Booster Heater Upgrade Kit

Transcription

1 Instructions-Parts Booster Heater Upgrade Kit A EN To install a booster heater on Reactor E-30i Proportioners. For professional use only. Part No. 24T552 Important Safety Instructions Read all warnings and instructions in this manual and in the Reactor E-30i and E-XP2i Operation manual. Save all instructions. ti2875a

2 Installation 3. Remove three screws (S) from back plate. Rest fan assembly on frame. Repairing this equipment requires access to parts that may cause electric shock or other serious injury if work is not performed properly. Be sure to shut off all power to equipment before repairing.. Flush system. See proportioner operation manual for complete instructions. 2. Shutdown system. See proportioner operation manual for complete instructions. B S F S Remove Components. Remove the screws (S) and motor shield (M). Set aside and do not discard. M ti2876a 4. Remove the electrical enclosure back panel (P). Set aside and do not discard. P S S F ti2877a FIG. 2. Remove two screws (S) and front plate (F). Set aside and do not discard. 5. Remove four plugs from system frame. Use a screwdriver to remove the top plug first and then press the larger plug out of the frame. ti2878a A

3 Rotate Displacement Pumps. Remove fluids lines between the pump fluid outlets and fluid manifold inlets. Install Heater and Tubing. Apply thread sealant on elbow (44) threads and tighten in fluid outlet until the outlet faces downward. 44 ti2880a 2. Remove fittings from pump fluid outlets. 3. Cut the iso lubrication tubing (T) at the end of the fittings (F). Cut remaining tubing from barbed fittings. ti288a F G T S 2. Install two grommets (40) in frame ports. See FIG. 2, page Install screws (4) in the inner mounting ports on the heater (3). 4. Route heater (3) behind the B side of the motor, with the RTDs facing upward and fluid fittings facing backward. Rotate heater and position on frame so that screws (4) drop in key holes. NOTE: Pull the motor fan assembly out of the way during heater installation. 5. Remove plugs from fluid tubes (34, 43). ti2883a 4. Use a 7/6 wrench to remove the two barbed fittings (F) and /2 in. wrench to remove elbow fittings (F). Do not discard Loosen bottom swivel (S). 6. Loosen locknut (G) by hitting firmly with a non-sparking hammer. 7. Grab cylinder with hands and rotate the pump until the outlet port is facing outward. NOTE: Remove plugs from exposed iso lube ports if necessary. 8. To have more access during the heater installation, remove the fuel tank. See proportioner repair manual for complete instructions A 3

4 6. Install tubes (3, 32) between heater outlets (3) and fluid manifold. Torque to 43 ft-lbs (4.8 N m). 7. Install u-shaped tubes (34, 43) between the heater (3) and pump. Torque to 43 ft-lbs (4.8 N m). NOTE: If longer tubes do not align with manifold, loosen four mounting screws under the manifold. If the tubes do not align with the heater outlet, rotate the elbow (44). 8. Tighten swivel at pump inlet. 9. Tighten locknut (G) by hitting firmly with a non-sparking hammer. 0. Install barbed fittings in the ISO pump. Apply thin film of TSL to barbed fittings. Using two hands, support tubes (T) while pushing straight onto barbed fittings. Do not let tubes kink or buckle. Secure each tube with a wire tie between two barbs.. Reinstall motor fan and motor shield. 2. Use a 3/8 wrench to tighten heater screws (4). 3 32, FIG. 2: Heater Installation 4 40 ti2884a A

5 Install Low Power Temperature Control Modules (LPTCM). Use a hammer to remove knockouts from electrical enclosure. 2. Install gaskets (2) on inside of enclosure. 3. Install LPTCM bases (5) with eight screws (4). 4. Tighten modules (4) to bases (5) ti2887a FIG A 5

6 Connect Cables Apply Labels. Apply heater and module labels from label on all supplied cables and system parts. NOTE: Some identification labels will need to be applied to cables already installed on the system. 2. Apply red and blue TCM labels on inside and outside of enclosure. Cable Ref. Cable and Label Identification Qty. TCM-A-5 PWR 2 TCM-B-5 PWR TCM-A-CAN TCM-H TCM-H-6 TCM-A 6 20 TCM-B-CAN TCM-A TCM-A-CAN TCM-B TCM-A- J23 J23 TCM-A/B 36 TCM-B- J23 TCM-B-3 HTR-B 38 2 TCM-A-3 HTR-A TCM-A-2 J24 J24 TCM-A A

7 Connect Module Wires See Booster Heater Wiring Diagram, page 9.. Open electrical enclosure door.. Disconnect 2 black power supply cable from large HPTCM. Remove TCM - H6PSU label. 2. Apply TCMB-CAN PSU label on black power supply cable and connect to LPTCM B base CAN fitting. 3. Connect cables (2, 26, and 30) to modules inside electrical enclosure. 4. Connect power supply cable (2) to circuit breaker. 5. Remove tall wire track cover and press LPTCM cables in track. Bundle cables with zip tie (45) and reinstall wire track cover. Connect Heater Wires See Outside Electrical Enclosure with Optional Heater Wiring Diagram, page 0.. Insert black wire leads through side grommets (40) on frame cabinet. LPTCMA A Side- RTD 2. Remove red plugs from splice kit connectors (39). Connect power splice kits (39) to black heater rod wires. Feed black cables out side grommet (40). 3. Pull B side RTD and overtemp switch cable towards the A side RTD and zip tie above the B side RTD. 4. Connect double splitter (36) to the heater overtemperature switch cable (J23 OVERTEMP-SW). 5. Connect cable (TCMA-2 HTRDA) to the A side RTD and cable (TCMB-2 HTRTDB) to the B side RTD. 6. Connect connectors (J23TCMA, J23 TCMB) to splitter (36). 7. Feed heater signal cables behind fluid inlet tube and zip tie them to frame. 8. Cover heater signal cables with split loom (35). 9. Zip tie split loom with fir tree cable tie (33) in frame. 0. Secure splice kit connector cables to inside of cabinet with zip ties (45).. Connect over temp switch cables to LPTCMA and LPTCMB. 2. Use zip ties (45) to bundle cables exposed from back end of split loom. Zip tie split loom (35) against other split looms secured to the bottom of the frame. Overtemp Switch B Side- RTD LPTCMB FIG. 4: Heater Wire Routing 45 ti2888a A 7

8 3. Install the electrical enclosure back panel (P). P Test. Set rotary dials for LPTCMA and LPTCMB. See Booster Heater Wiring Diagram, page Power on system. Load software with token (37) in all GCA modules. 3. Check connections for leaks. ti2877a 4. Install heater shroud (4) and screws (4) on heater ti2877a A

9 Electrical Schematics Electrical Schematics Booster Heater Wiring Diagram ENCLOSURE BOUNDARY 2 LPTCM, 24L95 GND L2 L { { { CIRCUIT BREAKER 24J728 TB8 TB7 TB6 TB5 TB4 TB3 GRN WHT BLK 4 GRN WHT 4 BLK GRN WHT BLK 6K799 6K799 CAN, CAN, 2597 TCM-A-CAN TCM-H TCM-A-5 PWR TCM-A-CAN TCM-B 3 TCM-B-CAN TCM-A TCM-B-5 PWR TCM-B-CAN PSU LPTCM, 24L95 CB0 CB0 2 CB03 CB04 TB TB2 CB05 CB06 CB0 7 CB08 5 POWER SUPPLY, TCM-H-6 TCM-A TCM-H-6 CAN- CAN, HPTCM, 24L950 CAN- TCM-H CAN- MCM To MCM CAN, BULKHEAD, 262 CT Rotary switch set to 0. Rotary switch set to A. Rotary switch set to B. Torque terminal blocks to 5-7 in.-lbs ( N m). Torque circuit breaker connections to in.-lbs ( N m) A 9

10 Electrical Schematics Outside Electrical Enclosure with Optional Heater Wiring Diagram TCM-A 24L95 TCM-A-3 HTR-A BLAC K BLACK TCM-A-2 J24 J24 TCM-A TCM-A- J23 J24 HT-RTD-A WHITE BLACK Electrical Enclosure 6A HEATER A J23 TCM-A/B J23 OVERTEMP-SW RTD B BOOSTER HEATER, 24L936 OT SWITCH RTD A HEATER B TCM-B 24L95 TCM-B-3 HTR-B BLAC K BLACK 6A TCM-B-2 HT-RTD-B WHITE 2x BLACK TCM-B- J23 Heater viewed from the back of the proportioner. Torque power wire connections to in.-lbs (6.2-7 N m) A

11 Parts Parts 24T552, Boost Heater Upgrade Kit Torque to 43 ft-lbs (4.8 N m) Ref. Part Description Qty. ENCLOSURE, upgrade; includes items -2 2 PROPORTIONER, upgrade; includes L936 HEATER, assy, 4.0 kw; 2 zone; see Reactor manual 4 6K36 COVER, heater * 6K799 CABLE, volex, f , 6 AWG LABEL, cable LABEL, cable MODULE, LPTCM MODULE, cube, base 2 6* CABLE, CAN, female x female 0.5m SCREW, machine, #8x SCREW, self tap, pan hd ENCLOSURE, cube door 2 20* 2597 CABLE, CAN, 90 f x 90 f 2 5V933 GASKET, LPHM 2 3 6K227 TUBE, A-side, outlet 32 6K229 TUBE, B-side outlet Ref. Part Description Qty TIE, cable, fir tree K228 TUBE, B-side, inlet CONDUIT, flexible, non-metallic 4 36* HARNESS, splitter, parallel, M TOKEN 38* CABLE, volex, 6 AWG, male, 76 2 in KIT, heater wire connector GROMMET, rubber SCREW, flanged, hex hd 4 42* CABLE, M8, 4 pin, mxf 43 6K226 TUBE, A-side, inlet FITTING, elbow 3/8 NPT x #8 JIC TIE, cable, 7.5 in. 0 Replacement Danger and Warning labels, tags, and cards are available at no cost. * See cable identification table, page Not available for purchase. Not shown A

12 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. 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 warranty applies only when the equipment is installed, operated and maintained in accordance with Graco s written recommendations. This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco. This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation. THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale. GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties. In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise. FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées. Graco Information For the latest information about Graco products, visit TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Phone: or Toll Free: Fax: All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice. For patent information, see Original instructions. This manual contains English. MM Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. AND SUBSIDIARIES P.O. BOX 44 MINNEAPOLIS MN USA Copyright 203, Graco Inc. All Graco manufacturing locations are registered to ISO