Graco Reactor A-XP Series Use and care manual

Repair - Parts
Air Powered, Heated, Plural Component Proportioner
For spraying polyurethane foam and polyurea coatings.
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.

2312408F
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Supplied Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Temperature Control Diagnostic Codes . . . . . . . . 7
E01: High fluid temperature . . . . . . . . . . . . . . . . 7
E02: High zone current . . . . . . . . . . . . . . . . . . . . 8
E03: No zone current . . . . . . . . . . . . . . . . . . . . . 8
E04: Fluid Temperature Sensor (FTS) or
thermocouple disconnected . . . . . . . . . . . . . 9
E05: Circuit board overheated . . . . . . . . . . . . . . 9
E06: Communication cable unplugged . . . . . . . . 9
Communication Diagnostic Code . . . . . . . . . . . . . 9
E99: Loss of communication . . . . . . . . . . . . . . . . 9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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 kW Heaters . . . . . . . . . . . . . . . 35
7.65 kW Single Zone Heater . . . . . . . . . . . . . . . 36
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Temperature Control . . . . . . . . . . . . . . . . . . . . . 38
Fluid Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Circuit Breaker Modules . . . . . . . . . . . . . . . . . . 40
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 46
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 46

Models
312408F 3
Models
Air Powered Reactors
A-XP Series
Heat Packages (do not include proportioner)
HT Series
All A-XP2 models are CE compliant.
Part,
Series Model
Voltage
(phase)
Full
Load
Peak
Amps
System
Watts
Heater
Watts
(no
hose)
Pressure
Ratio
Flow
gpm
(lpm) at
78 cpm
Output
per Cycle
(A+B)
gal. (liter)
Maximum Fluid
Working Pressure
psi (MPa, bar)
259060, A A-XP2 230V (1) 62 14,540 10,200 25:1 1.5 (5.7) 0.0193
(0.73)
3000 (20.7, 207)
259061, A A-XP2 230V (3) 40 14,540 10,200 25:1 1.5 (5.7) 0.0193
(0.73)
3000 (20.7, 207)
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 14,540 10,200 3500 (24.1, 241)
259074, B HT-10.2 230V (3) 40 14,540 10,200 3500 (24.1, 241)
259075, B HT-10.2 400V (3) 22 14,540 10,200 3500 (24.1, 241)
259076, B HT-15.3 230V (1) 84 19,640 15,300 3500 (24.1, 241)
259077, B HT-15.3 230V (3) 57 19,640 15,300 3500 (24.1, 241)
259078, B HT-15.3 400V (3) 33 19,640 15,300 3500 (24.1, 241)

Supplied Manuals
4312408F
Supplied Manuals
The following manuals are shipped with the Reactor™
Proportioner. Refer to these manuals for detailed equip-
ment information.
Order Part 15M334 for a compact disk of Reactor manu-
als translated in several languages
Manuals are also available at www.graco.com.
Related Manuals
The following manuals are for accessories used with the
Reactor™.
Order Part 15M334 for a compact disk of Reactor manu-
als translated in several languages. Order Part 15B381
for a compact disk of Fusion manuals translated in sev-
eral languages.
Reactor Air Powered Proportioner
Part Description
312407 Reactor Air Powered Proportioner,
Operation Manual (English)
Reactor Electrical Diagrams
Part Description
312409 Reactor Air Powered Proportioner,
Electrical Diagrams (English)
Proportioning 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 (English)
Air Supply Kit
Part Description
309827 Instruction-Parts Manual (English) for
Feed Pump Air Supply Kit
Circulation and Return Tube Kits
Part Description
309852 Instruction-Parts Manual (English)
Heated Hose
Part Description
309572 Instruction-Parts Manual (English)
Fusion Air Purge Spray Gun
Part Description
309550 Instruction-Parts Manual (English)
Fusion Mechanical Purge Spray Gun
Part Description
309856 Instruction-Parts Manual (English)
Circulation Kit
Part Description
309818 Instruction-Parts Manual (English)
Data Reporting Kit
Part Description
309814 Instruction-Parts Manual (English)

Warnings
312408F 5
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 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 hear-
ing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
• Hearing protection
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut,
but it is a serious injury that can result in amputation. Get immediate surgical treatment.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
•FollowPressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking,
or servicing equipment.

Warnings
6312408F
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.
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids contain-
ing such solvents in pressurized aluminum equipment. Such use can cause serious chemical reaction and equip-
ment 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 area 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 equip-
ment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your mate-
rial, 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.
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.
WARNING

Temperature Control Diagnostic Codes
312408F 7
Temperature Control Diagnostic Codes
Temperature control diagnostic codes appear on tem-
perature 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,
turn main power OFF then ON to clear.
E01: High fluid temperature
Causes of E01 Errors
• Thermocouple A or B (310) 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 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 6.0 and 10.2 kW heater 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 temperature control board and ther-
mocouples A and B (310) or FTS (21) [depending
on which zone is displaying E01]. See TABLE 3, page
19. Ensure that all wires are securely connected to
connector B.
Code Code Name Alarm
Zone
Corrective
Action page
01 High fluid temperature Individual 7
02 High zone current Individual 8
03 No zone current with
hose heater on
Individual 8
04 FTS not connected Individual 9
05 Board overtemperature Individual 9
06 Communication cable
unplugged from module
Individual 9
99 Loss of communication A 9
For hose zone only, if FTS is disconnected at
startup, display will show hose current 0A.
Troubleshooting this equipment requires access to
parts that may cause electric shock or other serious
injury if work is not performed properly. Have a quali-
fied electrician perform all electrical troubleshooting.
Be sure to shut off all power to the equipment before
repairing.

Temperature Control Diagnostic Codes
8312408F
4. Remove connector B from temperature control mod-
ule, 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.
5. Verify fluid temperature, using an external tempera-
ture 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 22.
7. 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 Assem-
bly Modules, page 20.
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 21.
E02: High zone current
1. Turn main power OFF .
2. Relieve pressure, page 15.
3. Disconnect hose connector (D) at Reactor.
4. Using an ohmmeter, check between the 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 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 20). If error disap-
pears, replace faulty module.
4. If E03 occurs for all zones, the contactor may not be
closing. Verify wiring from heater control to contac-
tor coil.
a. Hose zone: test hose continuity, page 23.
Before doing the following checks, note which zone
(A, B, FTS, or all) has high fluid temperature.
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
Disconnect whip hose.
When there is a a high current error, the LED on
that zone’s module will turn red while the error is
displayed.

Communication Diagnostic Code
312408F 9
b. Perform Transformer Primary Check and
Transformer Secondary Check, starting on
page 25.
E04: Fluid Temperature Sensor
(FTS) or thermocouple
disconnected
1. Check temperature sensor connections to long
green connector (B) on temperature control module,
page 19. Unplug and re-plug sensor wires.
2. Test fluid temperature sensor continuity with ohm-
meter, page 8.
3. 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.
5. To verify heater control module is not causing the
problem, use a wire to short-circuit the two pins cor-
responding 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.
6. If an error occurred for the hose zone, temporarily
use the current control mode. Refer to Reactor
Operation manual 312407.
E05: Circuit board overheated
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 bot-
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
Communications between the display and the motor
control board or the temperature control board has been
lost. When communication is lost, the corresponding
display will show E99.
1. Check all wiring between the display and the corre-
sponding control board. Pay close attention to the
wire crimping on plug J13 for each board.
2. Measure the incoming voltage to the board (it
should be ~ 230Vac).
3. If it was only receiving 1 leg of the 230Vac the board
may light up, and still not function properly. Correct
the incoming voltage problem.
When a no current error occurs, the LED on the
specific zone’s module turns red when the error is
displayed.
Each module has an on-board temperature sensor.
Heat is turned off if module temperature exceeds
185°F (85°C) within the heater module.
ti9878a
F
Step 2 measures line voltage and should be done by a
qualified electrician. If work is not performed properly
it may cause electric shock or other serious injury.

Troubleshooting
10 312408F
Troubleshooting
Reactor Electronics
Before performing any troubleshooting procedures:
1. Relieve pressure, page 15.
2. Turn main power OFF .
3. Allow equipment to cool.
Try the recommended solutions in the order given for
each problem, to avoid unnecessary repairs. Also,
determine that all circuit breakers, switches, and con-
trols are properly set and wiring is correct before assum-
ing there is a problem.
PROBLEM CAUSE SOLUTION
Both sides of display do not
illuminate.
No power.
Plug in power cord.
Turn disconnect ON .
Low voltage. Ensure input voltage is within specifi-
cations, page 26.
Loose wire. Check connections, page 26.
Display disconnected. Check cable connections, page 26.
Temperature display does not
illuminate.
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 turns on and
off.
Low voltage. Ensure input voltage is within specifi-
cations, page 26.
Poor display connection. Check cable connections, page 26.
Replace damaged cable.
Display cable damaged or corroded. Clean connections; replace cable if is
damaged.
Display cable not grounded. Ground cable, page 26.
Display extension cable too long. Must not exceed 100 ft (30.5 m)
Hose display reads OA at startup. FTS disconnected or not installed. Verify proper installation of FTS (see
Operation manual 312407), or adjust
FTS to desired current setting.

Troubleshooting
312408F 11
Display does not respond properly to
button pushes.
Poor display connection. Check cable connections, page 26.
Replace damaged cable.
Display cable damaged or corroded. Clean connections; replace cable 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.
PROBLEM CAUSE SOLUTION

Troubleshooting
12 312408F
Primary Heaters (A and B)
Before performing any troubleshooting procedures:
1. Relieve pressure, page 15.
2. Turn main power OFF .
3. Allow equipment to cool.
Try the recommended solutions in the order given for
each problem, to avoid unnecessary repairs. Also,
determine that all circuit breakers, switches, and con-
trols are properly set and wiring is correct before assum-
ing there is a problem.
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 7.
Signal failure from thermocouple. See E04: Fluid Temperature Sen-
sor (FTS) or thermocouple discon-
nected, page 9.
Control 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 (T) contacts
heater element (307). Holding themo-
couple tip (T) against heater element,
tighten ferrule nut (N) 1/4 turn past
tight. See page 22 for illustration.
Failed heater element. See Primary Heaters, page 21.
Signal failure from thermocouple. See E04: Fluid Temperature Sen-
sor (FTS) or thermocouple discon-
nected, page 9.
Thermocouple wired incorrectly. See E04: Fluid Temperature Sen-
sor (FTS) or thermocouple discon-
nected, page 9. Power up zones one
at a time and verify that temperature
for each zone rises.
AB

Troubleshooting
312408F 13
Hose Heat System
Before performing any troubleshooting procedures:
1. Relieve pressure, page 15.
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 that all circuit breakers, switches, and con-
trols are properly set and wiring is correct before assum-
ing there is a problem.
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 9.
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.
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 voltage. Low line voltage
significantly reduces power available
to hose heat system, affecting longer
hose lengths.
Hose temperature exceeds setpoint.
A and/or B heaters are overheating
material.
Check primary heaters for either a
thermocouple problem or a failed ele-
ment attached to thermocouple, page
9.
Faulty thermocouple connections. Verify that all FTS connections are
snug and that pins of connectors are
clean. Examine connection of ther-
mocouples 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 con-
trol board.

Troubleshooting
14 312408F
Erratic hose temperature.
Faulty thermocouple connections. Verify that all FTS connections are
snug and that pins of connectors are
clean. Examine connection of ther-
mocouples 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 not installed correctly. FTS should be installed close to end
of hose in same environment as gun.
Verify FTS installation, page 24.
Hose does 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 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.
PROBLEM CAUSE SOLUTION

Repair
312408F 15
Repair
Pressure Relief Procedure
1. Relieve pressure in gun and perform gun shutdown
procedure. See gun manual.
2. Engage gun piston safety lock.
3. Close gun fluid manifold valves A and B.
4. Shut off feed pumps and agitator, if used.
5. Turn PRESSURE RELIEF/SPRAY valves (SA, SB)
to PRESSURE 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 sure to
shut off all power to the equipment before repairing.
ti2409a
ti2421a
ti9879a
SA
SB
ti2554a

Repair
16 312408F
Flushing
• 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 . 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-ventilated area. Do not
spray flammable fluids. Do not turn on heaters while
flushing with flammable solvents.
SA
SB
ti9880a
N
N

Repair
312408F 17
Proportioning Pumps
1. Shut off , , and heat zones.
2. Flush, page 16.
3. Relieve pressure, page 15.
4. Turn PRESSURE RELIEF/SPRAY valves (SA, SB)
to PRESSURE RELIEF.
5. Turn main 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.
AB
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

Repair
18 312408F
Circuit Breaker Module
1. Turn main power OFF . Disconnect power
supply. Turn circuit breakers on to test.
2. Relieve pressure, page 15.
3. Using an ohmmeter, check for continuity across cir-
cuit breaker (top to bottom). If no continuity, trip
breaker, reset, and retest. If still no continuity,
replace breaker as follows:
a. Refer to electrical diagrams and to TABLE 2. Dis-
connect wires and remove bad breaker.
b. Install new breaker and reconnect wires.
* Depending on model.
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 Transformer
Primary
812A 25A, 40A* Heater A
812B 25A, 40A* Heater B
813 20A Motor/Pumps
FIG. 2. Circuit Breaker Module
FIG. 3. Fan Fuses
ti9884a
812A 813
809
811
NOTE: To reference cables and con-
nectors, see the electrical diagrams and
the parts drawings on pages 40-41.
812B
F
ti9884a-1

Repair
312408F 19
Temperature Control Module
Table 4: Temperature Power Module Connections
Table 3: 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 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
POWER/RELAY (G) Circuit board power input and
contactor control output
Connector Description
COMMUNICATION
(H)
Communication to control
board
POWER (J) Power to heater
FIG. 4: Temperature Control Module Connections
A
B
C
Bottom of Power Modules
Right Side of
Control Heater Module
D
E
F
G
ti9875a
ti9843a1
ti9843a4
H
J

Repair
20 312408F
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 current.
Hose current should ramp up to 45A. If there is
no hose current, see E03: No zone current,
page 8. If hose current exceeds 45A, see E02:
High zone current, page 8. 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 ambi-
ent hose temperature.
d. Turn on heat zone by pressing .
e. 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. Temperature control assem-
bly 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 assem-
bly; see Parts - Temperature Control, page 38.
7. Remove nuts and take entire temperature control
assembly to workbench.
8. Replace defective module.
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.