Graco Reactor HT Series, Repair Parts

Page 1: ...gs Not for use in explosive atmospheres See page 3 for model information including maximum working pressure and approvals Important Safety Instructions Read all warnings and instructions in this manual Save these instructions TI11252a Model 259060 Shown 312408F EN For patent information see www graco com patents ...

Page 2: ... Reactor Electronics 10 Primary Heaters A and B 12 Hose Heat System 13 Repair 15 Pressure Relief Procedure 15 Flushing 16 Proportioning Pumps 17 Circuit Breaker Module 18 Electric Fan 18 Temperature Control Module 19 Primary Heaters 21 Heated Hose 23 Fluid Temperature Sensor FTS 24 Display Module 26 Parts 28 Air Powered Reactors 28 Air Powered Reactors 29 Heat Control Packages 30 10 2 kW and 6 0 k...

Page 3: ... 259062 A A XP2 400V 3 22 14 540 10 200 25 1 1 5 5 7 0 0193 0 73 3000 20 7 207 Part Series Model Voltage phase Full Load Peak Amps System Watts Heater Watts no hose Maximum Fluid Working Pressures psi MPa bar 259070 B HT 6 0 230V 1 44 10 340 6 000 3500 24 1 241 259071 B HT 6 0 230V 3 27 10 340 6 000 3500 24 1 241 259072 B HT 6 0 400V 3 18 10 340 6 000 3500 24 1 241 259073 B HT 10 2 230V 1 62 14 54...

Page 4: ...tioning Pump Part Description 308224 President Pump A XP2 Repair Parts Manual English Motor Part Description 306982 President Air Motor A XP2 Repair Parts Manual English Displacement Pump Part Description 307430 Displacement Pumps A XP2 Repair Parts Manual English Air Regulators Part Description 308168 Instruction Parts Manual English Feed Pump Kits Part Description 309815 Instruction Parts Manual...

Page 5: ...ntainers 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 hear ing loss This equipme...

Page 6: ...d 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 compatib...

Page 7: ...ter models only Jumper wire on J1 connector between module 3 and dis play 4 is loose or incorrectly wired Checks Check which zone is displaying the E01 error 1 Check that connector B is firmly plugged into tem perature control board see FIG 4 page 19 2 Clean and re plug connections 3 Check connections between the temperature control board and overtemperature switches A and B 308 and between temper...

Page 8: ...e two termi nals of the connector D There should be no conti nuity 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 25 E03 No zone current 1 Check for tripped circuit breaker inside electrical cabinet or at power so...

Page 9: ... tom of electrical cabinet 4 Clean heatsink fins behind heater control modules 5 Ambient temperature may be too high Allow Reac tor to cool by moving to a cooler location E06 Communication cable unplugged 1 Unplug and re plug cable that connects heater con trol module to heater module 2 Replace communication cable if problem persists Communication Diagnostic Code E99 Loss of communication Communic...

Page 10: ...luminate Display disconnected Check cable connections page 26 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 Erratic display display tu...

Page 11: ...able if is damaged Ribbon cable on display circuit board disconnected or broken Connect cable page 26 or replace Broken display button Replace page 26 Red stop button does not work Broken button fused contact Replace page 26 Loose wire Check connections page 26 Fan not working Blown fuse Verify with ohmmeter replace if nec essary page 26 Loose wire Check fan wire Defective fan Replace page 26 PROB...

Page 12: ...of primary heat is abnormal high temperature overshoots or E01 error occurs intermittently Dirty thermocouple connections Examine connection of thermocou ples 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 Thermocouple not contacting heater element Loosen ferrule nut N push in ther mocouple 310 so tip...

Page 13: ...g A and B setpoints too low Increase A and B setpoints Hose is designed to maintain temperature not to increase it Ambient temperature is too cold Increase A and B setpoints to increase fluid temperature and keep it steady Flow too high Use smaller mix chamber Decrease pressure Hose was not fully preheated Wait for hose to heat to correct tem perature before spraying Low supply voltage Verify line...

Page 14: ...oes not heat FTS failed or is not contacting correctly Check FTS page 24 FTS not installed correctly FTS should be installed close to end of hose in same environment as gun Verify FTS installation page 24 Temperature control alarm Check temperature display or diag nostic code page 24 Hoses near Reactor are warm but hoses downstream are cold Shorted connection or failed hose heating element With ho...

Page 15: ...RE RELIEF CIRCULATION Route fluid to waste containers or supply tanks Ensure gauges drop to 0 6 Disconnect gun air line and remove gun fluid mani fold 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 elec trician connect power and ground to main power switch terminals see operation manual Be s...

Page 16: ...parately from heated hoses set PRESSURE RELIEF SPRAY valves SA SB to PRESSURE RELIEF CIRCULATION Flush through bleed lines N 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 mois ture free plasticizer or oil Do not use water Flush equipment only in a well ventila...

Page 17: ...n power OFF Disconnect power supply 6 Disconnect hoses and fittings from fluid inlets C and outlets D See FIG 1 7 Remove pump See applicable manuals supplied 8 Reinstall in reverse order A B SA SB ti9880a See applicable pump and motor repair parts manu als Displacement pump E may be removed with out removing entire proportioning pump FIG 1 Pump Removal TI11252a C E 413 D D C E ...

Page 18: ...l Electric Fan 1 Turn main power OFF Disconnect power supply 2 Relieve pressure page 15 3 Check fuses F at left of breaker module FIG 3 Replace if blown If good continue with step 4 4 Refer to electrical diagrams Disconnect fan wires from fuses F 5 Remove fan 6 Install fan in reverse order Table 2 Circuit Breakers see FIG 2 Ref Size Component 809 50A Hose Transformer Secondary Side 811 40A Transfo...

Page 19: ...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 POWER RELAY G Circuit board power input and contactor control output Connector Description COMMUNICATION H Communication to co...

Page 20: ...Using a voltmeter carefully measure the voltage at the hose connector You should not get a volt age reading If you do the SCR on the tempera ture control board is bad Replace the temperature control assembly Replacing Temperature Control Assembly Modules 1 Turn main power OFF Disconnect power supply 2 Relieve pressure page 15 3 Refer to electrical diagrams see Electrical Dia grams manual 312409 Te...

Page 21: ...uld 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 22 11 Reconnect heater element leadwires to heater wire connector 12 Replace heater shroud Line Voltage The primary heaters output ...

Page 22: ...he adapter 8 Replace thermocouple FIG 6 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 d Holding thermocouple T against heater ele ment tighten ferrule nut N 1 4 turn past tight 9 Route wires S into cabinet and thread into bundle...

Page 23: ...nect hose connector D at Reactor FIG 7 4 Using an ohmmeter check between the two termi nals of the connector D There should be continu ity 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 supply 2 Relieve pressure page 15 3 Disconnect FTS cable F at Reactor FIG 7 4 Test with ohmmeter between pin...

Page 24: ...l connec tors 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 309572 for instructions Pins Result 1 to 2 approximately 10 ohms 1 to 3 infinity 3 to FTS...

Page 25: ...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 Dia grams manual 312409 For 230 Vac line voltage Replace Transformer 1 Turn main power OFF Disc...

Page 26: ...s secured between cable bushing and cover 504 with screws 512 Red Stop Button 1 Turn main power OFF Disconnect power supply 2 Relieve pressure page 15 3 Refer to electrical diagrams 4 Put on static conductive wrist strap 5 Remove screws 509 510 and cover 504 FIG 10 6 Disconnect button cable connectors 506 from back of temperature display 501 and pressure display 502 7 Remove red stop button 506 8 ...

Page 27: ... Module TI3703a 502 501 503 504 505 J1 507 508 510 511 512 506 TI3702aa 20 501 502b 502c 502a G 511 R Detail of Membrane Switches and Display Boards Temperature Display Pressure Display Apply medium strength thread sealant 1 1 1 1 J1 ...

Page 28: ...8 30 44 28 29 27 37 3 4 5 15 25 6 2 7 8 9 17 20 31 Detail of Cycle Counter Switch Ref 26 magnet is on back side of yoke Dimension from bottom of switch mounting plate 18 to top of tie plate must be 2 in 51 mm to maintain correct relationship between magnet 26 and switch 27 2 3 3 2 Model A XP2 Shown ...

Page 29: ...078 101078 2 11a ELEMENT 20 mesh not shown 180199 180199 180199 1 12 NIPPLE 3 4 npt C20487 C20487 C20487 2 13 UNION swivel 3 4 npt m x 3 4 npt f 157785 157785 157785 2 14 VALVE ball 3 4 npt fbe 109077 109077 109077 2 15 KIT air control see 308168 241661 241661 241661 1 16 NIPPLE 156849 156849 156849 2 17 ELBOW street 3 8 npt mxf 155699 155699 155699 2 18 PLATE mounting switch 15C256 15C256 15C256 ...

Page 30: ...F Heat Control Packages TI11251a TI11258 192 104 164 158 140 117 103 190 191 138 107 112 141 110 101 120 116 102 114 130 134 133 159 195 TI11261a 197 172 164 Frame Rail 170 196 165 Heater Block 149 148 160 157 127 151 ...

Page 31: ...Parts 312408F 31 Left Side of Cabinet Right Side of Cabinet 142 105 129 161 162 128 131 133 TI9835a TI11259a 141 193 400V unit only 108 123 ...

Page 32: ...Parts 32 312408F TI10962a Detail Fluid Manifold Area Detail Cabinet Area 189 199 141 187 116 107 Ref 114 112 135 142 186 119 TI11266a 148 138 106 57 113 109 126 161 125 124 103 ...

Page 33: ...1 126 15B360 GASKET fan 1 127 255047 BUSHING strain relief M40 thread 1 128 MODULE breaker see page 34 1 129 247782 SPACER 1 130 255037 FITTING elbow sae x npt 2 131 117666 TERMINAL ground 1 133 123969 SWITCH disconnect 1 134 123967 KNOB operator disconnect 1 135 117723 SCREW mach slotted hd 4 137 247791 WIRE hose harness 1 138 15M338 TUBE plastic 1 140 117623 NUT cap 3 8 16 4 141 113796 SCREW fla...

Page 34: ... heater outlet b 247918 247918 247918 247918 247918 247918 247915 247915 247915 1 128 BREAKER module see page 40 C A B C A B C A B 1 164 BOLT 113796 113796 113796 113796 113796 113796 2 113796 113796 113796 4 165 INSULATOR 167002 167002 167002 167002 167002 167002 2 167002 167002 167002 4 170 BOLT 100469 100469 100469 100469 100469 100469 2 100469 100469 100469 4 172 BRACKET heater 247523 247523 2...

Page 35: ...r 1 303 121309 ADAPTER 4 304 15H304 PLUG 2 305 15H306 ADAPTER thermocouple 2 306 120336 O RING fluoroelastomer 2 307 16A110 HEATER immersion 2550 W 10 2 kW only 247507 4 16A112 HEATER immersion 550 W 6 kW only 247506 308 15B137 SWITCH overtemperature 1 309 15B135 MIXER immersion heater 3 310 117484 SENSOR 2 311 100518 SCREW machine pan hd 2 313 15H305 PLUG hollow 5 314 247520 DISC rupture 2 315 12...

Page 36: ...ption Qty 301 HOUSING heater 1 303 121309 ADAPTER 2 304 15H304 PLUG 3 305 15H306 ADAPTER thermocouple 1 306 120336 O RING fluoroelastomer 1 307 16A110 HEATER immersion 2550 W 3 308 15B137 SWITCH overtemperature 1 309 15B135 MIXER immersion heater 3 310 117484 SENSOR 1 311 100518 SCREW machine pan hd 2 313 15H305 PLUG hollow 5 314 247520 DISC rupture not shown 1 315 124132 O RING 3 Ref Part Descrip...

Page 37: ...mperature includes 402a 402c 1 402a 246130 BOARD circuit 1 402b 246479 SWITCH membrane 1 402c 112324 SCREW 4 403 15B293 GASKET 1 404 15B292 COVER 1 405 15B291 PLATE 1 406 246287 HARNESS wire red stop button 1 407 117499 HANDLE 2 408 117523 NUT cap 10 24 8 409 111008 SCREW tapping 6 32 1 4 in 6 mm 8 410 111393 SCREW machine pan hd M5 x 0 8 16 mm 4 411 15B386 CABLE display 1 412 195853 SCREW machine...

Page 38: ...B Heater Module To A Heater Module To Hose Heater Module 606 Ref Part Description Qty 601 247772 PANEL module mounting 1 602 247827 HOUSING control module 1 603 247828 HOUSING heater module 3 604 115942 NUT hex 4 605 247801 CABLE communication 1 606 247825 KIT cover connector with screws 1 ...

Page 39: ...ad sealant to tapered threads 1 2 3 TI9839b 708 706 718 702 703 705 714 715 704 701 712 713 717 714 707 716 1 2 3 2 3 3 702a 702b Ref Part Description Qty 701 247837 MANIFOLD fluid 1 702 247824 VALVE drain cartridge 2 702a 158674 O RING 1 702b 247779 SEAL seat valve 1 703 102814 GAUGE pressure fluid 2 704 162453 FITTING 1 4 npsm x 1 4 npt 2 705 198241 PLUG pressure control 2 706 247788 HANDLE red ...

Page 40: ... refer to electrical diagrams manual 312409 supplied See page 42 for parts A 230V 3 Phase Circuit Breaker Modules For wiring and cable connections refer to electrical diagrams manual 312409 supplied See page 42 for parts 818 807 809 812 813 819 801 808 815 817 814 816 811 810 806 805 820 802 803 804 818 807 809 812 813 819 801 808 817 816 811 810 806 805 820 802 803 804 822 822 ...

Page 41: ... 238CR 168BR C 230V 1 Phase Circuit Breaker Modules For wiring and cable connections refer to electrical diagrams manual 312409 supplied See page 42 for parts 818 807 809 812 813 819 801 808 815 817 814 816 811 810 806 805 820 802 803 804 822 ...

Page 42: ...1 809 BREAKER 1 pole 50A 255026 255026 255026 1 810 CONTACTOR relay 65A 255022 255022 255022 1 811 BREAKER 2 phase 40A 247768 247768 247768 1 812 BREAKER 2 phase 25A 255050 255050 255050 2 BREAKER 2 phase 40A 247768 247768 247768 2 813 BREAKER 2 phase 20A 255049 255049 255049 1 814 CONNECTOR power lug 117679 3 CONNECTOR power lug 117679 2 815 BAR power buss 3 phase 117805 1 BAR power buss 1 phase ...

Page 43: ...Parts 312408F 43 ...

Page 44: ... 49 1245 B All 35 889 C All 36 5 927 D All 25 635 E All 27 686 F All 11 279 G hole diameter All 0 625 16 Weight A XP2 400 lb 180 kg HT Series 333 lb 150 kg Dimension Model in mm A B TI3700a Mounting Hole Dimensions C D F E G Front View Side View TI11256a TI11257a ...

Page 45: ... adapter Fluid Circulation Ports 1 4 npsm m with plastic tubing 250 psi 1 75 MPa 17 5 bar maximum Maximum Fluid Tempera ture 190 F 88 C Maximum Output 10 weight oil at ambient tem perature Model A XP2 1 5 gpm 5 7 liter min at 78 cycles min Output per Cycle A and B Model A XP2 0 0193 gal 073 liter Line Voltage Requirement 230V 1 phase and 230V 3 phase units 195 264 Vac 50 60 Hz 380V 3 phase units 3...

Page 46: ...t disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy...