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Graco Reactor A-25 Repair Parts

Air and hydraulic, heated, plural component proportioners
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Parts
Repair - Parts
309813B
Air and Hydraulic, Heated, Plural
Component Proportioners
For spraying polyurethane foam and polyurea coatings.
Not for use in explosive atmospheres.
See Models on page 4.
TI3699b
Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2003, Graco Inc. is registered to I.S. EN ISO 9001

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Summary of Contents for Graco Reactor A-25

  • Page 1 Component Proportioners For spraying polyurethane foam and polyurea coatings. Not for use in explosive atmospheres. See Models on page 4. TI3699b Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441 Copyright 2003, Graco Inc. is registered to I.S. EN ISO 9001...

  • Page 2: Table Of Contents

    Graco Standard Warranty ....58 Graco Information ......58...

  • Page 3: Manual Conventions

    Manual Conventions Manual Conventions Warning Caution CAUTION WARNING A caution alerts you to possible equipment damage or destruction if you do not follow instructions. A warning alerts you to possible serious injury or Note death if you do not follow instructions. A note indicates additional helpful information.

  • Page 4: Models

    Models Models Air Powered Reactors A SERIES Full Flow Load Heater lb/min Output per Maximum Fluid Part No., Voltage Peak System Watts (kg/min) Cycle (A + B) Working Pressure Series Model (phase) Amps* Watts** (no hose) at 75 cpm gal. (liter) psi (MPa, bar) 246037, B A-25...

  • Page 5: Heat Packages (Do Not Include Proportioner)

    Models Heat Packages (do not include proportioner) Full Load Heater Part No., Voltage Peak System Watts Series Model (phase) Amps* Watts** (no hose) 246365, B HT-6.0 230V (1) 10,340 6,000 246760, B HT-6.0 230V (3) 10,340 6,000 246761, B HT-6.0 380V (3) 10,340 6,000...

  • Page 6: Supplied Manuals

    Supplied Manuals Supplied Manuals Order Part No. 15B535 for a compact disk of Reactor ™ The following manuals are shipped with the Reactor manuals translated in several languages. Refer to them for detailed equipment information. Air and Hydraulic Reactors Part No. Description 309812 Air and Hydraulic Reactors, Operation Manual (English)

  • Page 7: Related Manuals

    Related Manuals Related Manuals The following manuals are for accessories used with the Order Part No. 15B535 for a compact disk of Reactor manuals translated in several languages. ™ Reactor Order Part No. 15B381 for a compact disk of Fusion manual translated in several languages.

  • Page 8: Warning

    Warning WARNING 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 medical attention. • Do not point the gun at anyone or at any part of the body. •...
  • Page 9 Misuse can cause serious injury or death. • For professional use only. • Use equipment only for its intended purpose. Call your Graco distributor for information. • Read manuals, warnings, tags, and labels before operating equipment. Follow instructions. • Check equipment daily. Repair or replace worn or damaged parts immediately.

  • Page 10: Before Beginning Repair

    Before Beginning Repair Before Beginning Flushing Repair WARNING WARNING Read warnings, page 8. Flush equipment only in a well-ventilated area. Do not spray flammable fluids. Do not turn on heaters while flushing with flammable sol- Repairing this equipment requires access to parts vents.

  • Page 11: Pressure Relief Procedure

    Pressure Relief Procedure Pressure Relief 6. Engage gun piston safety lock. Procedure 1. Relieve pressure in gun and perform gun shutdown procedure. See gun manual. TI2409A 7. Disconnect gun air line and remove gun fluid mani- 2. Verify gun fluid manifold valves A and B are closed. fold.

  • Page 12: Temperature Control Diagnostic Codes

    Temperature Control Diagnostic Codes Temperature Control Diagnostic Codes Temperature control diagnostic codes E01 through E05 These alarms turn off heat. Turn main power OFF appear on temperature display. then ON to clear. Code Code Name Alarm Zone Corrective Action page High fluid temperature Individual High hose current...

  • Page 13: E03: No Hose Current

    Temperature Control Diagnostic Codes E03: No hose current b. Check cable connections between all hose lengths. Do steps in order. Do not skip any step. c. Check temperature sensor connection at J1 on a. Check hose connectors for broken electrical temperature control board, page 20.

  • Page 14: Troubleshooting

    Troubleshooting Troubleshooting PROBLEM CAUSE SOLUTION Reactor does not operate. No power. Plug in power cord. Turn main power ON Turn circuit breakers ON, page 18. No air or hydraulic power. Open red-handled valve. Red stop button circuit open. Check button connections. See page 32 and electrical diagrams.
  • Page 15 Troubleshooting PROBLEM CAUSE SOLUTION Hose display reads 0A on startup. Install FTS (see operation manual), FTS not installed and zone off. or adjust current to desired setting. Erratic display; display turns on and Cable not grounded. Ground cable, page 32. off.
  • Page 16 Troubleshooting PROBLEM CAUSE SOLUTION No hose heat. Loose hose electrical connections. Check connections. Repair as neces- sary. Circuit breakers tripped. Reset breakers (CB1 or CB2), page Hose zone not turned on. Press zone key. A and B temperature setpoints too Check.

  • Page 17: Repair

    Repair Repair Proportioning Pump Removal 7. Remove pump. See applicable manuals, supplied. 1. Shut off , and heat zones. See page 6 for applicable pump and motor repair-parts manuals. Displacement pumps (E) may be removed without removing entire propor- tioning pump. 2.

  • Page 18: Circuit Breaker Module

    Repair Circuit Breaker Module 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: 1. Turn main power OFF . Disconnect power a.

  • Page 19: Fan

    Repair 2. Relieve pressure, page 11. 3. Check fuses (F) at left of breaker module, F . 3. 1. Turn main power OFF . Disconnect power Replace if blown. If good, continue with step 4. supply. 4. Refer to electrical diagrams. Disconnect fan wires from fuses (F).

  • Page 20: Temperature Control Board

    Repair Temperature Control Board 2. Relieve pressure, page 11. 3. Refer to electrical diagrams. Temperature control board is on left side inside cabinet. Temperature control board has seven green LEDs. Power must be on to check. See F . 4 for 4.
  • Page 21 Repair Apply 110009 thermal heatsink compound to mating surfaces. TI2572a . 4. Temperature Control Board 309813B...

  • Page 22: Heater

    Repair Heater Heater Element 1. Turn main power OFF . Disconnect power supply. 2. Relieve pressure, page 11. WARNING Read warnings, page 9. Wait for heaters to cool before repairing. 3. Wait for heaters to cool. 4. See F . 5. Remove tape and wire connector (63, not shown), and disconnect heater element wires (W) from heater wire harness.
  • Page 23 Repair Temperature Sensor d. Push in sensor (211) so tip (T) contacts heater element (207), avoiding mixer (202). e. Tighten ferrule nut (N), holding sensor (T) 1. Turn main power OFF . Disconnect power against heater element. supply. 9. Route wires into cabinet and thread into bundle as before.
  • Page 24 Repair Overtemperature Switch 3. Wait for heaters to cool. 4. Disconnect one leadwire from overtemperature switch (208), F . 6. Test across switch with ohmme- 1. Turn main power OFF . Disconnect power ter. Resistance must be approximately 0 ohms. supply.

  • Page 25: Heated Hose

    Repair Heated Hose 3. Disconnect FTS cable (F) at Reactor, F . 7. 4. Test with ohmmeter between pins of cable connec- tor. Refer to the heated hose manual 309572 for hose replacement parts. Check Hose Connectors Pins Result 1 to 2 approximately 35 ohms per 50 ft (15.2 m) of hose, plus approximately 10 ohms for FTS 1.

  • Page 26: Fluid Temperature Sensor (Fts)

    Repair Fluid Temperature Sensor 6. Disconnect FTS from whip hose (W) and fluid hoses (A, B). (FTS) 7. Remove ground wire (K) from ground screw on underside of FTS. Test/Removal 8. Remove FTS probe from component A (ISO) side of hose.
  • Page 27 Repair TI2684a1 . 8. Fluid Temperature Sensor and Heated Hoses 309813B...

  • Page 28: Transformer

    Repair Transformer Test Hose Continuity c. Connector pin 3 (P3) and T2 on 20A hose circuit breaker (817A). d. Connector pin 4 (P4) and PA on transformer ter- 1. Turn main power OFF . Disconnect power minal block (B). supply. Leave hose plugged in. e.
  • Page 29 Repair Detail B: Circuit Breaker Module and Hose Heat Wire Harness 817A To J1 Connector, pins 5 and 6 J13 on Temperature Control Board Detail A: Terminal Block TI4335A TI3934a TI3470b . 9. Transformer Continuity Tests 309813B...
  • Page 30 Repair Transformer Primary Check Transformer Secondary Check 1. Ensure that all harnesses, cables, and connectors 1. Ensure that all harnesses, cables, and connectors are properly connected. Connect hose. are properly connected. Connect hose. 2. Connect power supply. Turn main power ON 2.
  • Page 31 Repair Replace Transformer WARNING Use this procedure to replace transformer. To replace terminal block (B) and wire harness (C) only, order Part No. 248113 Transformer Repair Read warnings, page 8. Wait 5 min for stored voltage Kit. See manual 309930. to discharge (E-30 and E-XP2 models only).

  • Page 32: Display Module

    Repair Display Module If replacing both displays, label temperature dis- play cables TEMP and cycle counter display cables CYCLES before disconnecting. Temperature and Cycle Counter Displays 7. Disconnect cable connectors J1 and J13 from back of temperature display (402) or cycle counter dis- CAUTION play (401).
  • Page 33 Repair Apply medium strength thread sealant. TI3703a Detail of Membrane Switches and Display Boards Temperature Display Cycle Counter Display 402c 402a 402b TI3702a . 11. Display Module 309813B...
  • Page 34 Repair Red Stop Button 2. Relieve pressure, page 11. 3. Refer to electrical diagrams. CAUTION 4. Put on static conductive wrist strap. Before handling board, put on a static conductive wrist strap to protect against static discharge which can 5. Remove screws (409, 410) and cover (404), F .

  • Page 35: Parts

    Parts Parts Hydraulic Reactors (Model H-XP3 Shown) Ref. No. 23 used on H-50 Models only. Not shown in this view. 42, 23 7, 8, 9 TI3582b TI3668b 3, 4, 5 27, 37 28, 29 44, 30 Detail of Cycle Counter Switch Ref.

  • Page 36: Hydraulic Reactors

    Parts Hydraulic Reactors Use this chart to find parts by model. Find ref. no. of part in left column, and Reactor model in top row. Intersection is correct part no. Hydraulic Reactor Models Ref. 246039 246756 246757 246040 246758 246759 Description H-50 H-50...
  • Page 37 Parts Hydraulic Reactor Models Ref. 246039 246756 246757 246040 246758 246759 Description H-50 H-50 H-50 H-XP3 H-XP3 H-XP3 PLATE, mounting, switch 15C256 15C256 15C256 15C256 15C256 15C256 UNION, swivel; 3/8 npt(m) x 3/8 npsm(f) 155665 155665 155665 UNION, swivel; 1-1/16 in. un(f) x 3/4 npt(f) 112574 112574 112574 MAGNET 116618 116618 116618 116618 116618 116618...

  • Page 38: Air Powered Reactors (Model A-Xp2 Shown)

    Parts Air Powered Reactors (Model A-XP2 Shown) Ref. No. 25 used on A-50 Models only. 15, 25 Not shown in this view. 7, 8, 9 TI3669b TI3704b 3, 4, 5 27, 37 28, 29 30, 44 Detail of Cycle Counter Switch Ref.

  • Page 39: Air Powered Reactors

    Parts Air Powered Reactors Use this chart to find parts by model. Find ref. no. of part in left column, and Reactor model in top row. Intersection is correct part no. Air Powered Reactor Models Ref. 246037 246750 246751 246038 246754 246755 246639...
  • Page 40 Parts Air Powered Reactor Models Ref. 246037 246750 246751 246038 246754 246755 246639 246752 246753 Description A-25 A-25 A-25 A-50 A-50 A-50 A-XP2 A-XP2 A-XP2 PLATE, mounting, switch 15C256 15C256 15C256 15C256 15C256 15C256 15C256 15C256 15C256 UNION, swivel; 3/8 npt(m) x 155665 155665 155665 155665 155665 155665 3/8 npsm(f)

  • Page 41: Heat Control Package

    Parts Heat Control Package 109, 124, 125 TI3707a 190, 191 107, 112, 141 113, 126, 135 170, 196, 197, 172 TI3708b 309813B...
  • Page 42 Parts 128, 161, 162 129, 142 141, 123, 130 TI2606A 133, 194 TI3705a 309813B...
  • Page 43 Parts Heat Control Package Use the following chart to find parts that vary by package. Find the ref. no. of part in left column, and package in top row. Intersection is correct part no. Heat Control Package Ref. Description 246364 246365 246607 246760 246761 246762 246763 246764 246765 FRAME 245955 245955 245955 245955 245955 245955 245955 245955 245955 HEATER;...
  • Page 44 Parts Heat Control Package Ref. Description 246364 246365 246607 246760 246761 246762 246763 246764 246765 ELBOW, street; 1/2 npt (mxf) 158683 158683 158683 158683 158683 158683 158683 158683 158683 NUT, hex flange; 3/8-16 112958 112958 112958 112958 112958 112958 112958 112958 112958 BOOT, wire feed through 15B361 15B361 15B361 15B361 15B361 15B361 15B361 15B361 15B361 PLATE, cover, wire...
  • Page 45 Parts Heat Control Package Ref. Description 246364 246365 246607 246760 246761 246762 246763 246764 246765 NUT, hex, keps; 10-24 113505 113505 113505 113505 113505 113505 113505 113505 113505 WASHER, plain; no. 10 112776 112776 112776 112776 112776 112776 112776 112776 112776 CONNECTOR, wire;...

  • Page 46: Fluid Heater

    Parts Fluid Heater 245962 10.2 kW Heater, for A-25 and A-XP2 245963 7.65 kW Heater, for A-50, H-50, and Reactors, and HT-10.2 Heat Packages H-XP3 Reactors, and HT-15.3 Heat Packages (2 required) Ref. No. 182 not included with heater. Order separately, see page 45. Ref.
  • Page 47 Parts 245975 6 kW Heater, for HT-6.0 Heat Ref. Packages Part No. Description 15B134 HOUSING 15B135 MIXER Ref. No. 182 not included with heater. 118426 CLAMP 15B132 MANIFOLD Order separately, see page 45. 107218 SCREW 15B140 HEATER, immersion; 1500 W; 230v 15B137 SWITCH, overtemperature 100361...

  • Page 48: Display

    Parts Display 246043 Display TI3703a 402c 402b 402a 401b 401a TI3702a Ref. Ref. Part No. Description Part No. Description 15B291 PLATE 246044 DISPLAY, counter; includes 401a-401b 246287 HARNESS, wire, red stop button 401a 117830 . COUNTER, digital 117499 HANDLE 401b 15B365 .

  • Page 49: Temperature Control

    Parts Temperature Control 245979 Temperature Control Apply 110009 thermal heatsink compound to mating surfaces. TI2575A-1 Ref. Part No. Description 15B779 HEAT SINK 246194 BOARD, temperature control 117683 SCREW, 6-32 x 1-1/2 in. (38 mm) 117526 SPACER 104590 SCREW, machine; 6-32 x 3/8 in. (10 309813B...

  • Page 50: Fluid Manifold

    Parts Fluid Manifold 246042 Fluid Manifold Apply 113500 thread lock (blue). Torque to 355-395 in-lb (40.1-44.6 N•m). Apply PTFE tape or thread sealant to tapered threads. Torque to 175-195 in-lb (19.8-22.0 N•m). Lubricate ends of spring when assembling. Assemble valves (702) and handles (709) with handles facing away from each other.

  • Page 51: Circuit Breaker Modules

    Parts Circuit Breaker Modules 230V, 3 Phase Circuit Breaker Modules For wiring and cable connections, refer to electri- cal diagrams supplied. See page 54 for parts list. Part No. 246087 (A-25, A-XP2) Part No. 246089 (A-50) 803, 814, To Temperature Control To Hose Transformer Board, J13 (Hose) To Hose...
  • Page 52 Parts 230V, 1 Phase Circuit Breaker Modules For wiring and cable connections, refer to electri- cal diagrams supplied. See page 54 for parts list. Part No. 246090 (A-25, A-XP2) Part No. 246092 (A-50) 803, 814, To Temperature Control To Hose Transformer Board, J13 (Hose) To Hose To Temperature...
  • Page 53 Parts 380V, 3 Phase Circuit Breaker Modules For wiring and cable connections, refer to electri- cal diagrams supplied. See page 54 for parts list. Part No. 246096 (A-25, A-XP2) Part No. 246098 (A-50) Neutral 803, 814, To Temperature Control Board, J13 (Hose) To Hose Transformer To Hose To Temperature...
  • Page 54 Parts Circuit Breaker Modules Parts List Breaker Modules Ref. 246087 246089 246090 246092 246096 246098 230V, 3 θ 230V, 3 θ 230V, 1 θ 230V, 1 θ 380V, 3 θ 380V, 3 θ No. Description 801 RAIL, mounting locally locally locally locally locally...

  • Page 55: Transformer

    Parts Transformer Part No. 15B352 Transformer To replace terminal block (B) and wire harness (H) only, order Part No. 248113 Transformer Repair Kit. See manual 309930. TI3470a 309813B...

  • Page 56: Technical Data

    Technical Data Technical Data Category Data Maximum Fluid Working Model A-25: 1920 psi (13 MPa, 130 bar) Pressure Models A-50 and H-50: 2000 psi (14 MPa, 140 bar) Models A-XP2 and H-XP3: 3000 psi (20.7 MPa, 207 bar) Maximum Input Pressure to Models A-25 and A-XP2: 120 psi (0.82 MPa, 8.2 bar) air Motor Model A-50: 75 psi (0.5 MPa, 5 bar) air...
  • Page 57 Technical Data Category Data Fluid Inlets Models A-25, A-XP2, and H-XP3: 3/4 npt(f) Models A-50 and H-50: 1” npt(f) Model HT heat packages: 1/2 npt(f) on heater inlet blocks Fluid Outlets Component A (ISO): #8 JIC (3/4-16 unf), with #5 JIC adapter Component B (RES): #10 JIC (7/8-14 unf), with #6 JIC adapter Fluid Circulation Ports 1/4 npsm(m), with plastic tubing, 250 psi (1.75 MPa, 17.5 bar) maximum...

  • Page 58: Graco Standard Warranty

    With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.

This manual is also suitable for:

Reactor a-xp2Reactor h-50Reactor h-xp3Reactor ht-6.0Reactor ht-10.2Reactor ht-15.3

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