note which zone (A, B, FTS, or all) has high fluid temperature. E02: High zone current 1. Turn main power OFF. 2. Relieve pressure, page 28. Disconnect whip hose. Table 1: Sensor Connector Continuity Checks Pins Description Reading 1 & 2 OT switch A nearly 0 ohms 3 & 4 OT switch B nearly 0 ohms 5 & 6 Thermocouple A 4-6 ohms 8 & 9 Thermocouple B 4-6 ohms 11 & 12 FTS approximately 35 ohms per 50 ft (15.2 m) of hose, plus approximately 10 ohms for FTS 10 & 12 FTS open 5. Verify fluid temperature, using an external temperature sensing device. If temperature is too high (sensor reading is 229 F [109 C] or above): 6. Check if thermocouples A and B are damaged, or not contacting the heater element, page To test that temperature control module turns off when equipment reaches temperature setpoint: a. Set temperature setpoints far below displayed temperature. b. Turn zone on. If temperature rises steadily, power board is failing. c. Verify by swapping with another power module. See Replacing Temperature Control Assembly Modules, page 37. d. If the swapped module does not fix the problem, the power module is not the cause. 8. Verify continuity of heater elements with an ohmmeter, see page Disconnect hose connector (D) at Reactor. 4. Using an ohmmeter, check between the two terminals of the connector (D). There should be no continuity. 5. Exchange zone module with another one. Turn zone on and check for error. If error disappears, replace faulty module. For hose zone: If error still occurs, perform Transformer Primary Check and Transformer Secondary Check starting on page 42. When there is a a high current error, the LED on that zone s module will turn red while the error is displayed. E03: No zone current 1. Check for tripped circuit breaker inside electrical cabinet or at power source for that zone. Replace circuit breaker if it trips habitually. 2. Check for loose or broken connection at that zone. 3. Exchange zone module with another one. Turn zone on and check for error (see page 37). If error disappears, replace faulty module. 4. If E03 occurs for all zones, the contactor may not be closing. Verify wiring from heater control to contactor coil. a. Hose zone: test hose continuity, page 40. b. Perform Transformer Primary Check and Transformer Secondary Check, starting on page 42. When a no current error occurs, the LED on the specific zone s module turns red when the error is displayed R

11 Temperature Control Diagnostic Codes E04: Fluid Temperature Sensor (FTS) or thermocouple disconnected 1. Check temperature sensor connections to long green connector (B) on temperature control module, page 36. Unplug and re-plug sensor wires. 2. Test fluid temperature sensor continuity with ohmmeter, page If an error occurred for the hose zone, check FTS connections at each section of hose. 4. If an error occurred for the hose zone, test FTS by plugging directly into machine. E05: Circuit board overheated Each module has an on-board temperature sensor. Heat is turned off if module temperature exceeds 185 F (85 C) within the heater module. 1. Check that fan above electrical cabinet is operating. 2. Check that electrical cabinet door is properly installed. 3. Check for obstructions blocking cooling holes in bottom of electrical cabinet. 4. Clean heatsink fins behind heater control modules. 5. Ambient temperature may be too high. Allow Reactor to cool by moving to a cooler location. F ti9878a E06: Communication cable unplugged 1. Unplug and re-plug cable that connects heater control module to heater module. 5. To verify heater control module is not causing the problem, use a wire to short-circuit the two pins corresponding to the FTS (red and yellow for A or B zone, red and purple for hose). The display will show the control heater module temperature. 2. Replace communication cable if problem persists. 6. If an error occurred for the hose zone, temporarily use the current control mode. Refer to Reactor Operation manual R 11

12 Motor Control Diagnostic Codes Motor Control Diagnostic Codes Motor control diagnostic codes E21 through E27 appear on pressure display. There are two types of motor control codes: alarms and warnings. Alarms take priority over warnings. Alarms Warnings Reactor will continue to run. Press to clear. A warning will not recur for a predetermined amount of time (varies for different warnings), or until main power is turned OFF then ON. Alarms turn off Reactor. Turn main power OFF then ON to clear. Alarms can also be cleared, except for code 23, by pressing. Code Code Name Alarm (A) or Warning (W) 21 No transducer (component A) 22 No transducer (component B) Corrective Action page A 13 A High fluid pressure A Pressure imbalance A/W (to 13 select, see page 33) 27 High motor temperature A Momentary loss of communication A Pumpline reversing switch failure/high cycle rate A Loss of communication A R

13 Motor Control Diagnostic Codes E21: No component A transducer 1. Check transducer A connection at J3 on motor control board, page 34, and clean contacts. 2. Reverse A and B transducer connections. If error moves to transducer B (E22), replace transducer A, page 35. If error does not move, replace motor control board, page 33. E22: No component B transducer 1. Check transducer B connection at J8 on motor control board, page 34, and clean contacts. 2. Reverse A and B transducer connections. If error moves to transducer A (E21), replace transducer B, page 35. If error does not move, replace motor control board, page 33. E23: High fluid pressure 1. Relieve pressure. Verify low pressure with analog gauges. Turn main power OFF. If error persists, do checks below. then ON 2. If pressure imbalance is set to Warning instead of Alarm (see page 33), an E23 will occur. See E24: Pressure imbalance for causes and checks. E24: Pressure imbalance Upon initial start-up this diagnostic code will not cause an alarm for 2 minutes. If the pressure difference between components A and B exceeds 500 psi (3.5 MPa, 35 bar), an E24 will occur. This default value is adjustable; see the operation manual. E24 can be an alarm or a warning, as desired. Set DIP switch on motor control board ON for alarm, OFF for warning. See page 33. Fast E24 Errors Fast E24 errors occur: within 10 seconds of turning the pumps on, or as soon as you trigger the gun. Causes of Fast E24 Errors one side of the gun is plugged. a pressure transducer has failed. damaged pump seals or check valve. no feed pressure or empty material drum plugged heater. plugged hose. plugged manifold. one PRESSURE RELIEF/SPRAY valve is leaking or is set to PRESSURE RELIEF/CIRCULATION. Checks for Fast E24 Errors If a fast E24 error occurs, first check the readings of the analog gauges. If the gauge readings are very close: 1. Clear the error (page 12) and try running the unit again. 2. If E24 recurs and the gauge readings are still very close, a pressure transducer has failed R 13

14 Motor Control Diagnostic Codes The digital display always shows the higher of the two pressures. As soon as the higher analog pressure drops below the lower analog pressure, the display changes to the new higher reading. Knowing this, the following checks will show which transducer has failed, or if the motor control board has failed. 3. For testing purposes only, set DIP switch 2 on the motor control board to OFF. See page 33. This will allow the Reactor to continue to run with a pressure imbalance. c. Run the unit until pressure is psi ( MPa, bar). Shut down the unit, clear the alarm, and power back up, but do not depressurize the unit. d. Check the analog gauges to see which pressure is higher, and check if the display matches. If the higher gauge and display match, that transducer is communicating with the motor control board. Continue with step e. If the higher gauge and display do not match, that transducer is not communicating with the motor control board. Check wire connections and replace transducer, page 35. e. Turn pumps off. Reduce pressure of higher component by slightly turning PRESSURE RELIEF/SPRAY valve for that component toward PRESSURE RELIEF/CIRCULATION, while watching the display and the analog gauges. As soon as the higher analog pressure drops below the lower analog pressure, the display should change to the new higher reading. Continue reducing the original higher pressure an additional 200 psi (1.4 MPa, 14 bar); digital display should stop dropping. f. Repeat for the other side, to check the other transducer. 1 Turn valve slightly to reduce pressure of higher component. a. Reverse connections at J3 and J8 on the motor control board. b. Run the unit until pressure is psi ( MPa, bar). c. If the problem stays on the same side as before, replace the motor control board. If the problem appears to move to the other side, replace the transducer. If the gauge readings are not very close: 1. Secure bleed lines in grounded waste containers, or route back to respective component A or B supply drum. Reduce pressure of higher component by slightly turning PRESSURE RELIEF/SPRAY valve for that component toward PRESSURE RELIEF/CIRCULATION balanced pressures. 2. If you cannot get the pressures to balance: a. Check for damaged pump seals or check valves. b. Check if you ve run out of material., until gauges show Turn PRESSURE RELIEF/SPRAY valve only enough to balance pressure. If you turn it completely, all pressure will bleed off. c. Check for a plugged fluid path by using the feed pump to push fluid through the gun manifold. 3. If you are able to balance pressures, try running the unit. 1 Turn valve slightly to reduce pressure of higher component. 1 ti9877a 1 4. To test if the failure is with the transducer or the socket on the motor control board: ti9877a R

15 Motor Control Diagnostic Codes 4. If a fast E24 error occurs again, and the gauges readings are not very close: a. Check and clean the gun inlet screens. b. Check and clean the gun mix chamber impingement ports and center port. See gun manual. Some mix chambers have counter bored impingement ports, requiring two drill sizes to clean completely. Slow E24 Errors Slow E24 errors occur gradually. The pressures are balanced when you begin spraying, but slowly become imbalanced until an E24 occurs. Causes of Slow E24 Errors one side of the gun is partially plugged. the A or B proportioner pump has failed. the A or B feed pump has failed. the A or B feed pump pressure is set too high. the A or B proportioner pump inlet screen is plugged. the hose is not heating properly. kinked supply hose. bottom of drum is damaged, causing blockage of feed pump inlet. drum is not vented. E27: High motor temperature Causes of E27 Errors Motor temperature is too high. Reduce pressure, gun tip size, or move Reactor to a cooler location. Allow 1 hour for cooling. Make sure there is no obstruction to fan airflow. Ensure that the motor/fan shroud is installed. 1. Turn main power OFF. 2. Allow motor to cool completely. Check continuity between pins 1 and 2 on connector J9 on the motor control board, page 33. If the resistance is infinity, the motor thermal switch or the wire harness is bad. Check wiring, measure thermal switch continuity at motor, and replace failed part. 3. Unplug motor from J9 on motor control board. Install jumper across pins 1 and 2 on board. If error still occurs, replace motor control board. 4. If the E27 error is still occurring, the problem is with the motor control board. E30: Momentary loss of communication If communication is lost between the display and the motor control board, the display will normally show E99. The motor control board will register E30 (the red LED will blink 30 times). When communications are reconnected, the display may show E30 briefly (no more than 2 seconds). If the display shows E30 continuously, there is a loose connection causing the display and board to repeatedly lose and regain communication. E31: Pumpline reversing switch failure/high cycle rate Failure of a pumpline switch or switch mechanism may result in a high cycle rate, causing an E31 to occur. Replace the switch or switch mechanism. See Pumps Do Not Reverse Direction, page 27. E31 may also occur if the system is modified to produce a higher flow rate. Check that the motor overtemperature wire assembly is plugged into J9 on the motor control board, page 34. If the preceding checks do not correct the problem, perform the following tests: R 15

16 Motor Control Diagnostic Codes E99: Loss of communication If communication is lost between the motor control display and the motor control board, or the temperature control display and the temperature control module, the affected display will show E Check all wiring between the display and the motor control board and the temperature control module. Pay close attention to the wire crimping at J13 on the motor control board (page 34) and (C) on the temperature control module (page 36). Unplug and re-plug connectors. 2. Incoming voltage should be 230 Vac. Check the temperature control module voltage at terminal block (805) on the circuit breaker module (see page 68). Check the motor control board voltage at motor/pumps circuit breaker (813), see page 31. Check if temperature control module or motor control board is causing error: 3. Swap display connection on temperature control module (C) with display connection on motor control board (J13). 4. If error no longer occurs, the board or module was at fault. Switch connections back to ensure connector was not poorly connected R

17 Troubleshooting Troubleshooting Reactor Electronics 2. Turn main power OFF. 3. Allow equipment to cool. Before performing any troubleshooting procedures: 1. Relieve pressure, page 28. 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 CAUSE SOLUTION Both sides of display do not illuminate. Temperature display does not illuminate. Pressure display does not illuminate. Erratic display; display turns on and off. No power. Plug in power cord. Turn disconnect ON. Low voltage. Ensure input voltage is within specifications, page 43. Loose wire. Check connections, page 43. Display disconnected. Check cable connections, page 43. Display disconnected. Check cable connections, page 43. Display cable damaged or corroded. Clean connections; replace cable if is damaged. Defective circuit board. Swap display connection to motor control board with connection to heater control board. If temperature display illuminates, heater control board is causing problem. Otherwise, display cable or display is failing. Display disconnected. Check cable connections, page 43. Display cable damaged or corroded. Clean connections; replace cable if is damaged. Defective circuit board. Swap display connection to motor control board with connection to heater control board. If pressure display illuminates, motor control board is causing problem. Otherwise, display cable or display is failing. Low voltage. Ensure input voltage is within specifications, page 43. Poor display connection. Check cable connections, page 43. Replace damaged cable. Display cable damaged or corroded. Clean connections; replace cable if is damaged. Display cable not grounded. Ground cable, page 43. Display extension cable too long. Must not exceed 100 ft (30.5 m) R 17

18 Troubleshooting Hose display reads OA at startup. FTS disconnected or not installed. Verify proper installation of FTS (see Operation manual ), or adjust FTS to desired current setting. Display does not respond properly to button pushes. Poor display connection. Check cable connections, page 43. Replace damaged cable. Display cable damaged or corroded. Clean connections; replace cable if is damaged. Ribbon cable on display circuit board Connect cable (page 43) or replace. disconnected or broken. Broken display button. Replace, page 43. Red stop button does not work. Broken button (fused contact). Replace, page 43. Loose wire. Check connections, page 43. Fan not working. PROBLEM CAUSE SOLUTION Blown fuse. Verify with ohmmeter; replace if necessary (page 43). Loose wire. Check fan wire. Defective fan. Replace, page R

19 Troubleshooting Primary Heaters (A and B) 2. Turn main power OFF. 3. Allow equipment to cool. Before performing any troubleshooting procedures: 1. Relieve pressure, page 28. 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 CAUSE SOLUTION Primary heater(s) does not heat. Control of primary heat is abnormal; high temperature overshoots or E01 error occurs intermittently. Heat turned off. Temperature control alarm. Signal failure from thermocouple. Dirty thermocouple connections. Thermocouple not contacting heater element. Press or zone keys. Check temperature display for diagnostic code, page 9. See E04: Fluid Temperature Sensor (FTS) or thermocouple disconnected, page 11. Examine connection of thermocouples to long green plug on heater control board. Unplug and re-plug thermocouple wires, cleaning off any debris. Unplug and re-plug long green connector. Loosen ferrule nut (N), push in thermocouple (310) so tip (T) contacts heater element (307). Holding themocouple tip (T) against heater element, tighten ferrule nut (N) 1/4 turn past tight. See page 39 for illustration. Failed heater element. See Primary Heaters, page 38. Signal failure from thermocouple. Thermocouple wired incorrectly. A B See E04: Fluid Temperature Sensor (FTS) or thermocouple disconnected, page 11. See E04: Fluid Temperature Sensor (FTS) or thermocouple disconnected, page 11. Power up zones one at a time and verify that temperature for each zone rises R 19

20 Troubleshooting Hose Heat System 2. Turn main power OFF. 3. Allow equipment to cool. Before performing any troubleshooting procedures: 1. Relieve pressure, page 28. Problems 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 CAUSE SOLUTION Ambient temperature is too cold. Use auxiliary hose heat system. Hose heats but heats slower than usual or it does not reach temperature. FTS failed or not installed correctly. Check FTS, page 11. Low supply voltage. Verify line voltage. Low line voltage significantly reduces power available to hose heat system, affecting longer hose lengths. Hose does not maintain temperature while spraying. Hose temperature exceeds setpoint. A and B setpoints too low. Ambient temperature is too cold. Flow too high. Hose was not fully preheated. Low supply voltage. A and/or B heaters are overheating material. Faulty thermocouple connections. Increase A and B setpoints. Hose is designed to maintain temperature, not to increase it. Increase A and B setpoints to increase fluid temperature and keep it steady. Use smaller mix chamber. Decrease pressure. Wait for hose to heat to correct temperature before spraying. Verify line voltage. Low line voltage significantly reduces power available to hose heat system, affecting longer hose lengths. Check primary heaters for either a thermocouple problem or a failed element attached to thermocouple, page 11. Verify that all FTS connections are snug and that pins of connectors are clean. Examine connection of thermocouples to long green plug on heater control board. Unplug and re-plug thermocouple wires, cleaning off any debris. Unplug and re-plug long green connector on heater control board R

21 Troubleshooting PROBLEM CAUSE SOLUTION Erratic hose temperature. Hose does not heat. Hoses near Reactor are warm, but hoses downstream are cold. Faulty thermocouple connections. FTS not installed correctly. FTS failed or is not contacting correctly. FTS not installed correctly. Temperature control alarm. Shorted connection or failed hose heating element. Verify that all FTS connections are snug and that pins of connectors are clean. Examine connection of thermocouples to long green plug on heater control board. Unplug and re-plug thermocouple wires, cleaning off any debris. Unplug and re-plug long green connector. FTS should be installed close to end of hose in same environment as gun. Verify FTS installation, page 41. Check FTS, page 41. FTS should be installed close to end of hose in same environment as gun. Verify FTS installation, page 41. Check temperature display or diagnostic code, page 41. With hose heat on and temperature setpoint above displayed hose zone temperature, verify voltage between connectors at each section of hose. Voltage should drop incrementally for each section of hose further from Reactor. Use safety precautions when hose heat is turned on R 21

22 Troubleshooting Hydraulic Drive System 2. Turn main power OFF. 3. Allow equipment to cool. Before performing any troubleshooting procedures: 1. Relieve pressure, page 28. Problems 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 CAUSE SOLUTION Electric motor will not start or stops during operation. Loose connections. Circuit breaker tripped. Damaged motor control board. Check connections at motor control board. Reset breaker (813); see Circuit Breaker Module, page 31. Check 230 Vac at output of breaker. Replace board. See Motor Control Board, page R

23 Troubleshooting PROBLEM CAUSE SOLUTION Hydraulic pump does not develop pressure. Low or zero pressure with screeching noise. Pump is not primed or lost its prime. Screeching noise is characteristic of cavitation and is normal at initial startup for a maximum of 30 seconds. Hydraulic fluid is too hot. Electric motor operating in wrong direction for 3 Phase system. Drive belt loose or broken. Check electric motor rotation. Both motor and hydraulic pump must rotate counterclockwise when viewed from shaft end. If rotation is incorrect, reverse leads L1 and L2. See Connect Electrical Cord in Operation manual Check dipstick to ensure that hydraulic reservoir is properly filled (see Operation manual). Check that inlet fitting is fully tight, to ensure no air is leaking into the pump inlet. To prime pump, run unit at lowest pressure setting and slowly increase pressure. In some cases it may be necessary to remove motor cover and drive belt to allow for manual (counterclockwise) rotation of hydraulic pump. Turn fan pulley by hand. Verify oil flow by removing oil filter to see flow into filter manifold. Reinstall oil filter. Do NOT operate unit without a properly installed oil filter. If noise continues longer than 30 seconds, press motor key to shut off the motor. Check that the inlet fittings are tight and that the pump has not lost its prime. Ensure that the reservoir is properly serviced. Improve ventilation to allow more efficient heat dissipation. Motor must operate counter-clockwise from pully end. Check drive belt condition. Replace if broken R 23

24 Troubleshooting Proportioning System 2. Turn main power OFF. 3. Allow equipment to cool. Before performing any troubleshooting procedures: 1. Relieve pressure, page 28. Problems 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 CAUSE SOLUTION Proportioning pump does not hold pressure when stalled. Pump piston or intake valve leaking. 1. Observe gauges to determine which pump is losing pressure. 2. Determine in which direction the pump has stalled by observing which directional valve indicator light is on. See Table 2, page 26 to isolate the problem. Material imbalance. See Pressure/Material Imbalance, page 26. Restriction at the gun. Inadequate flow from pump; cavitation. Pressure relief/circulation valve leaking back to supply. 3. Repair the valve; see pump manual Clean the gun; see your separate gun manual. Increase fluid supply to proportioning pump: Use 2:1 supply pump Use minimum 3/4 in. (19 mm) ID supply hose, as short as practical Fluid is too thick. Consult your material supplier for the recommended fluid temperature to maintain a viscosity of 250 to 1500 centipoise. Clean inlet strainer screen, page 45. Worn pump inlet valve ball/seat or gasket. Replace, see pump manual Remove return line and determine if flow is present while in SPRAY mode R

25 Troubleshooting PROBLEM CAUSE SOLUTION Pumps do not reverse direction or pumps do not move. Bent or loose activator plate, rocker arm, or reversing switch. Loose piston packing bolt. Faulty directional valve. See Pumps Do Not Reverse Direction, page 27. See Pumps Do Not Reverse Direction, page 27. See Pumps Do Not Reverse Direction, page 27. Erratic pump movement. Pump cavitation. Feed pump pressure is too low. Adjust pressure to maintain 100 psi (0.7 MPa, 7 bar) minimum. Fluid is too thick. Consult your material supplier for recommended fluid temperature to maintain a viscosity of 250 to 1500 centipoise. Loose activator plate, rocker arm, or reversing switch. See Pumps Do Not Reverse Direction, page 27. Pump output low. Faulty directional valve. Obstructed fluid hose or gun; fluid hose ID too small. Worn piston valve or intake valve in displacement pump. Inadequate feed pump pressure. Replace directional valve. Open, clear; use hose with larger ID. See pump manual Check feed pump pressure and adjust to 100 psi (0.7 MPa, 7 bar) minimum. Fluid leak at pump rod seal. Worn throat seals. Replace. See pump manual No pressure on one side. Fluid leaking from pump outlet rupture disk (216). Check if heater (2) and PRESSURE RELIEF/SPRAY valve (SA or SB) are plugged. Clear. Replace rupture disk (216) with a new one; do not replace with a pipe plug. Inadequate feed pump pressure. Check feed pump pressure and adjust to 100 psi (0.7 MPa, 7 bar) minimum R 25

26 Troubleshooting A (ISO) Proportioning Pump A (ISO) Inlet Supply Valve A (ISO) Over-pressure Rupture Disk B (Resin) Over-pressure Rupture Disk Directional Valve Activator Plate Reversing Switch Rocker Arm B (Resin) Proportioning Pump B (Resin) Inlet Supply Valve FIG. 1. Proportioning System ti9874a Table 2. Directional Valve Indicator Status Left Pump Directional Indicator Lighted B-side pump piston valve dirty or damaged A-side pump inlet valve dirty or damaged Right Pump Directional Indicator Lighted B-side pump inlet valve dirty or damaged A-side pump piston valve dirty or damaged Pressure/Material Imbalance To determine which component is out of balance, check the color of some sprayed material. Two-component materials are usually a mix of light and dark fluids, so the under-proportioned component can often be readily determined. When you have determined which component is under-proportioned, spray off-target, focusing on the pressure gauge for that component. For example: if component B is under-proportioned, focus on the B-side pressure gauge. If the B gauge reads considerably higher than the A gauge, the problem is at the gun. If the B gauge reads considerably lower than the A gauge, the problem is at the pump R

27 Troubleshooting Pumps Do Not Reverse Direction 1. For the proportioning pumps to reverse direction, the activator plate (219) must contact the rocker arm to activate the reversing switch (210). Check for a bent or loose activator plate, rocker arm, or reversing switch. See FIG. 1 on page 26, and the parts drawing on page Check the function of the directional valve. Direction indication lights should switch on and off based on the reversing switch (210) position. LEDs D19 and D20 (near J5 reversing switch connector on motor board) should alternately illuminate based on the reversing switch position. There are two possible problems with the directional valve: a. If D19 and D20 do not alternately illuminate, the possible causes include: faulty reversing switch wiring, faulty reversing switch, or faulty motor board. To resolve this problem: verify the continuity of each reversing switch wire. Replace faulty wires. verify reversing switch. Unplug the J5 reversing switch connector. Verify that continuity alternates between NC2 to com and N03 to com by toggling the reversing switch (see Electrical Diagrams manual ). If continuity does not alternate, replace the reversing switch and reconnect the J5 reversing switch connector. if the reversing switch and wiring are not the cause, and D19 and D20 will not alternately illuminate, replace the motor board. b. If D19 and D20 do illuminate but the direction indication lights do not, the possible causes include: faulty motor board, faulty directional valve wiring, or faulty directional valve. To resolve this problem: verify the motor board output voltages at the J18 directional valve connector. When the reversing switch is toggled one direction, there should be 230V output between pins 1 and 2 (A+ and A-). When it is toggled the other direction, there should be 230V output between pins 3 and 4 (B+ and B-). If output voltages are not present, replace the motor board. verify continuity of each directional valve wire and verify wiring connections (see Electrical Diagrams manual ). if motor board and wiring are not the cause, replace the directional valve. For diagnostic purposes, it is possible to manually override the directional valve by using a small screwdriver to depress the button in the center of either directional valve end cap. Depressing the button in the right end cap should cause the pump to travel to the right. Depressing the left button should cause the pump to travel to the left. 3. If you have determined that the cause is none of the above, check for a loose piston packing retaining bolt. This causes the piston to contact the inner face of the pump inlet flange before the activator plate contacts the rocker arm. Shut down the unit and disassemble the appropriate pump for repair R 27

28 Repair Repair 5. Turn PRESSURE RELIEF/SPRAY valves (SA, SB) Repairing this equipment requires access to parts that may cause electric shock or other serious injury if work is not performed properly. Have a qualified electrician connect power and ground to main power switch terminals, see operation manual. Be sure to shut off all power to the equipment before repairing. Pressure Relief Procedure to PRESSURE RELIEF/CIRCULATION. Route fluid to waste containers or supply tanks. Ensure gauges drop to 0. SA SB ti9879a 1. Relieve pressure in gun and perform gun shutdown procedure. See gun manual. 6. Disconnect gun air line and remove gun fluid manifold. 2. Engage gun piston safety lock. ti2409a 3. Close gun fluid manifold valves A and B. ti2554a ti2421a 4. Shut off feed pumps and agitator, if used R

29 Repair Flushing Proportioning Pumps Flush equipment only in a well-ventilated area. Do not spray flammable fluids. Do not turn on heaters while flushing with flammable solvents. Flush out old fluid with new fluid, or flush out old fluid with a compatible solvent before introducing new fluid. Use the lowest possible pressure when flushing. All fluid components are compatible with common solvents. Use only moisture-free solvents. To flush feed hoses, pumps, and heaters separately from heated hoses, set PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION lines (N). SA. Flush through bleed SB See manual for pump repair instructions. 1. Shut off,, and heat zones. 2. Flush, page If pumps are not parked, press. Trigger gun until pumps stop. 4. Turn main power OFF. Disconnect power supply. A B 5. Shut off both feed pumps. Close both fluid inlet ball valves (B). N ti9880a To flush entire system, circulate through gun fluid manifold (with manifold removed from gun). To prevent moisture from reacting with isocyanate, always leave the system dry or filled with a moisture-free plasticizer or oil. Do not use water. N 6. Turn both PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION. Route fluid to waste containers or supply tanks. Ensure gauges drop to 0. B ti9883a SA SB ti9879a R 29

30 Repair Use drop cloth or rags to protect Reactor and surrounding area from spills. 1 Torque to 200 in-lb (22.6 N m). 7. See FIG. 2. Disconnect the B (Resin) side pump inlet and outlet lines. Remove the pin (219) from the clevis (218) to disconnect the pump from the hydraulic cylinder (201). Remove the four screws (203) holding the pump to the spacers (413) of the cylinder. Take the pump assembly to a workbench Torque to 200 in-lb (22.6 N m) FIG. 3: Proportioning Pump - A Side 9. See manual for pump repair instructions. 10. Reconnect the pump in the reverse order. Torque the screws (203) to 200 in-lb (22.6 N m) ti9882a FIG. 2. Proportioning Pump - B Side 8. See FIG. 3. Disconnect the A (ISO) side pump inlet and outlet lines. Use the pin extractor tool (244) to remove the pin (219), which disconnects the pump from the hydraulic cylinder (201). Remove the four screws (203) holding the pump to the spacers (413) of the cylinder. Take the pump assembly to a workbench R

31 Repair Circuit Breaker Module 1. Turn main power OFF. Disconnect power supply. Turn circuit breakers on to test. 2. Relieve pressure, page Using an ohmmeter, check for continuity across circuit breaker (top to bottom). If no continuity, trip breaker, reset, and retest. If still no continuity, replace breaker as follows: Table 3: Circuit Breakers, see FIG. 4 Ref. Size Component A Hose/Transformer Secondary Side A Transformer Primary 812A 812B * Depending on model. 25A, 40A, or 50A* 25A, 40A, or 50A* Heater A Heater B A or 30A* Motor/Pumps a. Refer to electrical diagrams and to TABLE 3. Disconnect wires and remove bad breaker. b. Install new breaker and reconnect wires NOTE: To reference cables and connectors, see the electrical diagrams and the parts drawings on pages A 812B 813 ti9884a FIG. 4. Circuit Breaker Module R 31

32 Repair Electric Motor Removal 1. Turn main power OFF. Disconnect power supply. 2. Relieve pressure, page Remove motor shroud. 4. Disconnect motor cables as follows: a. Refer to electrical diagrams in the Reactor Electrical Diagram manual Motor control board is on right side inside cabinet, see page 33. Installation 1. Place motor on unit. 2. Fasten motor with screws. 3. Connect the wires, using wire nuts. Refer to the Reactor Electrical Diagram manual and the diagram inside the motor junction box cover. The motor must operate counterclockwise when looking at the output shaft. 3-Phase Motors: motor must rotate counterclockwise when viewed from shaft end. If rotation is incorrect, reverse power leads L1 and L2. See Reactor Operation manual , Connect Electrical Cord. 4. Return to service. b. Remove motor electric junction box cover. c. Make a note of or label the wire connections. Refer to the Reactor Electrical Diagram manual and the diagram inside the motor junction box cover. The motor must operate counterclockwise when looking at the output shaft. CAUTION Motor is heavy. Two people may be required to lift. 5. Remove screws holding motor to bracket. Lift motor off unit R

33 Repair Motor Control Board Motor control board has one red LED (D11). Power must be on to check. See FIG. 5 for location. Function is: Startup: 1 blink for 60 Hz, 2 blinks for 50 Hz. Motor running: LED on. Motor not running: LED off. Diagnostic code (motor not running): LED blinks diagnostic code, pauses, then repeats (for example, E21=21 blinks, pause, 21 blinks). CAUTION Before handling board, put on a static conductive wrist strap to protect against static discharge which can damage board. Follow instructions provided with wrist strap. 1. Turn main power OFF. Disconnect power supply. Table 4: DIP Switch (SW2) Settings DIP Switch ON (up) OFF (down) Switch 1 Switch 2 Motor soft start ON (factory default) ON for pressure imbalance alarm (factory default) Motor soft start OFF (Not applicable to 3-phase motors) OFF for pressure imbalance warning Switch 3 Standby ON Standby OFF (factory default) Switch 4 ON for Models H-25 and H-40 (system dependent) 9. Install new board in reverse order. Apply thermal heatsink compound to mating surfaces of board and heatsink. Order Part Thermal Compound. OFF for Models H-XP2 and H-XP3 (system dependent) Table 5: Motor Control Board Connectors Connector Pin Description 2. Relieve pressure, page Refer to electrical diagrams. Motor control board is on right side inside cabinet. 4. Put on static conductive wrist strap. 5. Disconnect all cables and connectors from board. 6. Remove nuts (40) and take entire motor control assembly to workbench. 7. Remove screws and take board off heatsink. 8. Set DIP switch (SW2) on new board. See TABLE 4 for factory settings. See FIG. 5 for location on board. To prevent overpressurization, DIP switch 2 must be set to ON for Model H-25. J1 n/a Main power J3 n/a Transducer A J4 n/a Not used J7 n/a Not used J8 n/a Transducer B J9 n/a Motor thermostat (NC) J10 n/a Not used J12 n/a Data reporting J13 n/a To display board J14 n/a Motor power J18 1 Directional valve, A+ 2 Directional valve, A- 3 Directional valve, B+ 4 Directional valve, B- 5 GND J5 1 Unused (VDD) 2 Pumpline reversing switch (COM) 3 Pumpline reversing switch (NC) 4 Pumpline reversing switch (NO) R 33

34 Repair Motor Control D11 J5 DIP Switch (SW2) Settings 1 Models H-25, H-40, H-50 ON Models H-XP2 & H-XP3 ON ti3178c-3 ON OFF J3 (A) J8 (B) J9 J ti3178c-4 SW2 1 Apply thermal heatsink compound to mating surfaces. J1 J14 J4 J18 J7 J13 ti7724a FIG. 5. Motor Control Board R

35 Repair Transducers 1. Turn main power OFF. Disconnect power supply. diagnostic code follows; see E21: No component A transducer, page If transducer fails test, thread cable through top of cabinet. Note path as cable must be replaced in same way. 6. Install o-ring (720) on new transducer (706), FIG Install transducer in manifold. Mark end of cable with tape (red=transducer A, blue=transducer B). 2. Relieve pressure, page Refer to electrical diagrams. Motor control board is on right side inside cabinet. 4. Disconnect transducer cables at board; see FIG. 5, page 34. Reverse A and B connections and check if 8. Route cable into cabinet and thread into bundle as before. 9. Connect transducer cable at board; see FIG. 5, page (A Side) 706 (B Side) ti9885a FIG. 6. Transducers Electric Fan 1. Turn main power OFF. Disconnect power supply. 5. Remove fan. 6. Install fan in reverse order. F 2. Relieve pressure, page Check fuses (F) at left of breaker module, FIG. 7. Replace if blown. If good, continue with step Refer to electrical diagrams. Disconnect fan wires from fuses (F). FIG. 7. Fan Fuses ti9884a R 35

36 Repair Temperature Control Module Table 6: Temperature Control Module Connections Connector Description A H DATA (A) Data reporting PIN 12 HOSE T/C P; FTS (purple) 11 HOSE T/C R; FTS (red) 10 HOSE T/C S; FTS (silver (unshielded bare wire)) 9 HEATER T/C B, Y; Thermocouple (yellow) SENSOR (B) 8 HEATER T/C B, R; Thermocouple (red) 7 Not used 6 HEATER T/C A, Y; Thermocouple (yellow) 5 HEATER T/C A, R; Thermocouple (red) 4, 3 OVERTEMPERATURE B; Overtemperature switch B 2, 1 OVERTEMPERATURE A; Overtemperature switch A DISPLAY (C) Display COMMUNICATION (D) Communication to power boards PROGRAM (E) Software programming BOOT (F) Software bootloader B C Right Side of Control Heater Module D E F G ti9875a ti9843a1 POWER/RELAY (G) Circuit board power input and contactor control output J Table 7: Temperature Power Module Connections Connector COMMUNICATION (H) POWER (J) Description Communication to control board Power to heater Bottom of Power Modules ti9843a4 FIG. 8: Temperature Control Module Connections R

37 Repair Test SCR Circuit 1. Test the SCR circuit in the on position: a. Make sure everything is connected, including the hose. b. Turn main power ON. Replacing Temperature Control Assembly Modules CAUTION Before handling assembly, put on a static conductive wrist strap to protect against static discharge which can damage assembly. Follow instructions provided with wrist strap. c. Adjust the hose heat setpoint above the ambient hose temperature. 1. Turn main power OFF. Disconnect power supply. d. Turn on heat zone by pressing. e. Hold down to view electrical current. Hose current should ramp up to 45A. If there is no hose current, see E03: No zone current, page 10. If hose current exceeds 45A, see E02: High zone current, page 10. If hose current stays several amps below 45A, hose is too long or voltage is too low. 2. Test the SCR circuit in the off position: a. Make sure everything is connected, including the hose. b. Turn main power ON. c. Adjust the hose heat setpoint below the ambient hose temperature. 2. Relieve pressure, page Refer to electrical diagrams; see Electrical Diagrams manual Temperature control assembly is on left side inside cabinet. 4. Remove bolts that secure transformer assembly and slide assembly to side in cabinet. 5. Put on static conductive wrist strap. 6. Disconnect all cables and connectors from assembly; see Parts - Temperature Control, page Remove nuts and take entire temperature control assembly to workbench. 8. Replace defective module. 9. Install assembly in reverse order. d. Turn on heat zone by pressing. e. Using a voltmeter, carefully measure the voltage at the hose connector. You should not get a voltage reading. If you do, the SCR on the temperature control board is bad. Replace the temperature control assembly R 37

38 Repair Primary Heaters Heater Element Line Voltage The primary heaters output their rated wattage at 230 Vac. Low line voltage will reduce power available and the heaters will not perform at full capability. 1. Turn main power OFF. Disconnect power supply. 2. Relieve pressure, page Wait for heaters to cool. 4. Remove heater shroud. 5. See pages for illustrations of each heater. Disconnect heater element wires from heater wire connector. Test with ohmmeter. Total Heater Wattage Element Ohms 6, , , , To remove heater element, first remove thermocouple (310) to avoid damage, see step 7, page Remove heater element (307) from housing (301). Be careful not to spill any fluid left in housing. 8. Inspect element. It should be relatively smooth and shiny. If there is a crusted, burnt, ash-like material adhered to element or sheath shows pitting marks, replace element. 9. Install new heater element (307), holding mixer (309) so it does not block thermocouple port (P). 10. Reinstall thermocouple, page Reconnect heater element leadwires to heater wire connector. 12. Replace heater shroud R

39 Repair Thermocouple 1. Turn main power OFF. Disconnect power supply. 2. Relieve pressure, page Replace thermocouple, FIG. 9. a. Remove protective tape from thermocouple tip (T). b. Apply PTFE tape and thread sealant to male threads and tighten thermocouple housing (H) into adapter (305). c. Push in thermocouple (310) so tip (T) contacts heater element (307). 3. Wait for heaters to cool. 4. Remove heater shroud. 5. Disconnect thermocouple wires from B on temperature control module. See TABLE 6, page 36 and FIG. 8, page Feed thermocouple wires out of cabinet. Note path as wires must be replaced in the same way. 7. See FIG. 9. Loosen ferrule nut (N). Remove thermocouple (310) from heater housing (301), then remove thermocouple housing (H). Do not remove the thermocouple adapter (305) unless necessary. If adapter must be removed, ensure that mixer (309) is out of the way when replacing the adapter. d. Holding thermocouple (T) against heater element, tighten ferrule nut (N) 1/4 turn past tight. 9. Route wires (S) into cabinet and thread into bundle as before. Reconnect wires to board. 10. Replace heater shroud. 11. Turn on heaters A and B simultaneously to test. Temperatures should rise at same rate. If one heater is low, loosen ferrule nut (N) and tighten thermocouple housing (H) to ensure thermocouple tip (T) contacts element (307). S 310 N 1 2 Apply PTFE tape and thread sealant. Apply thermal heatsink compound. H T 309 ti7924a FIG. 9. Thermocouple R 39

40 Repair Overtemperature Switch 1. Turn main power OFF. Disconnect power supply. 2. Relieve pressure, page Using an ohmmeter, check between the two terminals of the connector (D). There should be continuity. 5. If hose fails test, retest at each length of hose, including whip hose, until failure is isolated. Check FTS Cables 1. Turn main power OFF. Disconnect power 3. Wait for heaters to cool. 4. Remove heater shroud. 5. Disconnect one leadwire from overtemperature switch (308), FIG. 9. Test across switch with ohmmeter. Resistance must be approximately 0 ohms. 6. If switch fails test, remove wires and screws. Discard failed switch. Apply thermal compound , install new switch in same location on housing (301), and secure with screws (311). Reconnect wires. If wires need replacement, disconnect from temperature control board. See TABLE 6, page 36 and FIG. 8, page 36. Heated Hose Refer to the heated hose manual for hose replacement parts. Check Hose Connectors 1. Turn main power OFF. Disconnect power supply. supply. 2. Relieve pressure, page Disconnect FTS cable (F) at Reactor, FIG. 10. FIG. 10. Heated Hose 4. Test with ohmmeter between pins of cable connector. Pins F Result 1 to 2 approximately 35 ohms per 50 ft (15.2 m) of hose, plus approximately 10 ohms for FTS 1 to 3 infinity 5. If cable fails test, retest at FTS, page 41. D ti9878a 2. Relieve pressure, page 28. Whip hose must be connected. 3. Disconnect hose connector (D) at Reactor, FIG R

41 Repair Fluid Temperature Sensor (FTS) Test/Removal 1. Turn main power OFF. Disconnect power supply. 2. Relieve pressure, page Remove tape and protective covering from FTS (21), FIG. 10. Disconnect hose cable (F). Test with ohmmeter between pins of cable connector. Pins Result 1 to 2 approximately 10 ohms 1 to 3 infinity 3 to FTS groundscrew 0 ohms 1 to FTS component A fitting (ISO) infinity 4. If FTS fails any test, replace FTS. 5. Disconnect air hoses (C, L), and electrical connectors (D). 6. Disconnect FTS from whip hose (W) and fluid hoses (A, B). 7. Remove ground wire (K) from ground screw on underside of FTS. 8. Remove FTS probe (H) from component A (ISO) side of hose. Installation The Fluid Temperature Sensor (FTS) is supplied. Install FTS between main hose and whip hose. See Heated Hose manual for instructions. D B K A W ISO B A H C L ti9581c FIG. 11: Fluid Temperature Sensor and Heated Hoses R 41

42 Repair Transformer Primary Check 1. Turn main power OFF. 2. Locate the two smaller (10 AWG) wires coming out of transformer. Trace these wires back to contactor and circuit breaker (811). Use an ohmmeter to test for continuity between two wires; there should be continuity. Transformer Secondary Check 1. Turn main power OFF. 2. Locate the two larger (6 AWG) wires coming out of transformer. Trace these wires back to large green connector under hose control module and circuit breaker (809). Use an ohmmeter to test for continuity between two wires; there should be continuity. If you are not sure which wire in green plug under hose module connects to transformer, test both wires. One wire should have continuity with the other transformer wire in breaker (809) and the other wire should not. 3. To verify transformer voltage, turn on hose zone. Measure voltage from 18CB-2 to POD-HOSE-P15-2; see Reactor Electrical Diagrams manual * For 230 Vac line voltage. Replace Transformer 1. Turn main power OFF. Disconnect power supply. Model 2. Open Reactor cabinet. Secondary Voltage 310 ft. 90 Vac* 410 ft. 120 Vac* Use this procedure to replace transformer. 3. Remove bolts holding transformer to cabinet floor. Slide transformer forward. 4. Disconnect the transformer wires; see Reactor Electrical Diagrams manual Remove transformer from cabinet. 6. Install new transformer in reverse order FIG. 12: Circuit Breaker Module R

43 Repair Display Module Temperature and Pressure Displays CAUTION Before handling board, put on a static conductive wrist strap to protect against static discharge which can damage board. Follow instructions provided with wrist strap. between cable bushing and cover (504) with screws (512). Red Stop Button CAUTION Before handling board, put on a static conductive wrist strap to protect against static discharge which can damage board. Follow instructions provided with wrist strap. 1. Turn main power OFF. Disconnect power supply. 1. Turn main power OFF. Disconnect power supply. 2. Relieve pressure, page Refer to electrical diagrams. 2. Relieve pressure, page Refer to electrical diagrams. 4. Put on static conductive wrist strap. 5. Disconnect main display cable (20) at lower left corner of display module; see FIG Remove screws (509, 510) and cover (504); see FIG. 13. If replacing both displays, label temperature display cables TEMP and pressure display cables PUMP before disconnecting. 4. Put on static conductive wrist strap. 5. Remove screws (509, 510) and cover (504), FIG Disconnect button cable connectors (506) from back of temperature display (501) and pressure display (502). 7. Remove red stop button (506). 8. Reassemble in reverse order. Be sure display cable ground wire (G) is secured between cable bushing and cover (504) with screws (512). 7. Disconnect cable connectors (506 and 511) from back of temperature display (501) or pressure display (502); see FIG Disconnect ribbon cable(s) (R) from back of display; see FIG Remove nuts (508) and plate (505). 10. Disassemble display, see detail in FIG Replace board (501a or 502a) or membrane switch (501b or 502b) as necessary. 12. Reassemble in reverse order, see FIG. 13. Apply medium strength thread sealant where shown. Be sure display cable ground wire (G) is secured R 43

44 Repair 1 Apply medium strength thread sealant. 511 G ti2574a Detail of Membrane Switches and Display Boards Temperature Display 1 502c Pressure Display 502a 502b 501c 1 501a R R 501b ti3172a FIG. 13. Display Module R

45 Repair Inlet Fluid Strainer Screen The inlet strainer at each proportioning pump filters out solid matter that can plug the inlet check valves. Inspect the screens daily as part of the startup routine, and clean as required. Isocyanate can crystallize from moisture contamination or from freezing. If the chemicals used are clean and proper storage, transfer, and operating procedures are followed, there should be minimal contamination of the A-side screen. Clean the A-side screen only during daily startup. This minimizes moisture contamination by immediately flushing out any isocyanate residue at the start of dispensing operations. 1. Close the material supply valve at the pump inlet to prevent material from being pumped while the strainer plug (59j) is removed. FIG. 14. Y Strainer Components * Fluid filter screen (59g) replacements: Part Description mesh (standard); 1 pack mesh (optional); 2 pack mesh (optional); 10 pack 59g* 59h 59j 59k Pump Lubrication System ti9886a 2. Place a container under the strainer base to catch drain off when removing the strainer plug. 3. Remove the screen (59g) from the strainer manifold. Thoroughly flush the screen with gun cleaner and shake it dry. Inspect the screen for blockage. No more than 25% of the mesh should be restricted. If more than 25% is blocked, replace the screen. Inspect the strainer gasket (59h) and replace as required. 4. Ensure the pipe plug (59k) is securely screwed into the strainer plug (59j). Install the strainer plug with the screen (59g) and gasket (59h) in place and tighten. Do not overtighten. Let the gasket make the seal. 5. Open the material supply valve, ensure that there are no leaks, and wipe the equipment clean. 6. Proceed with operation. Check the condition of the ISO pump lubricant daily. Change the lubricant if it becomes a gel, its color darkens, or it becomes diluted with isocyanate. Gel formation is due to moisture absorption by the pump lubricant. The interval between changes depends on the environment in which the equipment is operating. The pump lubrication system minimizes exposure to moisture, but some contamination is still possible. Lubricant discoloration is due to continual seepage of small amounts of isocyanate past the pump packings during operation. If the packings are operating properly, lubricant replacement due to discoloration should not be necessary more often than every 3 or 4 weeks. To change pump lubricant: 1. Relieve pressure, page Lift the lubricant reservoir (LR) out of the bracket (RB) and remove the container from the cap. Holding the cap over a suitable container, remove the check valve and allow the lubricant to drain. Reattach the check valve to the inlet hose. See FIG R 45

46 Repair 3. Drain the reservoir and rinse with clean lubricant. 4. When the reservoir is clean, fill with fresh lubricant. Change Hydraulic Fluid and Filter 5. Thread the reservoir onto the cap assembly and place it into the bracket. 6. Push the larger diameter supply tube (ST) approximately 1/3 of the way into the reservoir. 7. Push the smaller diameter return tube (RT) into the reservoir until it reaches the bottom. Important: The return tube (RT) must reach the bottom of the reservoir, to ensure that isocyanate crystals will settle to the bottom and not be siphoned into the supply tube (ST) and returned to the pump. 8. The lubrication system is ready for operation. No priming is required. RT LR ST RB See Table 8 for recommended frequency of oil changes. Change break-in oil in a new unit after first 250 hours of operation or within 3 months, whichever comes first. Ambient Temperature 0 to 90 F (-17 to 32 C) Table 8: Frequency of Oil Changes 90 F and above (32 C and above) Recommended Frequency 1. Relieve pressure, page Allow hydraulic fluid to cool hours or 12 months, whichever comes first 500 hours or 6 months, whichever comes first 3. Place a pan under reservoir drain plug (110k) to catch oil. ti9911a 135 ST RT FIG. 16: Change Hydraulic Fluid and Filter ti9888a 110k LR ti9887a 4. Remove drain plug (110k). FIG. 15. Pump Lubrication System R

47 Repair 5. Place a rag around base of oil filter (135) to prevent oil from spilling. Unscrew filter 1/4-3/4 turn to break air lock in filter. Wait five minutes to allow oil in filter to drain back into reservoir. Unscrew filter and remove. 6. Reinstall drain plug (110k). 7. Replace filter (135): a. Coat filter seal with fresh oil. b. Screw filter on snug, then an additional 1/4 turn. 8. Refill reservoir with approved hydraulic fluid. See Table Proceed with normal operation. Upon starting motor, hydraulic pump may make a screeching noise until primed. If this noise continues for more than 30 seconds, switch off motor control. See Hydraulic Drive System, page 22. Table 9: Approved Anti-Wear (AW) Hydraulic Oils Supplier Name Citgo A/W ISO Grade 46 Amsoil AWI ISO Grade 46 (synthetic*) BP Oil International Energol HLP-HM, ISO Grade 46 Carl Bechem GmbH Staroil HVI 46 Castrol Hyspin AWS 46 Chevron Rykon AW, ISO 46 Exxon Humble Hydraulic H, ISO Grade 46 Mobil Mobil DTE 25, ISO Grade 46 Shell Shell Tellus, ISO Grade 46 Texaco Texaco AW Hydraulic, ISO Grade 46 * Note: Do not mix mineral-based and synthetic hydraulic oils. Completely drain oil from reservoir and pump prior to converting between oils. If the approved oils are not available in your area, use an alternative hydraulic oil meeting the following requirements: Oil Type: Anti-Wear (AW) Hydraulic ISO Grade: Viscosity, cst at 40 C: Viscosity, cst at 100 C: Viscosity Index: or higher Pour Point, ASTM D 97: F (-26 C) or lower Other essential properties: formulated for anti-wear, anti-foaming, oxidation stability, corrosion protection, and water separation R 47

48 Parts Parts See page See page 51 See page See page See page See pages ti9831a R

49 Parts Detail of Cabinet Area kw Heater Bracket (Ref. 36) Shown See page 50 25, TI9834a R 49

50 Parts Left Side of Cabinet , (Ref) 39 TI9835a 103 (Ref) Right Side of Cabinet TI9836a R

51 Parts Detail, Fluid Manifold Area , see page (Ref) (Ref) TI9838a Detail, Proportioner Area (Ref) , see page 53 See page , see page 53 TI9833a R 51

52 Parts Detail, Electric Motor Area (Ref) 118 (Ref) ti7709a Detail, Hydraulic Reservoir Area (Ref) , (Ref) , See page 53 See page (Ref) TI9832b R

53 Parts Ref. 59, Fluid Inlet Kit 59e A Side 59f 59n 60 59j 59a 59p 34 59g 59h 59d 59c 59n 59b 59p 59m 59d 59c 59b B Side 59k 59h 59e TI9841a 59f 59j 60 59k NOTE: Fluid Inlet Kit (59) has two versions: Series A and Series B. Fluid Inlet Kit Series A uses a flat gasket (59h) and can be identified by a white seal. The gasket material has been upgraded for improved sealing and is now a light gray color. Fluid Inlet Kit Series B, shown above, uses an o-ring seal (59h) with a different manifold (59d) and strainer plug (59j). The seal is not visible when fully assembled a 59g 59a Ref. 110, Hydraulic Reservoir f 110m 110b 110c 110d ti9840a 110j 110k R 53

54 Parts Parts Used on All Models Ref Part Description Qty. 2 HEATER; see page 56 for part 2 numbers 3 MOTOR; see page 56 for part numbers DISPLAY; page CONTROL, temperature; see page 1 66 for part numbers 6 BOARD, circuit, motor control; see 1 page 56 for part numbers MANIFOLD, fluid; page TRANSFORMER; see page 56 for 1 part numbers COVER, motor COVER, main cabinet 1 11 PUMP, proportioning; see page 56 1 for part numbers FAN, cooling 1 14 TUBE, inlet, component A; see 1 page 56 for part numbers 15 TUBE, outlet, component A; see 1 page 56 for part numbers 16 TUBE, inlet, component B; see 1 page 56 for part numbers 17 TUBE, outlet, component B; see 1 page 56 for part numbers CABLE, harness, heater overtemp., 1 includes 12-pin connector 19 15B380 CABLE, hose, control; see manual B383 CABLE, display KIT, fluid temp sensor, coupler WASHER, lock ext B360 GASKET, fan STRAIN RELIEF, M40 thread 1 26 MODULE; see page 56 for part 1 numbers SPACER TERMINAL, ground 1 30 C19843 SCREW, CAP, socket hd SWITCH, disconnect KNOB, operator disconnect SCREW, mach, slotted hd 4 34 C20487 NIPPLE, hex 2 35 COVER, heater wire; see page 56 2 for part numbers 36 BRACKET, heater; see page 56 for 2 part numbers INSULATOR, heat NUT, cap (3/8-16) SCREW, flanged, hex hd NUT, hex, flange head K817 LABEL, fault codes 1 44 RIVET, pop; 3/16 in. (5 mm) x 0.4 in. (10 mm) 8 Ref Part Description Qty LABEL, caution BRACKET, reservoir, lube PULLEY, drive BELT B593 SHIELD, membrane switch PAD, pamphlet safety B775 COVER, wire access 1 52 COVER, heater; see page 56 for 2 part numbers 53 SCREW, machine, pan hd; 8-32 x 3/ G280 LABEL, warning NUT, KEPS, hex hd WASHER, plain SCREW, hex hd, flanged 8 58 STRAP, tie, wire FLUID INLET KIT; see page a UNION, swivel; 3/4 npt(m) x 3/4 3 npsm(f) 59b VALVE, ball; 3/4 npt (fbe) 2 59c C NIPPLE; 3/4 npt 2 59d. MANIFOLD, strainer, inlet (Fluid Inlet Kit Series A) 2 16W714. MANIFOLD, strainer, inlet (Fluid 2 Inlet Kit Series B) 59e THERMOMETER, dial 2 59f GAUGE, pressure, fluid 2 59g ELEMENT, filter; 20 mesh (standard) 2 59h 15H200. GASKET, strainer; PTFE (Fluid 2 Inlet Kit Series A) C GASKET, strainer; PTFE (Fluid Inlet Kit Series B) 2 59j 15H199. PLUG, strainer (Fluid Inlet Kit Series A) 2 16V879. PLUG, strainer (Fluid Inlet Kit 2 Series B) 59k PLUG, pipe; 3/8 npt (Fluid Inlet Kit 2 Series A) PLUG, pipe; 1/4 npt (Fluid Inlet Kit Series B) 2 59m UNION, swivel; 3/4 npt(m) x 1/2 1 npt(f); A side only 59n 15D757. HOUSING, thermometer 2 59p GUARD, gauge SCREW, cap, hex hd RESERVOIR, lube hose assy SPACER COVER, front H185 WIRE, mechanical switch cable; 1 see page CONNECTOR, 2 PIN, motor power; see page 56 for part numbers R

55 Parts Ref Part Description Qty GRILL, fan guard 1 68 SWITCH, added pole; see page 56 for part numbers THROAT SEAL LIQUID; 1 quart GUARD, finger CLIP, spring COUPLING, hose TUBE, PTFE; 1/4 in. (6 mm) ID; 8 ft 8 (2.4 m) 82 15H207 BRACKET, tensioner LABEL, caution GROMMET, rubber FITTING, reducer #5 x #8 JIC FITTING, reducer #6 x #10 JIC SCREW, cap, hex hd; 1/2-13 x 3/4 2 in. (19 mm) NUT, hex, flanged; 3/ T895 HOSE, supply TUBE, return ADJUSTER, belt, tensioner G816 COVER, plate, wire way CASTER PLUG, tube LABEL; see page 56 for part numbers H189 BOOT, wire feed through CONDUIT, assembly, motor power; 1 see page 56 for part numbers SUPPRESSOR, ferrite; 151 ohm RESERVOIR, hydraulic; includes 1 110b-110m; see page b HOUSING, inlet 1 110c GASKET, inlet 1 110d TUBE, inlet 1 110f TUBE, return 1 110j FILTER, inlet 1 110k PLUG 1 110m FITTING, straight BRACKET, motor mount BRACKET, mounting, pump H-40, H-50, H-XP3 models only H-25, H-XP2 models only 113 PUMP, hydraulic H-40, H-50, H-XP3 models only H-25, H-XP2 models only BRACKET, reservoir, hydraulic BRACKET, support, pumpmount COOLER, hydraulic ELBOW; 1-1/16 npt(m) x 1/2 in. (13 1 mm) tube H-40, H-50, H-XP3 models only H-25, H-XP2 models only 118 PULLEY, fan H-40, H-50, H-XP3 models only H-25, H-XP2 models only H512 LABEL, control H204 KNOB, pressure SCREW, set, socket hd 1 Ref Part Description Qty HOSE, inlet, coupled GAUGE, pressure, fluid, panel 1 mount 127 ELBOW H-40, H-50, H-XP3 models only H-25, H-XP2 models only ELBOW, male GUN, grease GREASE, lubricant G782 HOSE, coupled G784 HOSE, coupled DIPSTICK with breather cap FILTER, oil,18-23 psi bypass FITTING H-40, H-50, H-XP3 models only H-25, H-XP2 models only SCREW, cap socket head FITTING, npt (part of hydraulic 1 pump assembly); H-25, H-XP2 models only SCREW (part of hydraulic pump assembly); H-25, H-XP2 models only SCREW, cap, hex hd NUT, hex, flange hd; 5/ C19862 NUT, lock, hex COVER, access NUT, strain relief, M40 thread CONNECTOR, heater SCREW, set; 1/4 x 1/2 (13 mm) CONNECTOR, wire, 6 AWG (pair) WASHER, thrust 2 Replacement Danger and Warning labels, tags, and cards are available at no cost. Not shown. Required for all A-D series models. Included in Knob Repair Kit (purchase separately). Fluid Inlet Kit (59) has two versions: Series A and Series B. Fluid Inlet Kit Series A uses a flat gasket (59h) and can be identified by a white seal. The gasket material has been upgraded for improved sealing and is now a light gray color. Fluid Inlet Kit Series B, shown on page 53, uses an o-ring seal (59h) with a different manifold (59d) and strainer plug (59j). The seal is not visible when fully assembled. Included in Strainer Manifold Kit Series A manifold is not available. Order replacement kit R 55

56 Parts Parts that Vary by Model Use the following tables to find parts that vary by model. See Parts, starting on page 48 for parts used on all models. H-25 and H-XP2 Models Ref Description 2 HEATER; pages H kw (230V, 1 phase) (Qty. 1) H kw (230V, 3 phase) (Qty. 1) H kw (400V, 3 phase) (Qty. 1) H-XP kw (230V, 1 phase) (Qty. 2) H-XP kw (230V, 3 phase) (Qty. 2) H-XP kw (400V, 3 phase) (Qty. 2) H kw (230V, 1 phase) (Qty. 2) H kw (230V, 3 phase) (Qty. 2) H kw (400V, 3 phase) Qty (Qty. 2) 3 MOTOR; page BOARD, motor control; page 50 8 TRANSFORMER; page PUMP, proportioning; page TUBE, inlet, component A; page TUBE, outlet, component A; page TUBE, inlet, component B; page TUBE, outlet, component B; page 51 Model 120 Model 120 Model 120 Model 80 Model 80 Model 80 Model 120 Model 120 Model R648 15R648 15R648 15R646 15R646 15R646 15R646 15R646 15R R649 15R649 15R649 15R645 15R645 15R645 15R645 15R645 15R R653 15R653 15R653 15R650 15R650 15R650 15R650 15R650 15R R651 15R651 15R651 15R644 15R644 15R644 15R644 15R644 15R MODULE, breaker; C A B C A B C A B 1 page COVER, heater wire 36 BRACKET, heater; page COVER, heater CONNECTOR, pin, motor power 68 SWITCH, added pole; 400V only LABEL 15H194 15H194 15H194 15H195 15H195 15H195 15H194 15H194 15H CONDUIT, assy, motor power R

57 Parts H-40 and H-XP3 Models Ref Description 2 HEATER; pages MOTOR; page 52 6 BOARD, motor control; page 50 8 TRANS- FORMER; page PUMP, proportioning; page TUBE, inlet, component A; page TUBE, outlet, component A; page TUBE, inlet, component B; page TUBE, outlet, component B; page MODULE, breaker; page COVER, heater wire 36 BRACKET, heater; page COVER, heater 66 CONNEC- TOR, 2-pin, motor power H kw (230V, 1 phase) H kw (230V, 3 phase) H kw (400V, 3 phase) H-XP kw (230V, 1 phase) H-XP kw (230V, 3 phase) H-XP kw (400V, 3 phase) H kw (230V, 3 phase) H kw (400V, 3 phase) Qty Model 120 Model 120 Model 120 Model 80 Model 80 Model 80 Model 120 Model R646 15R646 15R646 15R646 15R646 15R646 15R646 15R R645 15R645 15R645 15R645 15R645 15R645 15R645 15R R650 15R650 15R650 15R650 15R650 15R650 15R650 15R R644 15R644 15R644 15R644 15R644 15R644 15R644 15R644 1 C D E C D E D E SWITCH, added pole; 400V only LABEL CONDUIT, assy, motor power R 57

58 Parts H-50 Models Ref Description 2 HEATER; pages H kw (230V, 1 phase) H kw (230V, 3 phase) H kw (400V, 3 phase) H kw (230V, 3 phase) H kw (400V, 3 phase) MOTOR; page BOARD, motor control; page 50 8 TRANSFORMER; page PUMP, Model 140 Model 140 Model 140 Model 140 Model proportioning; page TUBE, inlet, component A; page 51 15R646 15R646 15R646 15R646 15R TUBE, outlet, component A; page TUBE, inlet, component B; page TUBE, outlet, component B; page MODULE, breaker; page COVER, heater wire 15R645 15R645 15R645 15R645 15R R650 15R650 15R650 15R650 15R R644 15R644 15R644 15R644 15R644 1 C D E D E BRACKET, heater; page COVER, heater CONNECTOR, pin, motor power 68 SWITCH, added pole; 400V only 100 LABEL CONDUIT, assy, motor power Qty R

59 Parts Sub Assemblies Proportioner Assembly , see page , see manual TI9837b Torque to ft-lb ( N m) R 59

60 Parts Proportioner Assembly Ref Part Description Qty CYLINDER, hydraulic, w/spacers; 1 see page 64 for parts 202 PUMP; see manual SCREW, socket hd; 5/16-24 x 3 in. 8 (76 mm) O-RING MANIFOLD, hydraulic SCREW, socket hd VALVE, directional, hydraulic C19986 SCREW, socket hd BRACKET, mounting SWITCH, reversing WASHER, lock SCREW, pan hd; 8-32 x 3/ WASHER, lock SCREW, socket hd ADAPTER HOUSING, rupture, disc; kit, see manual M70430 SCREW, socket hd; 1/4-28 x CLEVIS, hex PIN, clevis KIT, activator and bushing ELBOW, 90 degree 1 Ref Part Description Qty BUSHING H524 ACCUMULATOR, pressure;1/4 npt FITTING, union, swivel, 90 degrees ELBOW; 3/4 SAE-ORB x 1/2 in. JIC PLUG, pipe, flush O-RING NUT ADAPTER, lube, cylinder O-RING CYLINDER, lube PLUG; 3/8 mpt x in ELBOW, 90 degree; 1/4 npt(m) x 1 3/8 in. (9.5 mm) OD tube ELBOW; 3/4 npt(m) x 1/2 in. (13 1 mm) OD tube FITTING, grease; 1/ ELBOW; 3/4 npt(f) CONNECTOR H184 WIRE, bidirectional cable assy H253 HOSE, gauge, hydraulic, 3000 psi; shown on page TOOL, clevis pin, extractor 1 Not shown. Parts available in Kit R

61 Parts 10.2 kw and 6.0 kw Heaters (Two Per Machine) Parts and r_247833_ Apply thermal heatsink compound. Ref Part Description Qty. 301 HOUSING, heater ADAPTER, 3/4 SAE-ORB x 1/2 in. JIC H304 PLUG H306 ADAPTER, thermocouple O-RING; fluoroelastomer HEATER, immersion 4 16A W; 10.4 kw heater only 16A W; 6.0 kw heater only B137 SWITCH, overtemperature B135 MIXER, immersion heater 4 Ref Part Description Qty SENSOR SCREW, machine, pan hd H305 PLUG, hollow PLUG; not shown O-RING R 61

62 Parts 8.0 kw Dual Zone Heater (One Per Machine) Part r_247815_ Apply thermal heatsink compound. 307 Ref. Part Description Qty. 301 HOUSING, heater H302 FITTING, reducer ADAPTER, 1/2 npt(m) x 1/2 in. JIC H304 PLUG H306 ADAPTER, thermocouple O-RING; fluoroelastomer A111 HEATER, immersion; 2000 W B137 SWITCH, over temperature 1 Ref. Part Description Qty B135 MIXER, immersion heater SENSOR SCREW, machine, pan hd M177 INSULATION; not shown O-RING R

63 Parts 7.65 kw Single Zone Heater (Two Per Machine) Part r_247813_ Apply thermal heatsink compound. Ref. Part Description Qty 301 HOUSING, heater ADAPTER, 3/4 SAE-ORB x 1/2 in. JIC H304 PLUG H306 ADAPTER, thermocouple O-RING; fluoroelastomer B138 HEATER, immersion; 2550 W B137 SWITCH, overtemperature B135 MIXER, immersion heater 3 Ref. Part Description Qty SENSOR SCREW, machine, pan hd H305 PLUG, hollow PLUG; not shown O-RING R 63

64 Parts Hydraulic Cylinder 411 Rod Bushing Detail See Rod Bushing Detail Piston Detail ti7727a Ref. Part Description Qty PLATE, retainer CYLINDER BUSHING, rod PISTON O-RING U-CUP RING, backup RING, wear 1 Ref. Part Description Qty O-RING RING, backup WIPER, rod SEAL, shaft SPACER, proportioning pump SPACER, reverse switch ROD, tie BLOCK, port R

65 Parts Display (Ref) ti2574a 502a 502c 502b 501c 501a 501b ti3172a Ref. Part Description Qty G884 DISPLAY, pressure; includes 1 501a-501c 501a 24G882.BOARD, circuit 1 501b SWITCH, membrane 1 501c SCREW G883 DISPLAY, temperature; includes 1 502a-502c 502a 24G882.BOARD, circuit 1 502b SWITCH, membrane 1 502c SCREW B293 GASKET B292 COVER 1 Ref. Part Description Qty B291 PLATE HARNESS, wire, red stop button HANDLE NUT, cap; SCREW, machine, pan-hd; M5 x 4 0.8; 16 mm B386 CABLE, display SCREW, machine; M2.5 x R 65

66 Parts Temperature Control To B Heater Module To A Heater Module To Hose Heater Module TI9843a Ref. Part Description Qty PANEL, module mounting HOUSING, control module HOUSING, heater module NUT, hex CABLE, communication KIT, cover, connector with screws R