Graco A-25 manual

Repair-P ar ts PLURAL COMPONENT PROPORTIONER ® A-25 Air operated, electrically heated , plural component pr opor tioner For spraying or disp ensing 1:1 ratio pol yurethane foam form ulations and other 1:1 fast setting materials. Not for use in e xplosive at mospheres or hazardous locations. This model is fi eld-configurab le to the f ollowing supp[...]

2 3A1570A Contents Proportioner Models . . . . . . . . . . . . . . . . . . . . . . . . 3 Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Related M anuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 W arnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Impor tant T wo-Component Materi[...]

Proportioner Models 3A1570A 3 Pr opor tioner Models All propor tioners can be configured t o operate on 380V (4 wire), 230V (3 wire), or 230V 1Ø .  Only av ailable in Asia. Systems All systems include a proportioner , spra y gun, and 60 ft (18.3 m) o f heated hose. Related Manuals Manuals ar e av ailable at www .gr aco. com. Component manu als [...]

Warnings 4 3A1570A Wa r n i n g s The f ollowing wa r nings are for t he setup, use , grounding, maintenan ce, and repair of this equipment. Th e exclama- tion point symbol ale r ts you to a gene ral warning and the hazard symbols ref er to procedure- specific r isks. When these symbols appear in the body of this manual, re fer ba c k to these W ar[...]

Warnings 3A1570A 5 FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fumes, in wo rk a r e a can ignite or e xplode. T o help pre vent fire and explosion: • Use equipment only in we ll v entilated area. • Eliminate all ignition sources; such as pilo t lights, cigarettes , por table electr ic lamps, and plast ic drop cloths (p[...]

Warnings 6 3A1570A EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury . • Do not oper ate the unit when f atigued or under the infl uence of drugs or alcohol. • Do not e xceed the maximu m working pressure or te mperature ratin g of the lowest r ated system component. See T echnical Data in all equipment manuals . • Use fluids a[...]

Important Two-Component Materi al Information 3A1570A 7 Impor tant T w o-Component Material Inf ormation Isocy anate Conditions Material Self-ignition K eep Components A and B Separate Moisture Sensitivity of Isocy anates Isocy anates (ISO) are catalysts used in tw o component f oam and polyurea coatings. ISO will react with moisture (such as humid[...]

Important Two-Component Material Information 8 3A1570A Changing Materials Changing the material types used in y our equipment requires special atte ntion to av oid equipment damage and downt ime. • When changing m ater ials, flush the equipment mul- tiple times to ensure it is thoroughly cle an. • Alwa ys clean the fluid inlet str ainers after [...]

Important Two-Component Materi al Information 3A1570A 9 DataT rak Diagnostic Codes DataT rak can diagnose se v eral problem s with the pump . When the monitor detects a problem, the LED will flash and a diagnostic code will appear on the displa y . T o ackno wledge the diagnosis and retu r n to the nor mal operating scr een, press once to wak e up [...]

Important Two-Component Material Information 10 3A1570A E01: High fluid temperature Causes of E01 Error s • Thermocouple A or B (361) senses a fluid temper a- ture above 230°F (110° C). • Fluid tempe rature sens or (FTS) se nses a flu id tem- peratu re abov e 230°F (110°C) . • Ov er temperature s w itch (359) senses a fluid tem- peratu re[...]

Important Two-Component Materi al Information 3A1570A 11 d. If th e sw apped module does not f ix the prob lem, the power module is not the cause. 8. V erify continuity of heater e lements w ith an oh mme- ter , see page 28. E02: High zone current 1. T ur n main pow er OFF . 2. Relie v e pressure, page 13. NO TE: Disconnect whip hose. 3. Disconnect[...]

Important Two-Component Material Information 12 3A1570A E05: Contr ol board o ver temperature NO TE: Each module has an on-bo ard temperature sen- sor . Heat is turned off if module tem perature e xceeds 185°F (85°C) within the heater module . 1. Chec k that f an abov e electrical cabinet is operating. 2. Check that electr ical ca binet do or is [...]

Before Beginning Rep air 3A1570A 13 Bef ore Beginning Repair 1. Flush if nec essar y . See Flushing , page 14. 2. T ur n main heat er power OFF . 3. Relie v e pressure. See Pres sure Relief Proc edure . Pressure Relief Pr ocedure The Fusion AP gun is show n. 1. T ur n off feed pumps and agitator if used. 2. P ark component A pump . F ollow Par k ; [...]

Park 14 3A1570A Pa r k P ark the pumps at the end of the da y to cycle compo- nent A pum p to home position, s ubmerging d isplace- ment rod. 1. Open the park v alve . 2. T r igger the gun until pum ps stops at the bott om and relie ves pressure. 3. Close the air motor shuto ff valv e. 4. Close the par k valv e. Flushing • Flush out old fluid wit[...]

Troubleshooting 3A1570A 15 T roub leshooting Befo r e performing any troubleshooting pr ocedures : 1. Relie v e pressure, page 13. 2. T ur n main pow er OFF . 3. Allow equipment to cool. Pr oblems T r y the recommended solutions in the orde r given f or each problem, to avoid unnecessar y repairs. Also, determine that all circuit break ers, s witch[...]

Troubleshooting 16 3A1570A Fluid pressure lo w or dropping Air supply pressure lo w when spra y- ing Increase inlet air pressure Increase air compressor siz e to meet flow requirements Remov e air line quick disconnects Use 3/8 in. (0.95 cm) ID or larger air supply hose. Use 1/2 in. (1 2.7 mm) if longer than 25 ft (7.6 m). Icing in air m otor exh a[...]

Troubleshooting 3A1570A 17 Electr onics Fluid pressures not b alanced between A and B side Fluid viscosities no t equal Adjust A and B temperature settin gs to balance viscosity . Sometimes nor- mal if pressure offset is below 200 psi (14 bar) Preheat material in drums b y recircu- lating; see Ope ration manual Inlet Y -str ainer screen plugged on [...]

Troubleshooting 18 3A1570A Erratic displa y; displa y tur ns on and off . Low v oltage. Ensure input vo ltage is within specifi- cations , page 36. P oor displa y connection. Chec k cabl e connections, page 36 . Replace damage d cable . Displa y cable damaged or corroded. Clean connectio ns; replace cable if is damaged. Displa y cable not g rounded[...]

Troubleshooting 3A1570A 19 Heater PROBLEM CA USE SOLUTION Primar y heater(s) does not heat. Heat turned off . Press or zone ke ys. T emperature contro l alarm. Chec k temperat ure display f or diag- nostic code, pag e 9. Signal f ailure from thermocouple. See E04: Fluid T emperature Sen- sor (FTS) or thermocouple discon- nected , page 11 . Control [...]

Troubleshooting 20 3A1570A Hose Heat System PROBLEM CA USE SOLUTION Hose heats b ut heats slower th an usual or it does not re ach tempera- ture. Ambient temperature is too cold. U se auxiliar y hose heat system. FTS f ailed or not installed correctly . Chec k FTS, page 11. Low supply v oltage. V erify line volt age. Low line v oltage significantly[...]

Troubleshooting 3A1570A 21 Hose does not heat. FTS failed or is not contacting correctl y . Check FTS , pa ge 11. FTS not installed correctl y . FTS should be installed close to end of hose in sa me environment as gun. V erify FTS installation, page 32. T emperature contro l alarm. Chec k temperat ure display or diag - nostic code, pag e 32. Hoses [...]

Repair 22 3A1570A Repair Disconnect Pump NO TE: See manu al 309577 fo r pump repair instructions. 1. T ur n main heat er power OFF . 2. F ollow Flushing , page 14. 3. F ollow Pressure Relief Pro cedure , page 13. 4. F ollow Pa r k instructions, page 14 . 5. Shut off both feed pumps and close b oth inlet supply va l ves ( F ) . 6. Shut off inlet air[...]

Repair 3A1570A 23 11. Push retaining wire clip (307) up . Push retaining pin (306) out. 12. Loosen loc k nut (302) b y hitting firmly with a non-sparking hammer . 13. Unscr ew pump out of pump mou nting plat e (301). 14. See pump manu al for repa ir procedures and replacement p ar ts. Connect Pump 1. Ensure loc knut (302) is scre wed on pump with f[...]

Repair 24 3A1570A Remo ve Air Motor 1. Press in tube fit ting ferrules and pull out tubing (65) to disconnect air line . 2. Disconnect DataT rak comm unication cable , if installed. 3. Place wrench on ada pter (315) and a another wrench on lock nut (313). Remo ve loc k nut (313). 4. Remove f our nuts (310) from tie r ods (309). 5. Loosen tw o screw[...]

Repair 3A1570A 25 Recir culation / Over Pressure Relief Bloc k V alves can be ser viced with the b lock on the machin e (see page 46 f or par ts view ). For thoro ugh cleaning, remov e the bloc k assembly as f ollows . 1. Disconnect t wo fluid tubes connecte d to back of recirculation b lock (3). 2. Loosen and re mov e two screws (10) in back of re[...]

Repair 26 3A1570A T emperature Control Module T able 2: T emperature Contro l Module Connections Connector Descript ion D A T A (A) D ata repor ting SENSOR (B) PIN HOSE T/C P; FTS (pur ple) 12 11 HOSE T/C R; FTS (red) 10 HOSE T/C S; FTS (silver (unshielded ba re wire)) 9 HEA TER T/C B, Y ; Thermocouple (yellow) 8 HEA TER T/C B, R; Ther mocoup le (r[...]

Repair 3A1570A 27 T est SCR Circuit 1. T est the SCR circuit in the on position: a. Mak e sure ev erything is connected, including the hose. b . T ur n main power ON . c. Adjust the hose heat setpoint abo ve the amb i- ent hose tempe rature. d. T ur n on heat z one by pressing . e. Hold down to view electrica l current. Hose current shou ld ramp up[...]

Repair 28 3A1570A Primary Heater Heater Element 1. T ur n main pow er OFF . Disconnect po wer supply . 2. Relie v e pressure, page 13. 3. W ait for heaters to c ool. 4. Remove heater shroud. 5. See F IG . 7. Disconnect heater element wires from heater wire connect or . T est with ohmmeter . 6. T o remove heater eleme nt, first re mov e ther mocou -[...]

Repair 3A1570A 29 F IG . 7. 6 kW Dual Zone Heater 1 351 361 354 357 356 362 359 352 358 360 355 353 T orque to 120 ft-lbs (163 N•m). T orque to 23 ft-lbs (31 N•m). T orque to 40 ft-lbs (54 N•m). Apply 110009 ther mal heatsink compound. Apply sealant and PTFE tape to all non swiveling and threads without o-r ings. Apply lubricant to o-r ings. [...]

Repair 30 3A1570A Thermocouple 1. T ur n main pow er OFF . Disconnect po wer supply . 2. Relie v e pressure, page 13. 3. W ait for heaters to c ool. 4. Remove heater shroud. 5. Disconnect thermocouple wires from B on temper a- ture control module . See T able 2, page 26 and F IG . 6, page 26. 6. F eed thermocouple wires out of cabine t. Note path a[...]

Repair 3A1570A 31 Overtemperature Switch 1. T ur n main pow er OFF . Disconnect po wer supply . 2. Relie v e pressure, page 13. 3. W ait for heaters to c ool. 4. Remove heater shroud. 5. Disconnect on e leadwire from ov er temperature s witch (359), F IG . 8. T est across switch with ohmme- ter . Resistance must be appr oximate ly 0 ohms. 6. If swi[...]

Repair 32 3A1570A Fluid T emperature Sensor (FTS) T est/Remov al 1. T ur n main pow er OFF . Disconnect po wer supply . 2. Relie v e pressure, page 13. 3. Remo ve tape and pr otective co vering from FTS . Disconn ect hose cab le (F). T est with ohmmet er between pin s of cable connecto r . 4. If FTS f ails any test, r eplace FTS. 5. Disconnect air [...]

Repair 3A1570A 33 T ransformer Primary Check 1. T ur n main pow er OFF . 2. Locate the t wo smaller (10 A WG) wires coming out of transf or mer . T race these wires back to contactor and circuit break er (911). Use an ohmmeter to test f or continuity betwee n two wires; there should be continuity . T ransformer Secondary Check 1. T ur n main pow er[...]

Repair 34 3A1570A Replace Circuit Breaker Module 1. T ur n main pow er OFF . Disconnect po wer supply . T urn circuit breakers on to test. 2. Relie v e pressure, page 13. 3. Using an ohmmeter , check f or continuity across cir - cuit breaker (top to bottom). If no continuity , tr ip breaker , reset, and retest. If still no continuity , replace brea[...]

Repair 3A1570A 35 Pump Lubrication System Check the condition of the ISO p ump lubr icant da ily . Change the lubricant if it be comes a gel, its color dar k- ens, or it becom es diluted with isocyanate. Gel f or mation is due to moisture absorption by the pump lubricant. The interval bet ween changes depends on t he envir onment in which the equip[...]

Repair 36 3A1570A Fluid Inlet Strainer Screen The inlet str ainers filter out par ticles that can plug the pump inlet chec k va lves. I nspect the screens daily as par t of the star tup routine , and clean as required. Isocyanate can crystallize fr om moisture contamination or from freezing. If the chemicals used a re clean and proper stora ge, tra[...]

Repair 3A1570A 37 F IG . 15. Displa y Module ti18003a 102b 102c 102a R Detail of Membrane Switches and Te mperature Display Board Temperature Disp lay 1 102 104 105 116 103 107 119 106 ti18026a G[...]

Repair 38 3A1570A Replace DataT rak Battery or Fuse Replace Battery 1. Unscre w cable from the ba ck of the reed s witch assembly . See F IG . 16. 2. Remove the cable from the two cable clips. 3. Remove Da taT rak mo dule from brack e t. See F IG . 17. T ake module and att ached cable to a non-haz- ardous location. 4. Remo ve tw o screws on bac k o[...]

Accessories 3A1570A 39 Accessories Feed Pump Kits Pumps, hose s, and mounting hardw are to supply fluids to Reactor . Includes 246483 Air Supply Kit. Se e 309815. 246483 Air Supply Kit Hoses and fittings t o supply air to f eed pumps, agita tor , and gun air hose . Included in fee d pump kits. See 309827. 246978 Circulation Kit Retur n hoses and fi[...]

Parts 40 3A1570A Pa r t s 262572, Bare Reactor A-25 262614, Reactor A-25 with DataT rak and Wheels 35 56 (x4) 59 100 (x4) 38 83 62 16 18 10 51 4 20 3 20 14 (x4) 50 66 67 11 84 79 9 (x4) 8 7 15 15 85 26 13 19 17 89 91, 92 88 58 62 52 ti18023a 57 57 6 1 90 (x6) 11 (x6)[...]

Parts 3A1570A 41 93 7 5 13 (x2) 63 63 13 (x2) 2 68 69 24 22 21 23 ti18024a 15 15 61 9 (x4) 25 (x2) T orque pump locking nuts to 66-74 ft-lbs (90-100 N•m). Apply anaerobic polyacrylate pipe sealant to all non-swiv eling pipe threads. T orque tube ends to 212-265 in-lbs (24-30 N•m). Connect ground wire (94) from motor lug to ground lug in cabinet[...]

Parts 42 3A1570A 262572, Bare Reactor A-25 262614, Reactor A-25 with DataT rak and Wheels 34 13 (x4) 60 5 33 13 (x4) 12 49 49 83 30 29 28 80 27 31 32 ti18025a ti18007a 98 37 10 Ref P ar t Description Qty . 1- - - C A R T 1 2 26 2573 PUMP; see page 48 1 3 26 2577 MANIFOLD , relief; see page 46 1 4 --- P AN EL, contro l, heater ; see page 45 1 5 24J7[...]

Parts 3A1570A 43  Replacement Danger and W ar ning labels, tags , and cards are av ailable at no cost. † Only us ed with 26261 4.  Only used with 262572.  Included in Reed Switch Kit 24B659. ‡N o t s h o w n . 17 123970 S WITCH, disconnect, 40a 1 18 123971 KNOB , disconnect, o perator 1 19 123972 SWITCH, f our th pole 1 20 205447 COUPL[...]

Parts 44 3A1570A Contr ol P anel, 262575 Ai r Flow ti18002a 113 111 113 113 113 114 Apply sealant to all non swiv eling pipe threads. Attach ground wire from har ness (116) between connector on harness (106) a nd display co ver (105). Attach har ness (106) to J13 on board (102). Attach har ness (119) to J1 on board (102). 1 2 3 4 121 108 112 115 10[...]

Parts 3A1570A 45 T emperature Control Wheel Kit, 262695 † Only used with 262614. A v ailable as add on wheel kit 262695. Ref. P art Description Qty . 151 16G925 P ANEL, pod, mounting 1 152 247827 MODULE, heater control 1 153 247828 MODULE, heater 3 154 114183 NUT , hex, flanged, serrat ed 4 155 247801 CABLE, communication 1 153 154 154 151 152 15[...]

Parts 46 3A1570A Fluid Manif old  Replacement Dange r and W ar ning labels, tags , and cards are av ailab le at no cost. Fluid Inlet Kit, 262695 Ref. P art Description Qty . 201 24K993 MANIFOLD , recirculation 1 202 108638 FITTING, pipe , tee 2 203 162 453 FI TTING, (1/ 4 npsm x 1/4 npt) 2 204 1136 41 GA UG E, pressure, fluid, SST 2 205 111600 P[...]

Parts 3A1570A 47 6 kw Dual Zone Heater , 24J788 1 351 361 354 357 356 362 359 352 358 360 355 353 T orque to 1 20 ft-lbs (163 N•m). T orque to 2 3 ft-lbs (31 N•m). T orque to 4 0 ft-lbs (54 N•m). Apply 110009 ther mal heatsink compound. Apply sealant and PTFE tape to all non swiv eling and threads without o-rings. Apply lubricant to o-rings. [...]

Parts 48 3A1570A A-25 Air Motor Pump Assembl y , 262573 Apply PTFE tape and sealant to non-swiveling pipe threads. T orque to 88.5-124 in.-lbs (10-14 N•m). T orque to 32-38 ft-lbs (43-51 N• m). T orque nut (313) after assembly of item pin (306) and spring (307). Install adapters so that pins (306) will be in-line with each other . Lubricate thr[...]

Parts 3A1570A 49 Air T ubing Connections Ref. Length ft (m) Connection Material Color Outside Diameter From To 64 0.75 ft (0.23 m) 503 503 UHMWPE Black 5/32 in. (4 mm) 65 2.66 ft (0.8 m) 501 501 Urethane Black 1/2 in. (12.7 mm) 65 1.66 ft (0.5 m) 502 502 Urethane Black 1/2 in. (12.7 mm) 65 0.75 ft (0.23 m) 500 500 Urethane Black 1/2 in. (12.7 mm) 5[...]

Parts 50 3A1570A Breaker Module, 262576 401 402 413 414 403 410 (4x) 411 412 403 404 (8x) 409 408 407 406 405 403 404 (7x) Ref. P art Description Q ty . 401 16H309 RAIL, mounting 1 402 112446 BLO CK, clamp end 1 403 1 20490 CO VER, end 3 404 120570 BLO CK, ter minal 15 405 2 55046 BLOCK , ter minal grou nd 1 406 255050 CIRCUIT BR EAKER, 25a, 2p 2 4[...]

Reactor A-25 Wiring Schematic 3A1570A 51 Reactor A-25 Wiring Schematic N L2 L3 DSC 1-4 TB13-19 T1 T2 T3 L1 N 380V WYE 3 PHASE 230V DELTA 3 PHASE 230V 1 PHASE PE 2 BRIDGES L1 L2 L3 TB13-19 PE L2 TB13-19 L1 PE BRIDGE BRIDGE BRIDGE BRIDGE 170 171 172 173 174 175 176 177 178 179 179-1 179-2 179-3 179-4 179-5 BRIDGE BRIDGE BRIDGE BRIDGE BRIDGE BRIDGE 17[...]

Reactor A-25 Wiring Schematic 52 3A1570A 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 176 179 197CB B-POD 238CR L3 T3 1 2 4 3 25A 178 175 187CB A-POD 238CR L2 T2 1 2 4 3 25A 1122 1120-A HEATER POWER MODULE ZONE A SCR CIRCUIT THERMO- COUPLE A APOD-2 AP[...]

Reactor A-25 Wiring Schematic 3A1570A 53 102GND 2 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 1 1 1 1 2 2 2 2 1 3 1 3 1 3 1 1 1 1 1 1 1 2 2 2 2 2 2 2 183CB 50A 178CB 30A 187CB 25A 197CB 25A 238CR 1 F U S E 1 2 1 F U S E 2 2 TB1-TB8 TB9-TB12 TB13-TB19 380V 3-PHASE 230V 3-PHASE 230V 1-PHASE INCOMING POWER (DISREGARD TERMINATION ID'S SHOWN ON DISCONNECT) I[...]

Reactor A-25 Wiring Schematic 54 3A1570A TO OVERTEMP A TO THERMOCOUPLE A TO THERMOCOUPLE B TO FTS TO OPTIONAL DATA REPORTING TO HOSE THERMOCOUPLE A OVERTEMP A THERMOCOUPLE B CONTROL HEATER MODULE HOSE HEATER MODULE A HEATER MODULE B HEATER MODULE Simplified Schematic, Heater Controls POD HOSE 2 1 POD A 2 1 POD B 2 1 1 2 3 4 204PCB S E C O N D A R Y[...]

Technical Data 3A1570A 55 Te c h n i c a l D a t a *Full load amps with all de vices operating at maximum capabilities with 210 ft (64.1 m) of hose. ***210 ft (64 m) of hea ted hose will produce the ma ximum allo wable heat capacity . 3 10 ft (94 m) of heated hose ma y be used, but will ha ve 25% less heat capacity . Category Data Maximum Fluid W o[...]

All written and visual data con tained in th is document reflects the late st product information availabl e at the time of publica tion. Graco reserves the right to make changes at any time without notice. Original instructions. T his manual contains English. MM 3A1750 Graco Headquarters: Minneapoli s Internationa l Offices: Belgium, China, Japan,[...]