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Repair - Parts
Air Powered, Heated, Plural Component Proportioner
For spraying polyurethane foam and polyurea coatings.
Not for use in explosive atmospheres.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
See page 3 for model information, including
maximum working pressure and approvals.
For patent information, see
www.graco.com/patents.
Model 259060 Shown
312408F
EN
TI11252a
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Table of Contents
Related Manuals for Graco Reactor A-XP Series
Summary of Contents for Graco Reactor A-XP Series
- Page 1 Not for use in explosive atmospheres. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. See page 3 for model information, including maximum working pressure and approvals. Model 259060 Shown For patent information, see www.graco.com/patents. TI11252a...
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Page 2: Table Of Contents
Graco Standard Warranty ....46 Graco Information ......46... -
Page 3: Models
Models Models Air Powered Reactors A-XP Series All A-XP2 models are CE compliant. Full Heater Flow Output Load Watts per Cycle Maximum Fluid Part, Voltage Peak System Pressure (lpm) at (A+B) Working Pressure Series Model (phase) Amps Watts hose) Ratio 78 cpm gal. -
Page 4: Supplied Manuals
Order Part 15B381 als translated in several languages for a compact disk of Fusion manuals translated in sev- eral languages. Manuals are also available at www.graco.com. Feed Pump Kits Reactor Air Powered Proportioner Part Description... -
Page 5: Warnings
Warnings 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. - Page 6 • 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.
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Page 7: Temperature Control Diagnostic Codes
Temperature Control Diagnostic Codes Temperature Control Diagnostic Codes Temperature control diagnostic codes appear on tem- perature display. Code Code Name Alarm Corrective Zone Action page These alarms turn off heat. E99 clears automatically High fluid temperature Individual when communication is regained. Codes E03 through High zone current Individual No zone current with... -
Page 8: E02: High Zone Current
Temperature Control Diagnostic Codes 4. Remove connector B from temperature control mod- 8. Verify continuity of heater elements with an ohmme- ule, and check continuity of overtemperature ter, see page 21. switches A and B, thermocouples A and B, or FTS by measuring resistance across the pins on the plug E02: High zone current end;... -
Page 9: E04: Fluid Temperature Sensor (Fts) Or Thermocouple Disconnected
Communication Diagnostic Code b. Perform Transformer Primary Check and 1. Check that fan above electrical cabinet is operating. Transformer Secondary Check, starting on 2. Check that electrical cabinet door is properly page 25. installed. 3. Check for obstructions blocking cooling holes in bot- When a no current error occurs, the LED on the tom of electrical cabinet. -
Page 10: Troubleshooting
Troubleshooting Troubleshooting Reactor Electronics 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- Before performing any troubleshooting procedures: trols are properly set and wiring is correct before assum- ing there is a problem. - Page 11 Troubleshooting PROBLEM CAUSE SOLUTION Poor display connection. Check cable connections, page 26. Replace damaged cable. Display cable damaged or corroded. Clean connections; replace cable if is Display does not respond properly to damaged. button pushes. Ribbon cable on display circuit board Connect cable (page 26) or replace.
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Page 12: Primary Heaters (A And B)
Troubleshooting Primary Heaters (A and B) 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- Before performing any troubleshooting procedures: trols are properly set and wiring is correct before assum- ing there is a problem. -
Page 13: Hose Heat System
Troubleshooting Hose Heat System 2. Turn main power OFF 3. Allow equipment to cool. Problems Try the recommended solutions in the order given for Before performing any troubleshooting procedures: each problem, to avoid unnecessary repairs. Also, determine that all circuit breakers, switches, and con- 1. - Page 14 Troubleshooting PROBLEM CAUSE SOLUTION 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 Erratic hose temperature. re-plug thermocouple wires, cleaning off any debris.
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Page 15: Repair
Repair Repair 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. -
Page 16: Flushing
Repair Flushing • 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). Flush equipment only in a well-ventilated area. Do not spray flammable fluids. Do not turn on heaters while flushing with flammable solvents. -
Page 17: Proportioning Pumps
Repair Proportioning Pumps 7. Remove pump. See applicable manuals, supplied. See applicable pump and motor repair-parts manu- als. Displacement pump (E) may be removed with- out removing entire proportioning pump. 8. Reinstall in reverse order. 1. Shut off , and heat zones. -
Page 18: Circuit Breaker Module
Repair Circuit Breaker Module 1. Turn main power OFF . Disconnect power supply. Turn circuit breakers on to test. ti9884a 812A 812B 2. Relieve pressure, page 15. NOTE: To reference cables and con- nectors, see the electrical diagrams and 3. Using an ohmmeter, check for continuity across cir- the parts drawings on pages 40-41. -
Page 19: Temperature Control Module
Repair Temperature Control Module Table 3: Temperature Control Module Connections Connector Description DATA (A) Data reporting HOSE T/C P; FTS (purple) HOSE T/C R; FTS (red) HOSE T/C S; FTS (silver (unshielded bare wire)) HEATER T/C B, Y; Thermocouple (yellow) SENSOR (B) HEATER T/C B, R;... - Page 20 Repair Test SCR Circuit e. Using a voltmeter, carefully measure the voltage at the hose connector. You should not get a volt- 1. Test the SCR circuit in the on position: age reading. If you do, the SCR on the tempera- a.
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Page 21: Primary Heaters
Repair Primary Heaters 6. To remove heater element, first remove thermocou- ple (310) to avoid damage, see step 7, page 22. Heater Element 7. Remove heater element (307) from housing (301). Be careful not to spill any fluid left in housing. See . - Page 22 Repair adapter must be removed, ensure that mixer (309) Thermocouple is out of the way when replacing the adapter. 8. Replace thermocouple, F . 6. 1. Turn main power OFF . Disconnect power a. Remove protective tape from thermocouple tip supply.
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Page 23: Heated Hose
Repair Overtemperature Switch 3. Disconnect hose connector (D) at Reactor, F . 7. 4. Using an ohmmeter, check between the two termi- nals of the connector (D). There should be continu- 1. Turn main power OFF . Disconnect power ity. supply. -
Page 24: Fluid Temperature Sensor (Fts)
Repair Fluid Temperature Sensor (FTS) 4. If FTS fails any test, replace FTS. 5. Disconnect air hoses (C, L), and electrical connec- Test/Removal tors (D). 6. Disconnect FTS from whip hose (W) and fluid hoses 1. Turn main power OFF . - Page 25 Repair Transformer Primary Check 3. To verify transformer voltage, turn on hose zone. Measure voltage from 18CB-2 to POD-HOSE-P15-2; see Reactor Electrical Dia- grams manual 312409. 1. Turn main power OFF Model Secondary Voltage 2. Locate the two smaller (10 AWG) wires coming out of transformer.
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Page 26: Display Module
Repair Display Module 9. Remove nuts (508) and plate (505). 10. Disassemble display, see detail in F . 10. Temperature and Pressure Displays 11. Replace board (501a or 502a) or membrane switch (501b or 502b) as necessary. CAUTION Before handling board, put on a static conductive wrist 12. - Page 27 Repair Apply medium strength thread sealant. TI3703a Detail of Membrane Switches and Display Boards Temperature Display Pressure Display 502c 502a 502b TI3702aa . 10. Display Module 312408F...
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Page 28: Parts
Parts Parts Air Powered Reactors Model A-XP2 Shown 15, 25 7, 8, 9 TI11252a TI11255a 3, 4, 5 27, 37 28, 29 30, 44 Detail of Cycle Counter Switch Ref. 26 magnet is on back side of yoke. Dimension from bottom of switch mounting plate (18) to top of tie plate must be 2 in. -
Page 29: Air Powered Reactors
Parts Air Powered Reactors Use this chart to find parts by model. Find ref. of part in left column, and Reactor model in top row. Intersection is cor- rect part number. Air Powered Reactor Models Ref. Description 259060, A-XP2 259061, A-XP2 259062, A-XP2 PACKAGE, control, heat 259073... -
Page 30: Heat Control Packages
Parts Heat Control Packages 134, 133 127, 151 TI11251a 107, 112, 141 190, 191 Heater Block Frame Rail TI11261a 170, 196 TI11258 312408F... - Page 31 Parts Left Side of Cabinet 161, 162 TI9835a Right Side of Cabinet 193 (400V unit only) TI11259a 312408F...
- Page 32 Parts Detail, Fluid Manifold Area 107 (Ref) TI10962a Detail, Cabinet Area TI11266a 312408F...
- Page 33 Parts Heat Control Packages Ref. Part Description Qty. 117623 NUT, cap (3/8-16) The following parts are common for all heat control 113796 SCREW, flanged, hex hd package models. See page 34 for parts that vary by 115942 NUT, flanged, hex hd model.
- Page 34 Parts Heat Control Packages (varying parts) Use this chart to find parts by model. Find ref. of part in left column, and model in top row. Intersection is correct part number. Heat Control Package Models Ref. Description 259070 259071 259072 259073 259074 259075...
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Page 35: 10.2 Kw And 6.0 Kw Heaters
Parts 10.2 kW and 6.0 kW Heaters (One Per Machine) Parts 247506 and 247507 r_247507_312408 Apply 110009 thermal heatsink compound. Ref. Part Description Ref. Part Description 15B137 SWITCH, overtemperature HOUSING, heater 15B135 MIXER, immersion heater 121309 ADAPTER 117484 SENSOR 15H304 PLUG 100518 SCREW, machine, pan hd 15H306 ADAPTER, thermocouple 15H305 PLUG, hollow... -
Page 36: 7.65 Kw Single Zone Heater
Parts 7.65 kW Single Zone Heater (Two Per Machine) Part 247509 r_247813_312066 Apply 110009 thermal heatsink compound. Ref. Part Description Ref. Part Description 15B135 MIXER, immersion heater HOUSING, heater 117484 SENSOR 121309 ADAPTER 100518 SCREW, machine, pan hd 15H304 PLUG 15H305 PLUG, hollow 15H306 ADAPTER, thermocouple 247520 DISC, rupture;... -
Page 37: Display
Parts Display 246043 Display TI3703a 402c 402b 402a 401b 401a TI3702a Ref. Part Description Ref. Part Description 246287 HARNESS, wire, red stop button 246044 DISPLAY, counter; includes 117499 HANDLE 401a-401b 117523 NUT, cap; 10-24 401a 117830 . COUNTER, digital 111008 SCREW, tapping, 6-32; 1/4 in. (6 401b 15B365 . -
Page 38: Temperature Control
Parts Temperature Control To B Heater Module To A Heater Module To Hose Heater Module TI9843a Ref. Part Description Qty. 247772 PANEL, module mounting 247827 HOUSING, control module 247828 HOUSING, heater module 115942 NUT, hex 247801 CABLE, communication 247825 KIT, cover, connector with screws 312408F... -
Page 39: Fluid Manifold
Parts Fluid Manifold Torque to 355-395 in-lb (40.1-44.6 N•m). Apply sealant (113500) to threads. Valve must be closed with handle position as shown on drawing. ** Apply PTFE tape or thread sealant to tapered threads. 702a 702b TI9839b Ref. Part Description Qty. -
Page 40: Circuit Breaker Modules
Parts Circuit Breaker Modules A - 230V, 3 Phase Circuit Breaker Modules For wiring and cable connections, refer to electrical diagrams manual 312409, supplied. See page 42 for parts. 803, 804 168BR 187CB 172CB 178CB 197CB B - 400V, 3 Phase Circuit Breaker Modules For wiring and cable connections, refer to electrical diagrams manual 312409, supplied. - Page 41 Parts C - 230V, 1 Phase Circuit Breaker Modules For wiring and cable connections, refer to electrical diagrams manual 312409, supplied. See page 42 for parts. 803, 804 168BR 197CB 172CB 178CB 187CB 312408F...
- Page 42 Parts Circuit Breaker Modules Parts List Breaker Modules Ref. Description 230V, 3 phase 400V, 3 phase 230V, 1 phase 255028 255028 255028 RAIL, mounting 255045 255045 255045 CLAMP, block, end 255043 255043 255043 HOLDER, fuse terminal, block 255023 255023 255023 FUSE 255042 255042...
- Page 43 Parts 312408F...
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Page 44: Dimensions
Dimensions Dimensions Dimension Model in. (mm) Dimension Model in. (mm) 11 (279) A-XP2 49 (1245) G (hole diameter) 0.625 (16) 35 (889) Weight A-XP2 400 lb (180 kg) 36.5 (927) HT Series 333 lb (150 kg) 25 (635) 27 (686) Side View Front View TI11256a... -
Page 45: Technical Data
Technical Data Technical Data Category Data Maximum Fluid Working Model A-XP2: 3000 psi (20.7 MPa, 207 bar) Pressure Maximum Input Pressure Model A-XP2: 120 psi (0.82 MPa, 8.2 bar) air to Motor Pressure Ratio Fluid:Air Model A-XP2: 25:1 Air Inlet Model A-XP2: 1/2 npsm(f) Recommended Air Supply Model A-XP2: 1/2 in. -
Page 46: 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.