Page 2 - Contents
2 3A1570A Contents Proportioner Models . . . . . . . . . . . . . . . . . . . . . . . . 3 Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 3 - Proportioner Models; Systems
Proportioner Models 3A1570A 3 Proportioner Models All proportioners can be configured to operate on 380V (4 wire), 230V (3 wire), or 230V 1Ø. Only available in Asia. Systems All systems include a proportioner, spray gun, and 60 ft (18.3 m) of heated hose. Related Manuals Manuals are available at w...
Page 4 - Warnings; WARNING
Warnings 4 3A1570A Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manua...
Page 7 - Important Two-Component Material Information; Isocyanate Conditions
Important Two-Component Material Information 3A1570A 7 Important Two-Component Material Information Isocyanate Conditions Material Self-ignition Keep Components A and B Separate Moisture Sensitivity of Isocyanates Isocyanates (ISO) are catalysts used in two component foam and polyurea coatings. ISO ...
Page 8 - Changing Materials
Important Two-Component Material Information 8 3A1570A Changing Materials Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime. • When changing materials, flush the equipment mul-tiple times to ensure it is thoroughly clean. • Always cl...
Page 9 - DataTrak Diagnostic Codes
Important Two-Component Material Information 3A1570A 9 DataTrak Diagnostic Codes DataTrak can diagnose several problems with the pump. When the monitor detects a problem, the LED will flash and a diagnostic code will appear on the display. To acknowledge the diagnosis and return to the normal operat...
Page 10 - E01: High fluid temperature; Causes of E01 Errors
Important Two-Component Material Information 10 3A1570A E01: High fluid temperature Causes of E01 Errors • Thermocouple A or B (361) senses a fluid tempera-ture above 230°F (110°C). • Fluid temperature sensor (FTS) senses a fluid tem-perature above 230°F (110°C). • Overtemperature switch (359) sense...
Page 11 - E02: High zone current
Important Two-Component Material Information 3A1570A 11 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 ohmme-ter, see page 28. E02: High zone current 1. Turn main power OFF . 2. Relieve pressure, page 13. NOTE: Di...
Page 12 - E99: Loss of communication
Important Two-Component Material Information 12 3A1570A E05: Control board over temperature NOTE: Each module has an on-board temperature sen-sor. 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...
Page 13 - Before Beginning Repair; Shutdown
Before Beginning Repair 3A1570A 13 Before Beginning Repair 1. Flush if necessary. See Flushing, page 14. 2. Turn main heater power OFF . 3. Relieve pressure. See Pressure Relief Procedure. Pressure Relief Procedure The Fusion AP gun is shown. 1. Turn off feed pumps and agitator if used. 2. Park comp...
Page 14 - Park; Flushing
Park 14 3A1570A Park Park the pumps at the end of the day to cycle compo-nent A pump to home position, submerging displace-ment rod. 1. Open the park valve. 2. Trigger the gun until pumps stops at the bottom and relieves pressure. 3. Close the air motor shutoff valve. 4. Close the park valve. Flushi...
Page 15 - Troubleshooting; Problems
Troubleshooting 3A1570A 15 Troubleshooting Before performing any troubleshooting procedures: 1. Relieve pressure, page 13. 2. Turn main power OFF . 3. Allow equipment to cool. Problems Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Also, determine th...
Page 17 - Electronics
Troubleshooting 3A1570A 17 Electronics Fluid pressures not balanced between A and B side Fluid viscosities not equal Adjust A and B temperature settings to balance viscosity. Sometimes nor-mal if pressure offset is below 200 psi (14 bar) Preheat material in drums by recircu-lating; see Operation man...
Page 19 - Heater
Troubleshooting 3A1570A 19 Heater PROBLEM CAUSE SOLUTION Primary heater(s) does not heat. Heat turned off. Press or zone keys. Temperature control alarm. Check temperature display for diag-nostic code, page 9. Signal failure from thermocouple. See E04: Fluid Temperature Sen-sor (FTS) or thermocouple...
Page 20 - Hose Heat System
Troubleshooting 20 3A1570A Hose Heat System PROBLEM CAUSE SOLUTION Hose heats but heats slower than usual or it does not reach tempera-ture. Ambient temperature is too cold. Use auxiliary hose heat system. FTS failed or not installed correctly. Check FTS, page 11. Low supply voltage. Verify line vol...
Page 22 - Repair; Disconnect Pump
Repair 22 3A1570A Repair Disconnect Pump NOTE: See manual 309577 for pump repair instructions. 1. Turn main heater power OFF . 2. Follow Flushing, page 14. 3. Follow Pressure Relief Procedure, page 13. 4. Follow Park instructions, page 14. 5. Shut off both feed pumps and close both inlet supply valv...
Page 23 - Connect Pump
Repair 3A1570A 23 11. Push retaining wire clip (307) up. Push retaining pin (306) out. 12. Loosen lock nut (302) by hitting firmly with a non-sparking hammer. 13. Unscrew pump out of pump mounting plate (301). 14. See pump manual for repair procedures and replacement parts. Connect Pump 1. Ensure lo...
Page 24 - Remove Air Motor; Install Air Motor
Repair 24 3A1570A Remove Air Motor 1. Press in tube fitting ferrules and pull out tubing (65) to disconnect air line. 2. Disconnect DataTrak communication cable, if installed. 3. Place wrench on adapter (315) and a another wrench on lock nut (313). Remove lock nut (313). 4. Remove four nuts (310) fr...
Page 25 - Air Filter Element Removal; Air Filter Element Installation
Repair 3A1570A 25 Recirculation / Over Pressure Relief Block Valves can be serviced with the block on the machine (see page 46 for par ts view). For thorough cleaning, remove the block assembly as follows. 1. Disconnect two fluid tubes connected to back of recirculation block (3). 2. Loosen and remo...
Page 26 - Temperature Control Module
Repair 26 3A1570A Temperature Control Module Table 2: Temperature Control Module Connections Connector Description DATA (A) Data reporting SENSOR (B) PIN HOSE T/C P; FTS (purple) 12 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) 8...
Page 27 - Test SCR Circuit
Repair 3A1570A 27 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 . c. Adjust the hose heat setpoint above the ambi- ent hose temperature. d. Turn on heat zone by pressing . e. Hold down to view electrical c...
Page 28 - Primary Heater; Heater Element; Line Voltage
Repair 28 3A1570A Primary Heater Heater Element 1. Turn main power OFF . Disconnect power supply. 2. Relieve pressure, page 13. 3. Wait for heaters to cool. 4. Remove heater shroud. 5. See F IG . 7. Disconnect heater element wires from heater wire connector. Test with ohmmeter. 6. To remove heater e...
Page 30 - Thermocouple
Repair 30 3A1570A Thermocouple 1. Turn main power OFF . Disconnect power supply. 2. Relieve pressure, page 13. 3. Wait for heaters to cool. 4. Remove heater shroud. 5. Disconnect thermocouple wires from B on tempera-ture control module. See Table 2, page 26 and F IG . 6, page 26. 6. Feed thermocoupl...
Page 31 - Overtemperature Switch; Heated Hose; Check Hose Connectors; Check FTS Cables
Repair 3A1570A 31 Overtemperature Switch 1. Turn main power OFF . Disconnect power supply. 2. Relieve pressure, page 13. 3. Wait for heaters to cool. 4. Remove heater shroud. 5. Disconnect one leadwire from overtemperature switch (359), F IG . 8. Test across switch with ohmme- ter. Resistance must b...
Page 32 - Installation
Repair 32 3A1570A Fluid Temperature Sensor (FTS) Test/Removal 1. Turn main power OFF . Disconnect power supply. 2. Relieve pressure, page 13. 3. Remove tape and protective covering from FTS. Disconnect hose cable (F). Test with ohmmeter between pins of cable connector. 4. If FTS fails any test, repl...
Page 33 - Transformer Primary Check
Repair 3A1570A 33 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 (911). Use an ohmmeter to test for continuity between two wires; there should be continuity. Transformer Se...
Page 34 - Replace Circuit Breaker Module
Repair 34 3A1570A Replace Circuit Breaker Module 1. Turn main power OFF . Disconnect power supply. Turn circuit breakers on to test. 2. Relieve pressure, page 13. 3. Using an ohmmeter, check for continuity across cir-cuit breaker (top to bottom). If no continuity, trip breaker, reset, and retest. If...
Page 35 - Pump Lubrication System
Repair 3A1570A 35 Pump Lubrication System Check the condition of the ISO pump lubricant daily. Change the lubricant if it becomes a gel, its color dark-ens, or it becomes diluted with isocyanate. Gel formation is due to moisture absorption by the pump lubricant. The interval between changes depends ...
Page 36 - Fluid Inlet Strainer Screen
Repair 36 3A1570A Fluid Inlet Strainer Screen The inlet strainers filter out particles that can plug the pump 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...
Page 38 - Replace DataTrak Battery or Fuse; Replace Battery; Replace Fuse
Repair 38 3A1570A Replace DataTrak Battery or Fuse Replace Battery 1. Unscrew cable from the back of the reed switch assembly. See F IG . 16. 2. Remove the cable from the two cable clips. 3. Remove DataTrak module from bracket. See F IG . 17. Take module and attached cable to a non-haz-ardous locati...
Page 39 - Accessories
Accessories 3A1570A 39 Accessories Feed Pump Kits Pumps, hoses, and mounting hardware to supply fluids to Reactor. Includes 246483 Air Supply Kit. See 309815. 246483 Air Supply Kit Hoses and fittings to supply air to feed pumps, agitator, and gun air hose. Included in feed pump kits. See 309827. 246...
Page 40 - Parts
Parts 40 3A1570A Parts 262572, Bare Reactor A-25262614, Reactor A-25 with DataTrak and Wheels 35 56 (x4) 59 100 (x4) 38 83 62 16 18 10 51 4 20 3 20 14 (x4) 50 66 67 11 84 79 9 (x4) 8 7 15 15 85 26 13 19 17 89 91, 92 88 58 62 52 ti18023a 57 57 6 1 90 (x6) 11 (x6)
Page 45 - Temperature Control
Parts 3A1570A 45 Temperature Control Wheel Kit, 262695 † Only used with 262614. Available as add on wheel kit 262695. Ref. Part Description Qty. 151 16G925 PANEL, pod, mounting 1 152 247827 MODULE, heater control 1 153 247828 MODULE, heater 3 154 114183 NUT, hex, flanged, serrated 4 155 247801 CABLE...
Page 46 - Fluid Manifold
Parts 46 3A1570A Fluid Manifold Replacement Danger and Warning labels, tags, and cards are available at no cost. Fluid Inlet Kit, 262695 Ref. Part Description Qty. 201 24K993 MANIFOLD, recirculation 1 202 108638 FITTING, pipe, tee 2 203 162453 FITTING, (1/4 npsm x 1/4 npt) 2 204 113641 GAUGE, pres...
Page 49 - Air Tubing Connections
Parts 3A1570A 49 Air Tubing Connections Ref. Length ft (m) Connection Material Color Outside Diameter From To 64 0.75 ft (0.23 m) 503 503 UHMWPE Black 5/32 in. (4 mm) 65 2.66 ft (0.8 m) 501 501 Urethane Black 1/2 in. (12.7 mm) 65 1.66 ft (0.5 m) 502 502 Urethane Black 1/2 in. (12.7 mm) 65 0.75 ft (0...
Page 51 - Reactor A-25 Wiring Schematic
Reactor A-25 Wiring Schematic 3A1570A 51 Reactor A-25 Wiring Schematic N L2 L3 DSC 1-4 TB13-19 T1 T2 T3 L1 N 380V WYE 3 PHASE 230V DELTA 3 PHASE 230V 1 PHASE PE 2 BRIDGES L1 L2 L3 TB13-19 PE L2 TB13-19 L1 PE BRIDGE BRIDGE BRIDGE BRIDGE 170 171 172 173 174 175 176 177 178 179 179-1 179-2 179-3 179-4 ...
Page 53 - INCOMING POWER
Reactor A-25 Wiring Schematic 3A1570A 53 102GND 2 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 1 1 1 1 2 2 2 2 1 3 1 3 1 3 1 1 1 1 1 1 1 2 2 2 2 2 2 2 183CB 50A 178CB 30A 187CB 25A 197CB 25A 238CR 1 F U S E 1 2 1 F U S E 2 2 TB1-TB8 TB9-TB12 TB13-TB19 380V 3-PHASE 230V 3-PHASE 230V 1-PHASE INCOMING POWER (DISR...
Page 54 - Simplified Schematic, Heater Controls
Reactor A-25 Wiring Schematic 54 3A1570A TO OVERTEMP A TO THERMOCOUPLE A TO THERMOCOUPLE B TO FTS TO OPTIONAL DATA REPORTING TO HOSE THERMOCOUPLE A OVERTEMP A THERMOCOUPLE B CONTROL HEATER MODULE HOSE HEATER MODULE A HEATER MODULE B HEATER MODULE Simplified Schematic, Heater Controls POD HOSE 2 1 PO...
Page 55 - Technical Data
Technical Data 3A1570A 55 Technical Data *Full load amps with all devices operating at maximum capabilities with 210 ft (64.1 m) of hose. ***210 ft (64 m) of heated hose will produce the maximum allowable heat capacity. 310 ft (94 m) of heated hose may be used, but will have 25% less heat capacity. ...
Page 56 - Graco Standard Warranty
All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice. Original instructions. This manual contains English. MM 3A1750 Graco Headquarters: Minneapolis Int...
