Graco Series B Operation manual

INSTRUCTIONS–P ARTS LIST 308–219
Rev. C
Supersedes A
FOAM-CAT HEA TER
For use ONL Y with two component
urethane fluids that are unfilled
and non-flammable.
3000 psi (210 bar) Maximum Working Pressure
T emp Class T2C (230  C) Maximum Fault T emperature
Nominal Operating T emperature: 95–158  F (35–70  C)
Ambient T emperature Range: 40–104  F (5–40  C)
This heater includes a heating element and an
independent temperature for each of two fluids,
Isocyanate and Resin, and an independent
temperature control for the Foam-Cat  Heated Hose.
Foam-Cat 200 15 lb/min
Model 235–259 With Heated Hose Control
Series B 8880 Watt
Model 235–839 Without Heated Hose Control
Series B 5100 Watt
Foam-Cat 400 30 lb/min
Model 235–260 With Heated Hose Control
Series B 13,980 Watt
Model 235–840 Without Heated Hose Control
Series B 10,200 Watt
U.S. Patent No. 4,501,952; 4,725,713
U.K. Patent No. 2,138,601
Patented Bréveté 1986 Canada
WARNING
The operating and safety features of this heater are
designed for use only with the Graco
Foam-Cat Heated Hoses, Models 218–613,
218–614, 947–514, 947–515 and 948–723.
NEVER connect other hoses to this heater .
CSA certified for use with 218–613,
Series B, and 218–614, Series B,
Heated Hoses, and with 218–654
Ambient T emperature Compensator
Sensor.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1992, GRACO INC.
This manual contains important
warnings and information.
READ AND RETAIN FOR REFERENCE
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Table of Contents
INTRODUCTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARNINGS 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AVERTISSMENT 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION 8–15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup Check List 8. . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Installation 8. . . . . . . . . . . . . . . . . . . . . . . . . .
Component Description 11. . . . . . . . . . . . . . . . . . . .
How to Size Generator 11. . . . . . . . . . . . . . . . . . . . .
Flush the Heater 12. . . . . . . . . . . . . . . . . . . . . . . . . . .
Connect the Electrical Service 13. . . . . . . . . . . . . . .
Ground the System 14. . . . . . . . . . . . . . . . . . . . . . . .
Prime the Heater 14. . . . . . . . . . . . . . . . . . . . . . . . . .
Connect the Hoses 15. . . . . . . . . . . . . . . . . . . . . . . .
Prime the Hoses 15. . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjust the Heater 15. . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING GUIDE 16–21. . . . . . . . . . . . . .
Electrical Resistance Checks
Setup 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Sensor Probe 18. . . . . . . . . . . . . . . . . . . . .
Thermostat 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional A TC (Ambient T emperature Compensator) 18 .
Heater Element 18. . . . . . . . . . . . . . . . . . . . . . . . .
Heater Wiring Schematics 19. . . . . . . . . . . . . . . .
Hose Section Simulator 20. . . . . . . . . . . . . . . . . .
Hose Control Circuit Board 20. . . . . . . . . . . . . . . .
Triac 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE 22–28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Triac 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hi-Limit Thermostat 22. . . . . . . . . . . . . . . . . . . . . . . .
Heater Sensor Probe 23. . . . . . . . . . . . . . . . . . . . . . .
Heater Element 24. . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Board 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calibrating the Controls 28. . . . . . . . . . . . . . . . . . . .
Hose Sensor Simulator , Optional A TC 30. . . . . . . .
PARTS LISTS & DRA WINGS 32 – 34 . . . . . . . . . . . . . . .
Heater Assembly 32. . . . . . . . . . . . . . . . . . . . . . . . . .
Heated Hose Control 33. . . . . . . . . . . . . . . . . . . . . .
Heater 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SCHEMA TICS 37. . . . . . . . . . . . . . . . . . .
DIMENSIONS 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANUAL CHANGE SUMMAR Y39. . . . . . . . . . . . . . . . .
ACCESSORIES 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DA TA 40. . . . . . . . . . . . . . . . . . . . . . . . . . . .
GRACO PHONE NUMBERS 40. . . . . . . . . . . . . . . . . . .
WARRANTY 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Introduction
Understanding how the Foam-Cat  Heater functions
and how to adjust it properly for your application condi -
tions, is the key to easy operation and early detection
of possible equipment problems.
Read this manual and the manuals for all of the
components in your spray system thoroughly before
installing or operating the equipment.
Reference letters and numbers
Information on parts referenced with letters can usually
be found in the separate instruction manuals accompa
-
nying those components.
Terms
RES and ISO refer to the foam chemicals Resin and
Isocyanate, respectively .
Ambient T emperature is the surrounding air
temperature.
A
TC is the optional Ambient T emperature Compen -
sator feature of the Foam-Cat Heater . See page 10 for
further explanation.
WARNING alerts the user to avoid or correct condi -
tions that could cause bodily injury .
CAUTION alerts the user to avoid or correct conditions
that could cause damage to or destroy equipment.
NOTE identifies helpful procedures and information.
WARNING
Graco Inc. does not manufacture or supply any of the reactive chemical materials that may be used in this
equipment and is not responsible for their ef fects. Because of the vast number of chemicals that could be used
and their varying chemical reactions, before using this equipment, the buyer and the user should determine all
facts relating to the materials used, including any of the potential hazards involved. Particular inquiry and investi -
gation should be made into potential dangers relating to toxic fumes, fires, explosions, reaction times, and
exposure of human beings to the individual components or their resultant mixtures. Graco assumes no respon -
sibility for loss, damage, expense or claims for bodily injury or property damage, direct or consequential, arising
from the use of such chemical components.

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WARNINGS
High Pressure Spray Can Cause Serious Injury . For Professional Use Only.
Observe All W arnings. Read and understand all instruction manuals before operating equipment.
FLUID INJECTION HAZARD
General Safety
This equipment generates very high fluid pressure. Spray
from the gun, leaks or ruptured components can inject fluid
through your skin and into your body and cause extremely
serious bodily injury , including the need for amputation. Also,
fluid injected or splashed into the eyes or on the skin can
cause serious damage.
NEVER point the spray gun at anyone or at any part of the
body . NEVER put hand or fingers over the nozzle.
ALWA YS follow the Pressure Relief Procedure , below , be -
fore cleaning or removing the nozzle or servicing any system
equipment.
NEVER try to stop or deflect leaks with your hand or body .
Be sure equipment safety devices are operating properly
before each use.
Medical Alert––Airless Spray W ounds
If any fluid appears to penetrate your skin, get EMERGENCY
MEDICAL CARE AT ONCE. DO NOT TREAT AS A SIMPLE
CUT
. T ell the doctor exactly what fluid was injected.
Note to Physician : Injection into the skin is a traumatic injury .
It
is important to treat the injury surgically as soon as
possible. Do not delay treatment to research toxicity . T ox-
icity
is a concern with some exotic coatings injected directly
into the blood stream. Consultation with a plastic surgeon or
reconstructive hand surgeon may be advisable .
Spray Gun Safety Devices
Be sure all gun safety devices are operating properly before
each use. Do not remove or modify any part of the gun; this
can cause a malfunction and result in serious bodily injury .
Safety Latch
Whenever you stop spraying, even for a moment, always set
the gun safety latch in the closed or “safe” position, making
the gun inoperative. Failure to set the safety latch can result
in accidental triggering of the gun.
Trigger Guard
Always have the trigger guard in place on the gun when
spraying to reduce the risk of accidentally triggering the gun if
it is dropped or bumped.
Spray T ip Safety
Use extreme caution when cleaning or changing spray tips. If
the spray tip clogs while spraying, engage the gun safety
latch immediately . AL WA YS follow the Pressure Relief Pro -
cedure
and then remove the spray tip to clean it.
NEVER wipe of f build–up around the spray tip until pressure
is fully relieved and the gun safety latch is engaged.
Pressure Relief Procedure
To reduce the risk of serious bodily injury , including fluid
injection, splashing in the eyes or on the skin, and electric
shock, always relieve the fluid pressure in the spray
system and hoses before checking or adjusting any part
of the system or any component.
1. Engage the spray gun trigger safety latch.
2. Shut of f the air to the feed pumps.
3. T urn of f the electric motor switch in a hydraulic
system.
4. T
urn of f the air to the proportioning pump in an air-
powered system.
5.
Close the gun manifold needle valves.
6. Disengage the trigger safety latch, trigger the gun to
relieve pressure, and engage the trigger safety latch
again.
7.
If possible, allow the heater to cool before opening
the drain valves. This prevents the Resin from
frothing.
8.
Open both fluid filter drain valves, having a container
ready to catch the draining fluid.
9. If you are working on any part of the heater , shut of f
the main electrical power to the heater .
HOSE SAFETY
The operating and safety features of this heater are designed
to be used only with Graco Foam-Cat  Heated Hoses,
Models 218–613, 218–614, 947–514, 947–515 and
948–723. NEVER connect other hoses to this heater .
High pressure fluid in the hoses can be very dangerous. If the
hose develops a leak, split or rupture due to any kind of wear ,
damage or misuse, the high pressure spray emitted from it
can cause a fluid injection injury or other serious bodily injury
or property damage.
TIGHTEN all fluid connections securely before each use.
High pressure fluid can dislodge a loose coupling or allow
high pressure spray to be emitted from the coupling.
Never use the hose until the couplings are properly insulated
and the hose abrasion cover is in place.
Never operate the hose when it is coiled. Doing so causes
excessive heat buildup which can result in hose rupture and
cause serious bodily injury , including fluid injection and prop -
erty damage.
NEVER use a damaged hose. Before each use, check the
entire hose for cuts, leaks, abrasion, bulging cover , or dam -
age or movement of the hose couplings. If any of these con -
ditions exist, replace the hose immediately . DO NOT try to
recouple high pressure hose or mend it with tape or any other
device. A repaired hose cannot contain the high pressure
fluid.
HANDLE AND ROUTE HOSES CAREFULLY . Do not pull on
hoses to move equipment. Do not use fluids or solvents
which are not compatible with the inner tube and cover of the
hose.

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EQUIPMENT MISUSE HAZARD
General Safety
Any misuse of the spray equipment or accessories, such as
overpressurizing, modifying parts, using incompatible chemi -
cals and fluids, or using worn or damaged parts, can cause
them to rupture and result in fluid injection, splashing in the
eyes or on the skin, or other serious bodily injury , or fire, ex -
plosion or property damage.
NEVER alter or modify any part of this equipment; doing so
could cause it to malfunction.
CHECK all spray equipment regularly and repair or replace
worn or damaged parts immediately .
T oxic fluids may be used with this heater . Consult the fluid
and solvent manufacturer to understand and protect against
associated hazards. Always wear protective eyewear , gloves,
clothing and respirator as recommended by that manufac -
turer.
System Pressure
This heater has a 3000 psi (210 bar) MAXIMUM WORKING
PRESSURE. Be sure that all spray equipment and accesso -
ries used are rated to withstand this pressure. DO NOT ex -
ceed the maximum working pressure of any component or
accessory used in the system.
Be sure all accessories added to the system are properly
rated to withstand the maximum air and fluid working pres -
sures of this system.
NEVER install any fluid shutof f device at the fluid outlet of
either heater or filter
. Shutting of f the fluid at the outlet causes
high back pressure which can cause component rupture and
result in serious bodily injury .
Fluid and Solvent Compatibility
Be sure that all chemicals used in the spray system are
chemically compatible with the wetted parts shown in the
TECHNICAL DATA on page 40. Consult your chemical
supplier to ensure compatibility .
FIRE OR EXPLOSION HAZARD
Do not expose the heater to rain.
Do not operate the heater with any covers removed.
Do not use the heater with flammable liquids, such as those
having flash points below 200  F (93  C).
Static electricity is created by the flow of fluid through the
pump and hose. If every part of the spray equipment is not
properly grounded, sparking may occur , and the system may
become hazardous. Sparking may also occur when plugging
in or unplugging a power supply cord or using a gasoline en -
gine. Sparks can ignite fumes from solvents and the fluid be -
ing sprayed, dust particles and other flammable substances,
whether you are spraying indoors or outdoors, and can cause
a fire or explosion and serious bodily injury and property
damage.
If you experience any static sparking or even a slight shock
while using this equipment, STOP SPRAYING IMMEDI-
ATELY
. Check the entire system for positive grounding. Do
not use the system again until the problem has been identi -
fied and corrected.
Grounding
T o reduce the risk of static sparking, ground the spray system
and all other spray equipment used or located in the spray
area. CHECK your local electrical code for detailed grounding
instructions for your area and type of equipment. BE SURE to
ground all of this spray equipment:
1. Pump: connect a ground wire and clamp (supplied) to a
true earth ground as shown in your separate pump
manual.
2.
Fluid hoses: use only grounded hoses with a maximum
of 500 ft (150 m) combined hose length to ensure
grounding continuity .
3.
Air hoses: use only Graco heated hose, which are elec -
trically grounded.
4. Heater: by wiring to a positively grounded power supply .
In a mobile installation, be sure the truck or trailer is
grounded to a true earth ground.
T o ensure positive grounding and further reduce the risk
of electric shock, redundant grounding is recommended.
The long lines of the shielded-wire heated hose have
higher than normal capacitive leakage current to ground.
5. Spray gun: obtain grounding through connection to a
properly grounded fluid hose and pump.
6. Object being sprayed: according to local code.
7. Fluid supply container: according to local code.
8. All solvent pails used when flushing, according to local
code. Use only metal pails, which are conductive. Do not
place the pail on a non-conductive surface, such as
paper or cardboard, which interrupts the grounding
continuity.
9.
T o maintain grounding continuity when flushing or reliev -
ing
pressure , always hold a metal part of the gun firmly to
the side of a grounded metal pail, then trigger the gun.
Electrical W iring
All electrical wiring should be performed only by trained and
qualified personnel in compliance with all local codes and
regulations.
Flushing Safety
Reduce the risk of fluid injection injury , static sparking, or
splashing by following the flushing procedure given on page
12. Follow the Pressure Relief Procedure on page 4, and
remove the nozzle before flushing. Hold a metal part of the
gun firmly to the side of a grounded metal pail and use the
lowest possible fluid pressure during flushing.
MOVING P ARTS HAZARD
Moving parts can pinch or amputate your fingers or other
body parts. KEEP CLEAR of moving parts when starting or
operating the spray system. Follow the Pressure Relief Pro -
cedure on page 4 before checking or servicing any part of
the spray system, to prevent it from starting accidentally .
IMPORTANT
United States Government safety standards have been adopted under the Occupational Safety and Health Act. These standards
– particularly the General Standards, Part 1910, and the Construction Standards, Part 1926 – should be consulted.

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AVERTISSEMENT
T oute pulvérisation à haute pressure peut causer des blessures corporelles graves.
Système á usage professionel uniquement. Observer scrupuleusement touse les avertissements.
Lire et assimiler tous les manuels d’instructions avant de mettre l’équipement en service.
DANGER D’INJECTIONS DE PRODUIT
Consignes générales de sécurité
Cet équipement fait partie d’un système qui engendre de très hautes
pressions de produit. Des projections issues du pistolet, de fuites ou
d’éléments rompus peuvent provoquer une injection de produit sous
la peau et dans le corps, et causer ainsi des blessures corporelles
graves, pouvant entraîner une amputation. De plus, du produit
injecté ou projeté dans les yeux ou sur la peau peut causer des
dommages
sérieux.
Ne jamais pointer le pistolet de pulvérisation vers quiconque ou vers
une quelconque partie du corps. Ne jamais placer les mains ou les
doigts sur le nez.
Toujours suivre la Procédure de décompression, exposée ci-
dessous, avant de nettoyer
ou de retirer le nez ou d’entreprendre
l’entretien d’une quelconque partie du systéme.
Ne jamais tenter de bloquer ou de dévier une fuite avec les mains
ou toute autre partie du corps.
S’assurer avant chaque utilisation que tous les dispositifs de sécu -
rité
de l’équipement fonctionnent correctement.
Blessures par pulvérisateur sans air – Recours à un
médicin
Si du produit pénètre dans votre peau, EXIGEZ DES SOINS MEDI -
CAUX
D’URGENCE. Ne pas traiter comme un simple coupure.
Expliquer exactement au Mèdicin quel produit s’est trouvé injecté.
Note destinée au Médicin: L’injection à travers la peau est une
blessure
traumatique. Il est important de traiter cette blessure par
lar chirurgie le plus vite possible. Ne pas perdre de temps à une
recherche de toxicité. La toxicité constitue un problème avec
certains
revêtements très particuliers s’ils sont injectés directement
dans le flux sanguin. Il est conseillé d’appeler en consultation un
spécialiste de la chirurgie restauratrice ou de la chirurgie
réparta -
trice des mains.
Dispositifs de sécurité du pistolet de pulvérisation
S’assurer avant chaque utilisation que tous les dispositifs de sécu -
rité
du pistolet de pulvérisation fonctionnent correctement. Ne pas
retirer ou modifier quelque pièce que ce soit du pistolet; ceci peut
entraîner un mauvais fonctionnement et être la cause de blessures
corporelles graves.
Sécurité de détente
A chaque fois que l’on s’arrête de pulvériser , même pour un moment,
toujours placer le système de sécurité de détente du pistolet en posi -
tion
verrouillée ou en position “sécurité engagée”, ce qui empêche
tout fonctionnement du pistolet. Ne pas engager le système de sécu -
rité de détente du pistolet permet une action accidentelle sur la
détente
de celui-ci.
Garde de détente
La garde de détente devra toujours être en place lorsqu’ón pulvé -
risera
afin de réduire les risques d’action accidentelle sur la détente
en cas de chute ou de choc sur le pistolet.
Sécurité lors de la manipulations de la buse de
pulvérisation
Prendre les plus grandes précautions lorsqu’ón nettoie ou qu’on
change
les buses de pulvérisation. Si la buse de pulvérisation s’ob -
strue
en cours de pulvérisation, engager immédiatement la sécurité
de détente. T oujours appliquer la Procédure de décompression,
avant de déposer la buse de pulvérisation pour la nettoyer .
Ne
jamais tenter de retirer les agglomérats de produit qui auraient
pu se former autour de las buse de pulvérisation tant que la pression
n’est pas intégralement retombée et que la sécurité de détente du
pistolet n’est pas engagée.
PROCEDURE DE DECOMPRESSION
Pour réduire les risques de blessures corporelles graves, y compris
l’injection de produit, les projections dans les yeux ou sur la peau,
et les chocs électriques, toujours faire retomber la pression du
produit
dans la système de pulvérisation et dans les flexibles avant
toute vérification d’une quelconque partie du système ou des
composants.
1. Engager
la sécurité de détente du pistolet.
2. Couper l’alimentation pneumatique des pompes d’alimenta-
tion.
3. Basculer
en position ARRET le commutateur Marche/Arrêt du
moteur électrique dans le cas d’un système hydraulique.
4. Couper l’arrivée d’air de la pompe doseuse dans le cas d’un
système
pneumatique.
5. Fermer les vannes à aiguille du collecteur du pistolet.
6. Dégager la sécurité de détente, actionner le pistolet pour faire
retomber la pression, et engager de nouveau la sécurité de
détente.
7. Si possible, laisser le réchauf feur refroidir avant d’ouvrir les
vannes
de purge. Ceci empêche la résine de mousser .
8. Ouvrir les deux vannes de purge du filtre de produit, en tenant
prêt un réservoir destiné à recevoir le produit qui s’écoule.
9. Si l’on doit travailler sur une quelconque partie du réchauf feur,
couper
au préalable l’alimentation électrique du réchauf feur.
SECURITE DES FLEXIBLES
Les dispositifs de conduite et de sécurité et de sécurité de ce
réchauffeur
ont été conçus pour être exclusivement utilisés avec les
flexibles chauf fants Graco Foam-Cat, modèles 218–613, 218–614,
947–514, 947–515 et 948–723. Ne jamais raccorder d’autres flex -
ibles
à ce réchauf feur.
Le produit sous pression élevée véhiculé par les flexibles peut
s’avérer très dangereux. Si le flexible fuit, se rompt ou se fend en
raison
d’une usure, du fait qu’il est endommagé ou d’une utilisation
incorrecte, le jet de produit à haute pression peut occasionner une
blessure par injection de produit, ou autre blessure corporelle grave,
ou encore des dégâts matériels.
Bien serrer tous les raccords de produit avant toute utilisation. La
pression élevée du produit peut débrancher un raccord mal serré,
ou permettre à un jet à haute pression de jaillir du raccord.
Ne jamais utiliser ce flexibles si ses raccord ne sont pas correcte -
ment
isolés et si le blindage anti-abrasion n’est pas en place.
Ne jamais utiliser ce flexible si celui-ci est lové. Une telle pratique
entraîne une élévation de températures exagérée, pouvant
entraîner
la rupture du flexibles, et causer des blessures corporelles
graves, y compris l’injection de produit, ainsi que des dégâts maté -
riels.
Ne jamais utiliser un flexible endommagé. A vant toute utilisations,
vérifier le flexible sur toute sa longeur ,à la recherche de coupures,
fuites, usure par abrasion, cloques du rêvetement, ou de dommages
ou de jeu au niveau des raccords du flexible. Si l’une quelconque de
ces conditions se présente, remplacer immédiatement le flexible.
Ne
jamais essayer de réparer les raccords d’un flexible sous haute
pression ou de réparer à l’aide de ruban adhésif ou autre méthode
analoque. Un flexible réparé n’est plus en mesure de véhiculer un
produit sous pression élevée.

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Manipuler et disposer les flexibles avec grand soin. Ne pas exercer
de traction sur les flexibles pour déplacer l’équipement. Ne pas
utiliser
de produits ou de solvants quie seraient incompatibles chimi -
quement
avec la gaine intérieure ou la gaine extérieure du flexible.
DANGERS LIES A UNE MAUVAISE UTILISATIONS D L’EQUIPEMENT
Consignes générales de sécurité
Toute mauvais utilisations de l’équipment de pulvérisation ou de ses
accessoires, telle que création de surpressions, modification de
pièces,
utilisation de composés chimiques et de produits incompa -
tibles,
utilisation de pièces usées ou endommagées, peut entraîner
des ruptures d’éléments du système, avec risque d’injections de
produit,
de projections dans les yeux ou sur la peau ou autres bles -
sures
corporelles graves, ou encore incendie, explosion ou dégâts
matériels.
Ne
jamais modifier ou transformer quelque partie de cet équipement
que ce soit; une telle pratique peut entraîner un mauvais fonctionne -
ment.
Verifier
régulièrement tout l’équipement de pulvérisation, et réparer
ou remplacer immédiatement toute pièce usée ou endommagé.
Il est possible d’utiliser ce réchauf feur avec des produits toxiques.
Consulter le fabricant du produit et du solvant pour évaluer et mettre
en œuvres les protections contre les dangers associés à de tels
produits. Toujours porter des lunettes de sécurité, des gants, de
vêtements de protection et un respirateur, en suivant les recom-
mandations
du fabricant du produit.
Pression dans la système
Ce réchauf feur développe une Pression maximum de travail de 210
bar . S’assurer que tout l’équipement de pulvérisation ainsi que tous
les accessoires utilisés sont correctement dimensionnés pour
supporter
les pression. Ne pas dépasser la pression maximum de
travail d’aucun des éléments ou accessoires utilisés dans le
système.
S’assurer que tous les accessoires ajoutés au système sont
correctement
dimensionnés pour supporter les pressions maximum
de travail de produit et d’air de ce système.
Ne jamais monter de dispositif de barrage en sortie de produit, que
ce soit en sortie du réchauf feur ou en sortie du filtre. Le fait de barrer
l’écoulement du fluide entraîne l’apparition d’une contre-pression
élevée,
qui peut causer la rupture de certains éléments et entraîner
des blessures corporelles graves.
Compatibilité des produits et des solvants
S’assurer que tous les produits chimiques utilisés dans le système
de pulvérisation sont chimiquement compatibles avec les pièces en
contact avec le produit énumérées dans les CARACTERISTIQUES
TECHNIQUES de la page 40. Consultez votre fournisseur de
produits
chimiques pour vous assurer de cette compatibilité.
DANGER D’INCENDIE OU D’EXPLOSION
Ne jamais exposer le réchauf feur à la pluie.
Ne pas faire fonctionner le réchauf feur si l’un des capots est ouvert.
Ne pas utiliser ce réchauf feur avec des produits inflammables, en
particulier ceux ayant un point d’éclair inférieur à 93  C.
De l’électricité statique est produite par las circulation du produit
dans
la pompe et les flexibles. Si toutes les parties de l’équipement
de pulvérisation ne sont pas correctement raccordées à la terre, il
peut y avoir émission d’étincelles, et le système peut devenir
dangereux. Il peut aussi se produire des étincelles lorsqu’on
branche
ou débranche un cordon secteur , ou si le système comporte
un moteur à essence. Les étincelles produites peuvent enflammer
les vapeurs de solvant et le produit en cours de pulvérisation, ainsi
que des particules de poussière et d’autres substances inflam-
mables,
que la pulvérisation s’ef fectue en intérieur ou en extérieur ,
et
ceci peut être cause d’un incendie ou d’une explosion, et de bles -
sures
corporelles graves ainsi que de dégâts matériels.
Si l’on constate un émission d’étincelles électrostatiques ou même
si on ressent un léger choc électrique pendant que l’on utilise cet
èquipment,
CESSER IMMEDIA TEMENT DE PUL VERISER. Vérifier
toute le système, à la recherche d’un éventuel défaut de mise à la
terre. Ne pas réutiliser le système tant que la cuase du problème n’a
pas été cliarment identifiée et éliminée.
Mis à la terre
Pour réduire les risque d’èmission d’étincelles électrostatiques,
raccorder
le système de pulvérisations à la terre, ainsi que tous les
autres éléments du systèmes de pulvérisations utilisés ou situés
dans la zone du pulvérisation. Consulter la réglementation élec-
trique
locale pour y trouver les instructions détaillées concernant les
normes de mise à la terre pour votre région et votre type d’équipe -
ment.
S’assurer que toutes les parties de cet équipement de pulvé -
risation
sont bien mises à la terre:
1. Pompe: raccorder un étrier (fourni) et en câble de mise à la terre
à une prise de terre correcte comme indiqué dans le manuel
spécifique de la pompe.
2. Flexibles de produits: n’utiliser que des flexibles conducteurs
mis à la terre, la longueur totale à ne pas dépasser étant de 150
m, pour assurer la continuité électrique du circuit de mise à la
terre.
3. Flexibles
d’air: n’utiliser des flexibles chauf fants GRACO, qui
sont conducteurs et mis à la terre.
4. Réchauffeur: mise à la terre par raccordement à une alimenta -
tion elle-même correctement mis à la terre. S’il s’agit d’une
installation
mobile, s’assurer que le chariot est mis à la terre par
l’intermédiaire d’une prise de terre correcte.
Pour assurer une réelle mise à la terre, et donc réduire les
risques
d’électrocution, il est recommandé d’assurer une mise
à la terre très redondante. Les longues canalisations du flexible
chauffant, blindé, présentent des courants de fuite à la terre
supérieurs
à la normale.
5. Pistolet de pulvérisation: on obtiendra une mise à la terre
correcte
par la raccordement à la pompe et à une flexible tous
deux correctement mis à la terre.
6. Objets à pulvériser: se conformer aux réglementations locales.
7. Réservoir d’alimentation en produit: se conformer aux régle-
mentations
locales.
8. Tous le seaux pour solvants utilisés lors d’un rinçage: selon
réglementation locate. N’utiliser que des seaux métalliques,
donc
conducteurs. Ne pas placer le seau sur une surface on
conductrice, telle que du papier ou du carton, ce qui interrom -
prait
la continuité du circuit de terre.
9. Afin de maintenir la continuité du circuit de terre lors d’un
rinçage
ou d’une décompression, toujours maintenir une partie
métallique du pistolet fermement appuyée sur le bord d’un seau
métallique, puis actionner le pistolet.
Câblage électrique
Toute le câblage ne doit être ef fectué que part du personnel formé
et qualifié, conformément aux réglementations et normes locales.
Sécurité lors du rinçage
Réduire les risques de blessure par injection de produit, d’émission
d’étincelles, ou de projections en appliquant la Procédure de
décompression
de la page 6 et retirer le nez avant de procéder au
rinçage. Maintenir une partie mètallique sous la pression de produit
la plus faible possible.
Les pièces en mouvements peuvent pincer ou couper les doigts ou
d’autres parties du corps. Appliquer la Procédure de décompres -
sion de la page 6 avant de vérifier ou d’intervenir sur une quel-
conque
pièce du système de pulvérisation, pour éviter de la mettre
en marche accidentellement.

 
Installation
Startup Check List
1. See the T ypical Installation drawing to help deter -
mine how to design your system. See below .
2.
Review the Component Descriptions to learn how
each control works. This will help you choose the
correct settings when you operate the equipment.
See page 9.
3. When using a generator to power your system,
see page 1 1 to determine the correct size.
4. Mount the heater in its permanent location. See
page 1 1.
5.
Flush the test oil from the heater . See page 12.
6. Connect the electrical service. See page 13.
7. Ground the system. See page 14
8. Prime the heater . See page 14.
9. Connect the hoses. See page 15.
10. Prime the hoses. See page 15.
11. Adjust the heater . See page 15.
1. Typical Installation
This drawing shows all the components and recommended accessories for a Foam-Cat 400 Sprayer , Model
224–556, with Heater and Hose Control, Model 235–260, and the correct routing of all air and fluid hoses.
KEY
A Fluid Hose Displacement
Pump to Heater
B Heated Hose
C Main Air Supply Hose
D Air Manifold
E Optional A TC Sensor
F Air Hose, Heated Hose
107 Inlet Swivel Union
113 Fluid Outlet Union
Fig. 1
B
A
C
E
Air Dryer Kit
Feed
Pump
Bulldog
Proportioning Pump
Foam–Cat
Gun
Foam-Cat
Heated Hose
F
113
107
D
01688


Installation
2. Component Description
Fluid heater and control
The fluid heater (G) is actually two separate heaters,
one for Resin and one for Isocyanate. The heaters
have independent controls on the heater control panel
(1 16); see Control panel , below . Each heater also has
a thermometer (204).
A sensor probe (256 – see page 23) in each heater
senses fluid temperature and turns the heater element
on and of f as needed. The heaters include a safety
limit thermostat which shuts of f the power if the fluid
gets too hot.
Heated hose control
(Models 235–259 and 235–260 only)
The heated hose control panel (317) controls power to
the heat tape in the heated hose assembly . The func -
tion of the heated hose is to maintain the proper fluid
temperature. The heated hose control panel is
discussed in the following section, “Control Panel”.
Control panel
Each side of the heater , and the heated hose, has an
independent T emperature Set dial (K), a main power
circuit breaker (210 and 319) and an indicator light
(214 and 314) on the control panel.
The independent circuit breakers turn on or of f the
main electrical power from the junction box. The
heated hose circuit breaker (319) (Models 235–259
and 235–260 only) includes a ground fault interrupter
(GFI) which shuts of f the electrical power to the heat
tape if it detects a fault. The GFI is a 30 mA trip
international version that meets IEC 479.
NOTE: The circuit breakers use the international
symbols, I for ON and O for OFF.
Each side of the heater control (1 16) and the heated
hose control (317) has an
indicator light (214 and
314) on the control panel which indicates when the
heater element is actually heating. The light blinks at
about 1 second intervals. Its on–of
f time ratio indicates
power consumption.
The T emp Set dial (K) is used to select the desired
fluid temperature. The range is approximately 95 F
(35
C) at MIN to 158 F (70 C) at MAX settings.
Fig. 2 01294
317
319
314
214
210
K
111
G
116
204

 
Installation
2. Component Description (continued)
Thermometer gauges
Each heater has an independent thermometer (204).
Because of the ef fect on the surrounding metal
exposed to the air , the thermometer usually reads far
below the selected fluid temperature during no-flow
conditions. The thermometer reading is only valid
when fluid is flowing.
Fluid filter
A fluid filter (112) at the outlet of each heater removes
particles from the foam chemicals that could clog the
spray nozzle or distort the spray pattern. Refer to the
separate instruction manual, 307–273, for mainte
-
nance instructions.
Junction box
Electrical power to the Foam-Cat Heater is wired
directly to the junction box (233), which supplies power
to the heater and heated hose controls.
The optional
Ambient T emperature Compensator
senses change in ambient temperature and increases
or decreases the amount of heat produced by the
heater or heated hose tape. The fluid is heated higher
on cold days than on hot days. The part number for
this accessory is 218–564. See page 30 to install.
How to use the OPTIONAL
Ambient T emperature Compensator (ATC)
Most fluid heaters produce, or output, just the amount
of heat selected on its Temp Set dial regardless of
ambient temperature changes during the day . So, in
order to maintain good foam development in outdoor
foam applications, the operator must continually adjust
the fluid temperature as ambient temperature changes.
The optional Foam-Cat Heater A TC feature automati -
cally checks and adjusts the fluid temperature. The
A TC Sensor (K) which is designed to have no effect on
heater output at 80 F (27 C), senses ambient temper -
ature above or below 80 F (27 C) and automatically
raises or lowers the heater output.
With the Heater T emp Set at 1 15F (46 C), and at an
ambient temperature of 60 F (16 C), the heater output
automatically rises to 125 F (52 C). As the ambient
temperature rises to 80 F (27 C), no compensation is
needed and the fluid is heated to just 1
15F (46C).
As the ambient temperature rises to 100 F (38 C), the
heater output is automatically lowered to 108 F
(42C).
Keep in mind these points when using the A TC:
1.
An A TC is needed only when the ambient temper -
ature varies more than 20  above or below 80 F
(27C).
2.
At an ambient temperature of about 80 F
(27
C), the heater heats the fluid only to the
selected temperature.
Fig. 3 01294
233
112
204


Installation
3. How to Size a Generator
for outdoor remote applications
Style Hose
Control
Model With Hydraulic
Pump Motor
WA TTS (240 V AC)
Control Pump Motor
1 Phase 3 Phase
Foam–Cat 200 NO 235–839 NO 5,100 7,650
Foam–Cat 200 YES 235–259 NO 8,880 11,340
Foam–Cat 400 NO 235–840 NO 10,200 15,300
Foam–Cat 400 YES 235–260 NO 13,980 15,300
Foam–Cat 400 YES 235–840 YES 13,980 15,300
Foam–Cat 400 YES 235–260 YES 13,980 15,300
4. Mount the Heater
WARNING
To reduce the risk of electric shock, do not expose
the heater to rain.
If you have purchased the heater module separately ,
bolt it securely to the Graco Pump Stand, part no.
217–296 (see manual 307–551) or to a wall. A
mounting hole diagram is on the back cover of manual
307–551.
CAUTION
All critical air and fluid connections in the Foam-Cat
equipment are clearly labeled ISO or RES. Make
only ISO to ISO and RES to RES connections to
avoid fluid crossover which will permanently
damage the components.
CAUTION
If you are using a Freon injector , mount it down -
stream from the heater .

 
Installation
5. Flush the Heater
WARNING
To reduce the risk of serious bodily injury , follow the
Pressure Relief Procedure on page 4 before
flushing the heater or spray system.
Before flushing, disconnect the electrical power to
the heater to reduce the risk of static sparking
which can cause fire or explosion.
CAUTION
The heater was tested in lightweight oil which was
left in to protect the parts during shipment. The oil
must be flushed or purged from the system to
avoid material contamination.
NOTES
1. Use a solvent that is recommended by your mate -
rial supplier , and be sure it is compatible with the
heater’ s wetted parts.
2. Some material will be contaminated whether you
simply purge the oil from the heater or use a
solvent to thoroughly flush. Discard that material.
3. For long term shutdown or storage, flush with a
compatible solvent and then flush with a light -
weight oil. Leave the oil in the system to protect it
during shutdown.
4. Some material suppliers provide maintenance
services which include flushing and storage.
5. Never flush the hoses. It is very dif ficult to remove
all moisture from hoses which have been flushed,
and the moisture will contaminate the ISO and
RES.
Procedure
1. Disconnect the material hoses, if connected.
2. Remove the outlet fittings (A) from both fluid filter
outlet nipples (1 14).
3.
Plug each outlet nipple (1 14) with a swivel (P/N
156–173) and plug (P/N 101–754). These parts
are shown exploded on the left side of Fig. 4 and
assembled on the right side of Fig. 4.
4. Connect your flushing system supply hose to the
IN port of one of the heaters.
5. Open the filter drain valve (1 1 1). Have a waste
container ready to catch the draining solvent.
6. T urn on the flushing system and use the lowest
possible pressure to flush the heater for several
seconds.
7.
Shut of f the flushing system and close the drain
valve.
8.
Repeat this procedure for the other side of the
heater.
9.
Continue the setup by connecting the electrical
service. When you are ready to prime the system,
that procedure tells how to purge the remaining
solvent from the heater .
Fig. 4 
114
111
156–173
101–754
A


Installation
6. Connect the Electrical Service
WARNING
The electrical wiring should be performed only by
trained and qualified personnel to reduce the risk of
serious bodily injury and electric shock.
Observe all local codes and regulations regarding
electrical wiring.
The electrical requirements for the heater and heated
hose controls and the wiring diagram are shown on the
inside cover of the junction box (233). Wire the heater
to your electrical service. Three jumper wires are
included.
This is the information on the label (205) under the
junction box cover .
Fig. 5
38 Amps
38 Amps
38 Amps
22 Amps
22 Amps
22 Amps
22 Amps
16 Amps
16 Amps
L1
L2
L3
RES
HTR
5.1 Kw
ISO
HTR
5.1 Kw
HOSE
3.8 Kw
(max)
TB1
TB2
TB3
TB4
TB5
TB6
60 Amps
60 Amps
22 Amps
22 Amps
22 Amps
22 Amps
16 Amps
16 Amps
L1
L2
TB1
TB2
TB3
TB4
TB5
TB6
RES
HTR
5.1 Kw
ISO
HTR
5.1 Kw
HOSE
3.8 Kw
(max)
Model 235–260
3 phase, 240 V AC
Model 235–260
1 phase, 240 V AC
28 Amps
28 Amps
28 Amps
11 Amps
11 Amps
11 Amps
11 Amps
16 Amps
16 Amps
L1
L2
L3
RES
HTR
2.6 Kw
ISO
HTR
2.6 Kw
HOSE
3.8 Kw
(max)
TB1
TB2
TB3
TB4
TB5
TB6
Model 235–259
3 phase, 240 V AC 38 Amps
38 Amps
11 Amps
11 Amps
11 Amps
11 Amps
16 Amps
16 Amps
Lx
Ly
TB1
TB2
TB3
TB4
TB5
TB6
RES
HTR
2.6 Kw
ISO
HTR
2.6 Kw
HOSE
3.8 Kw
(max)
Model 235–259
1 phase, 240 V AC
38 Amps
38 Amps
38 Amps
22 Amps
22 Amps
22 Amps
22 Amps
L1
L2
L3
RES
HTR
5.1 Kw
ISO
HTR
5.1 Kw
TB1
TB2
TB3
TB4
Model 235–840
3 phase, 240 V AC
Model 235–260
1 phase, 240 V AC
44 Amps
44 Amps
22 Amps
22 Amps
22 Amps
22 Amps
L1
L2
RES
HTR
5.1 Kw
ISO
HTR
5.1 Kw
TB1
TB2
TB3
TB4
19 Amps
19 Amps
19 Amps
11 Amps
11 Amps
11 Amps
11 Amps
L1
L2
L3
RES
HTR
2.6 Kw
ISO
HTR
2.6 Kw
TB1
TB2
TB3
TB4
Model 235–839
3 phase, 240 V AC
Model 235–839
1 phase, 240 V AC
22 Amps
22 Amps
11 Amps
11 Amps
11 Amps
11 Amps
L1
L2
RES
HTR
2.6 Kw
ISO
HTR
2.6 Kw
TB1
TB2
TB3
TB4
FOAM–CAT 400
FOAM–CA T 200
FOAM–CA T 200
FOAM–CA T 400
FOAM–CA T 400
FOAM–CA T 400
FOAM–CA T 200
FOAM–CA T 200

 
Installation
7. Ground the System
The heater is grounded through the electrical wiring to
a grounding screw (227) in the junction box base
(228). See Fig. 6.
Redundant grounding is recommended to further
reduce the risk of electric shock. The long lines of the
shielded-wire heated hose have higher than normal
capacitive leakage current to ground.
Ground the proportioning pump as instructed in the
separate instruction manual for your pump.
Fig. 6
227
228
Fig. 7 01292
113
K
107
313
8. Prime the Heater
CAUTION
Prime the heater and sprayer with fluid before
turning on the heater to reduce the risk of over -
heating and burning out the heater element.
Specific priming instructions for the Foam-Cat
Sprayers are given in the sprayer manual, 307–541 or
307–542. If the heater is used in other spray systems,
use the following priming guidelines together with your
system priming instructions.
NOTE: Refer to Fig. 1, page 8 to identify the parts
mentioned in this section, except where noted
otherwise.
1.
Be sure the heater has been flushed.
2. Close the feed pump air inlet valves.
3. Put a waste container under each heater drain
valve.
4.
Be sure the heater and heated hose controls (K)
are turned OFF . See Fig. 7.
5. Open each pump’ s fluid intake valve.
6. Open the main air shutof f valve.
7. Adjust the supply container air dryer equipment.
See the air dryer manual.
8. Open the feed pump air valve.
9. With the air or hydraulic power to the proportioning
pump set at a low pressure, turn on the pump.
10. When the solvent has been thoroughly purged
from both sides of the heater and ISO and RES
appear , shut of f the proportioning pump and close
the heater drain valves.
11. Remove the swivel and plug from each filter fluid
outlet.


Installation
9. Connect the Hoses
WARNING
To reduce the risk of overpressurizing the heater
and pump, which can result in serious injury or
property damage, follow these precautions:
1. Do not install any fluid shutof f device at the
fluid outlet (F) of either heater or filter (1 12)!
See Fig. 8.
2. Use at least 15 ft. (4.5 m) of fluid hose
between the fluid outlet and any fluid control
device such as a shutof f valve, regulator or
spray gun.
3. T o reduce strain on the hose near the hose
couplings, route the heated hoses through the
clamp (126) on the front of the heater .
4. T
urn hose heat on 15 minutes before turning
pump on to reduce heat expansion pressure.
1. Connect the fluid supply hoses from the displace -
ment pump to the proper fluid inlet union (107) on
each side of the heater .
2. Connect the fluid dispense hoses of the heated
hose assembly to the fluid outlet union (1 13) of
each fluid filter . See Fig. 8.
3. Connect a main air supply hose (C) to the manifold
(D) on the side of the pump stand. See Fig. 1,
page 8.
4. Connect the heat tape connector of the heated
hose assembly to the heated hose control box
cable (313). See Fig. 8.
5. Connect the heated hose assembly air hose (F) to
the jumper hose from the air manifold (D).
10. Prime the Hoses
1. Tightly close the spray gun fluid valves and discon -
nect the gun from its manifold. Refer to the gun
manual.
2.
Hold each side of the gun manifold over a sepa -
rate grounded waste container , open the fluid
valves and allow fluid to flow out until all air is
purged. Close fluid valves. See the gun manual.
3. Check for fluid connection leaks. Relieve fluid
pressure and correct.
4. Increase pressure and check again for leaks.
5. Insulate hose connections and install the abrasion
cover as instructed in manual 307–544.
01691
Fig. 8
F
112
113
K
210
319
107
313
N
111
204
126
11. Adjust the Heater
1. Measure the incoming voltage on the junction box
power in terminal block from pins 1 to 2, pins 3 to
4, and pins 5 to 6. See Fig. 10 or 1 1, pages 19 and
20. V oltage must read 200 to 240 V AC rms
between each set of pins.
2. Set all three T emperature Set dials (K) to CAL .
See Fig. 8.
3. T urn the circuit breakers (210 and 319) to I (ON ).
See Fig. 8.
4. Check that the input voltage is still correct.
5. The heater lamps should blink within 10 seconds
after turning on the circuit breakers. With fluid
flowing only , check the heater thermometers (204)
regularly and manually adjust the fluid temperature
as needed. See Fig. 8.
6. The heated hose control lamp should start blinking
soon after turning on the circuit breaker . The dura-
tion of ON versus OFF time indicates power
applied.
NOTE: If the lamps do not start blinking in the time
specified above, check for possible problems and
solutions in the T
roubleshooting Guide starting on
page 16.
7. If using a heated hose control, test the Ground
Fault Interrupter (GFI) daily
. T o test, depress the
button (N). See Fig. 8. If the circuit breaker shuts
of f, the GFI is working properly .

 
Troubleshooting
WARNING
Never operate the heater with any shield or cover
removed to reduce the risk of getting burned or
receiving an electric shock.
Follow the Pressure Relief Procedure on page
4 before checking or repairing any part of these
components.
*T
ry the recommended solutions in order given for each problem to avoid unnecessary repairs.
Heated Hose
Problem Cause Solution
Heated Hose Control indicator
lamp stays on
Faulty triac (281) Check triac wiring. See Fig. 14, page 22.
Faulty circuit board (223 or 306) Replace. See page 26.
Faulty Hose Sensor Simulator (304) Be sure simulator is firmly plugged into circuit
board.
Check simulator resistance. See page 20.
Hose Sensor Simulator (304) not
plugged in
Plug in.
Heated Hose Control indicator
lamp stays of f
Heated hose not plugged into control
box
Check, plug in.
Wiring or voltage problem Check the wiring and the voltage:
200–240 VRMs during fluid flow and at stall.
See Adjust the Heater , Step 1, page 15.
Faulty circuit board Replace. See page 26.
Hose thermostat is bad Check. See manual 307–544.
Hose temperature fluctuates Hose Sensor Simulator (304) out of
calibration
Be sure simulator is firmly plugged into circuit
board. Check calibration. See page 30.
Faulty Hose Sensor Simulator (304) Replace. See page 30.
Heater
Problem Cause Solution
Heater Control indicator lamp stays
on
Flow rate too high to maintain set
temperature
Decrease flow rate; using smaller orifice nozzle
reduces flow rate.
Release gun trigger; lights should go of f in a
few seconds.
Maximum flow rates are:
Foam-Cat 200: 15 lb/min (6.8 kg/min)
Foam-Cat 400: 30 lb/min (13.5 kg/min)
Faulty Sensor Probe (256) Check the following for both sides of heater:
1 Probe connector is aligned properly into
all 3 male pins of circuit board.
2 Probe protrudes 1.44” (36 mm) from
manifold. See Fig. 16, page 23.
3 Check resistance. See page 18.
P1 connector unplugged
See drawing to the left
Plug in.
Check resistance. See page 18.
Problem continued on next page
Faulty T riac Check triac wiring. See Fig. 12, page 21.
Check resistance. See page 21.


Troubleshooting
Problem Cause Solution
Heater Control indicator lamp stays
on (continued)
The A TC, if used, is not plugged in Be sure A TC connector , if used, is properly
plugged into circuit board.
Check resistance. See page 18.
Circuit board out of calibration See page 28. Calibration procedure is included
in replacement procedure.
Sensor Probe (256) not plugged in Plug in. See page 23.
Heater Control indicator lamp
stays of f – no heat.
Thermostat(s) (252) open
(normally closed)
Reset thermostat by pushing reset button. See
Fig. 13, page 22.
T riac wires not connected properly Check triac detail. See Fig. 14, page 22.
T emp Set dial wires not connected Check wiring. See Fig. 10, page 19.
Faulty circuit board Replace. See page 26.
AC power wiring or voltage problem Check for 200–240 VRMs. See Adjust the
Heater , Step 1, page 15.
Elements burned out or not plugged
in
Check element resistance. See page 18.
T emperature erratic or
inaccurate
Sensor probe (256) out of
position
Probe must protrude 1.44” (36 mm) from
manifold. See Fig. 16, page 23.
Indicator light should go out within 5 seconds of
shutting gun of f after flowing.
Heater out of calibration Calibrate controls. See page 28.
Improper incoming voltage Check the wiring and the voltage:
200–240 VRMs during fluid flow and at stall.
See Adjust the Heater , Step 1, page 15.
One thermostat open
(normally closed)
(Model 235–260 & 235–840 only)
Reset thermostat by pushing reset button. See
Fig. 13, page 22.
Faulty sensor probe (256) Check resistance. See page 18.
Replace. See page 23.
Large pressure dif ference between
ISO and RES side, For example:
600 i (42 b ) ISO
Thermostat(s) (252) open Reset thermostat by pushing reset button. See
Fig. 13, page 22.
600 psi (42 bar) ISO
1000 psi (70 bar) RES
Fluid on high pressure side is too
thick
Increase heater temperature on high pressure
side to reduce viscosity , which should level the
pressure, OR lower the temperature on the low
pressure side.
Gun nozzle impingers clogged or
damaged
Clean nozzle. Using an oversized cleanout pin
or damaging nozzle during cleaning may
increase impinger hole size and cause an
imbalance of fluid. See gun manual 307–546.
Blocked filters Check outlet filter (1 12; also see manual
307–273).
Check gun check valve screen. See gun
manual 307–546.
Clogged hoses Flush clean, if possible, or replace hose. Use
and clean filters regularly . Don’t allow mixed
fluid to back up into hoses.
Fluid supply low or empty Refill; prime system to remove air .
Fluid pump or hose connections
leaking
Check for leaks and repair or tighten as
needed. See pump manual also.

 
Troubleshooting – Electrical Resistance Checks
WARNING
Always disconnect the main electrical power to the
heater before removing the front control panel
covers (216, 217) to reduce the risk of serious
bodily injury from electric shock.
Setup
1. Measuring the resistance of a part helps determine
if it is working properly . Determine the approximate
temperature of the part; if the heater was operated
recently , the temperature will be high. If you get a
measurement other than those given in the
following procedures, replace the faulty part.
2. Shut of f the main power to the heater and remove
the appropriate control panels.
3. T o remove wires, use the accessory tool, P/N
1 10–968 or a 3/16 in. wide screwdriver . Insert the
tool into the slot below each wire on the terminal
block, push the tool away from the wire and pull
out the wire. See Fig. 9.
4. T o reconnect the wires, push the tool into the slot,
slide in the wire and release the tool.
Fig.
9
01698
T ool 1 10–968
Heater Sensor Probe
1. Remove the heater control panel (216).
2. Unplug the connector P1 at position J2 on the
heater circuit board in question. See Fig. 10.
3. Check the resistance across the two outside termi -
nals of connector P2. The resistance should be:
45K to 55K ohms at 77  F (26 C), or
10K to 20K ohms at 120  F (49 C)
4. T o replace the sensor probe (256), see page 22.
Thermostat (normally closed)
1. T o check continuity from inside the wiring junction
box, remove the wires from connector T1 and
check continuity across the wires.
2. T o check continuity at the thermostat, remove the
front heater element shroud (238). Check for conti -
nuity across the terminals at each switch, with one
lead disconnected and after pushing the reset
button. See Fig. 14, page 22.
3. If there is no continuity achieved, replace the ther -
mostat. See page 22.
Optional ATC
(Ambient Temperature Compensator)
1. Remove the heater control panel (216).
2. Unplug the connector P1 at position J1 on both
heater circuit boards and the hose circuit board.
See Fig. 10 and 1 1.
3.
Check resistance across the two terminals of each
connector P1. The resistance should be:
45K to 55K ohms at 77  F (26 C), or
10K to 20K ohms at 120  F (49 C)
4. T o replace the A TC, see page 30.
Heater Element
Use this chart to identify the heater assembly and
heater element wires used in your Foam-Cat  Heater .
Foam-Cat
Heater
Model No.
Flow
Capacity
Heater
Assy. No.
Heater
Element W ire
Numbers
235–260
235–840
30 lb/min
(13.5 kg/min)
235–840 7,8,9,10 RES
17,18,91,20
ISO
235–259
235–839
15 lb/min
(6.75 kg/min)
235–839 7,8 RES
17,18 ISO
1. Remove the heater control panel (216).
2. Using the procedure in Setup, disconnect the
wires indicated below .
3.
Check the resistance across wires 7 & 8, and 9 &
10, on the RES board. Check the resistance
across wires 17 & 18, and 19 & 20 on the ISO
board. The resistance should be as follows. If an
open conditions exists, check the hi-limit thermo -
stat. See Fig. 10.
20 to 25 ohms at 77  F (26 C)
4. T o replace the heater element, see page 24.


Troubleshooting – Electrical Resistance Checks
Heater Wiring Schematics
NOTE: Heater No. 235–840 is shown in Fig. 10. The
wiring for Heater No. 235–839 is identical except the
second set of elements (wires 9, 10, 19, 20) are not
used.
RESIN HEATER
ISO HEATER
Fig. 10
OPTIONAL A TC
P1
OPTIONAL P1
STANDARD P2
CONNECTOR
N.T.C
TEMP DIAL
A
B
J2
J1
G
MT2
MT1
M–
M+
WHT
WHT
BLK
BLK
4
3
2
1
–
–
+
+
LAMP
BOARD
A
BC
LIMIT
THERMOSTAT
ELEMENTS
CIRCUIT BREAKER
1
2
3
4
5
6
AA
BB
CAL
POWER IN
TERMINAL BLOCK (TB)
OPTIONAL ATC
P1
OPTIONAL P1
STANDARD P2
CONNECTOR
N.T.C
TEMP DIAL
A
B
J2
J1
G
MT2
MT1
M–
M+
WHT
WHT
BLK
BLK
4
3
2
1
–
–
+
+
LAMP
BOARD
A
BC
LIMIT
THERMOSTAT
ELEMENTS
CIRCUIT BREAKER
1
2
3
4
5
6
AA
BB
CAL
POWER IN
TERMINAL BLOCK (TB)
TRIAC
SENSOR
PROBE
10
8
9
12
11
12
7
D
C
T1
+ +
+ +
TRIAC
D
C
T1
+ +
+ +
SENSO
R
PROBE
34
21
22
19
18
20

 
Troubleshooting – Electrical Resistance Checks
Hose Section Simulator
1. Remove the heated hose control panel (317).
2. Unplug the connector P2 at position J2 on the
hose circuit board. See Fig. 1 1.
3.
Using the procedure in Setup, page 18, discon -
nect the two leads from the hose sensor simulator
(304) connect to the circuit board connector T1 at
positions 2 & 4.
4. Check the resistance across the two outside termi -
nals of connector P2. The resistance should be:
45K to 55K ohms at 77  F (26 C), or
10K to 20K ohms at 120  F (49 C)
5. Check the resistance across the two leads
removed from T1. The resistance should be:
13K T O 17K ohms
6. T o replace the simulator , see page 30.
Hose Control Circuit Board
–
–
Fig. 1 1
OPTIONAL
ATC
P1
OPTIONAL P1
STANDARD P2
CONNECTOR
TEMP DIAL
A
B
J2
J1
G
MT2
MT1
M–
M+
WHT
WHT
BLK
BLK
4
3
2
1
+
+
LAMP
BOARD
A
BC
1
2
3
4
5
6
AA
BB
CAL
POWER IN
TERMINAL BLOCK (TB)
A
B
GFI
HOSE
CONNECTOR
TRIAC T1
D
C
HOSE SECTION SIMULA TOR
01690