Graco 333024J, Reactor 2 E-30 and E-XP2 Proportioning System Repair, Parts Owner's Manual

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Graco 333024J, Reactor 2 E-30 and E-XP2 Proportioning System Repair, Parts Owner's Manual | Manualzz
Repair-Parts
Reactor 2 E-30 and E-XP2
Proportioning System
333024J
EN
Electric, Heated, Plural Component Proportioning System. For spraying polyurethane foam and
polyurea coatings. For professional use only. Not approved for use in explosive atmospheres or
hazardous locations.
Important Safety Instructions. Read all warnings and instructions in
this manual. Save these instructions.
WL E
PROVEN QUALITY. LEADING TECHNOLOGY.
Contents
Warnings ............................................................. 3
Important Isocyanate Information........................... 7
Models................................................................. 9
Approvals........................................................... 11
Accessories........................................................ 11
Supplied Manuals ............................................... 12
Related Manuals ................................................ 12
Troubleshooting.................................................. 13
Troubleshoot Errors ..................................... 13
Pressure Relief Procedure .................................. 46
Shutdown........................................................... 47
Flushing ............................................................. 49
Repair................................................................ 50
Before Beginning Repair............................... 50
Flush Inlet Strainer Screen ........................... 50
Change Pump Lubricant ............................... 51
Remove Pump............................................. 52
Install Pump ................................................ 53
Repair Drive Housing ................................... 54
Repair Electric Motor.................................... 57
Repair Circuit Breaker Module ...................... 58
Replace Fluid Inlet Sensor............................ 59
2
Replace Pressure Transducers ..................... 59
Replace Fans .............................................. 60
Repair Primary Heater.................................. 62
Repair Heated Hose..................................... 66
Repair Fluid Temperature Sensor
(FTS) ............................................. 68
Replace Power Supply ................................. 71
Replace Surge Protector .............................. 71
Replace Advanced Display Module
(ADM) ............................................ 71
Replace Motor Control Module (MCM) ........... 72
Software Update Procedure.......................... 72
Replace Temperature Control Module
(TCM) ............................................ 72
Parts.................................................................. 73
Electrical Schematics.......................................... 93
Reactor 2 Repair Spare Parts Reference ............. 96
Performance Charts............................................ 97
Technical Specifications.................................... 100
Notes ............................................................. 102
Graco Extended Warranty for Reactor® 2
Components ....................................... 103
333024J
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific
risks. When these symbols appear in the body of this manual or on warning labels, refer back to these
Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout
the body of this manual where applicable.
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can
cause electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before
servicing or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes
and regulations.
• Do not expose to rain. Store indoors.
TOXIC FLUID OR FUMES
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin,
inhaled or swallowed.
• Read Safety Data Sheet (SDS) for handling instructions and to know the specific hazards of
the fluids you are using, including the effects of long-term exposure.
• When spraying, servicing equipment, or when in the work area, always keep work area
well ventilated and always wear appropriate personal protective equipment. See Personal
Protective Equipment warnings in this manual.
• Store hazardous fluid in approved containers, and dispose of it according to applicable
guidelines.
PERSONAL PROTECTIVE EQUIPMENT
Always wear appropriate personal protective equipment and cover all skin when spraying,
servicing equipment, or when in the work area. Protective equipment helps prevent serious
injury, including long-term exposure; inhalation of toxic fumes, mists or vapors; allergic reaction;
burns; eye injury and hearing loss. This protective equipment includes but is not limited to:
• A properly fitting respirator, which may include a supplied-air respirator, chemically
impermeable gloves, protective clothing and foot coverings as recommended by the fluid
manufacturer and local regulatory authority.
• Protective eyewear and hearing protection.
333024J
3
Warnings
WARNING
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.
treatment
•
•
•
•
•
•
Do not spray without tip guard and trigger guard installed.
Engage trigger lock when not spraying.
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.
Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking,
or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
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 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 power or light switches on or off when flammable
fumes are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless
they are antistatic or conductive.
• Stop operation immediately if static sparking occurs or you feel a shock.. Do not use
equipment until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
THERMAL EXPANSION HAZARD
Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure
due to the thermal expansion. Over-pressurization can result in equipment rupture and serious
injury.
• Open a valve to relieve the fluid expansion during heating.
• Replace hoses proactively at regular intervals based on your operating conditions.
4
333024J
Warnings
WARNING
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious
chemical reaction and equipment rupture. Failure to follow this warning can result in death,
serious injury, or property damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon
solvents or fluids containing such solvents.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material
supplier for compatibility.
PLASTIC PARTS CLEANING SOLVENT HAZARD
Many solvents can degrade plastic parts and cause them to fail, which could cause serious
injury or property damage.
• Use only compatible water-based solvents to clean plastic structural or pressure-containing
parts.
• See Technical Data in this and all other equipment instruction manuals. Read fluid and
solvent manufacturer’s MSDSs and recommendations.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• 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 equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete
information about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals
and create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• 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, cut 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 and disconnect all power sources.
333024J
5
Warnings
WARNING
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid
severe burns:
• Do not touch hot fluid or equipment.
6
333024J
Important Isocyanate Information
Important Isocyanate Information
Isocyanates (ISO) are catalysts used in two component materials.
Isocyanate Conditions
Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and
atomized particulates.
• Read and understand the fluid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific
hazards and precautions related to isocyanates.
• Use of isocyanates involves potentially hazardous procedures. Do not spray with this equipment unless
you are trained, qualified, and have read and understood the information in this manual and in the fluid
manufacturer’s application instructions and SDS.
• Use of incorrectly maintained or mis-adjusted equipment may result in improperly cured material, which
could cause off gassing and offensive odors. Equipment must be carefully maintained and adjusted
according to instructions in the manual.
• To prevent inhalation of isocyanate mists, vapors and atomized particulates, everyone in the work
area must wear appropriate respiratory protection. Always wear a properly fitting respirator, which
may include a supplied-air respirator. Ventilate the work area according to instructions in the fluid
manufacturer’s SDS.
• Avoid all skin contact with isocyanates. Everyone in the work area must wear chemically impermeable
gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local
regulatory authority. Follow all fluid manufacturer recommendations, including those regarding handling
of contaminated clothing. After spraying, wash hands and face before eating or drinking.
• Hazard from exposure to isocyanates continues after spraying. Anyone without appropriate personal
protective equipment must stay out of the work area during application and after application for the time
period specified by the fluid manufacturer. Generally this time period is at least 24 hours.
• Warn others who may enter work area of hazard from exposure to isocyanates. Follow the
recommendations of the fluid manufacturer and local regulatory authority. Posting a placard such as the
following outside the work area is recommended:
333024J
7
Important Isocyanate Information
Self--Ignition
Material Self
Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings
and SDS.
Keep Components A and B Separate
Moisture Sensitivity of Isocyanates
Exposure to moisture (such as humidity) will cause
ISO to partially cure, forming small, hard, abrasive
crystals that become suspended in the fluid.
Eventually a film will form on the surface and the ISO
will begin to gel, increasing in viscosity.
NOTICE
Partially cured ISO will reduce performance and
the life of all wetted parts.
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere.
Never store ISO in an open container.
Cross-contamination can result in cured
material in fluid lines which could cause serious
injury or damage to equipment. To prevent
cross-contamination:
• Never interchange component A and component
B wetted parts.
• Never use solvent on one side if it has been
contaminated from the other side.
Changing Materials
NOTICE
Changing the material types used in your
equipment requires special attention to avoid
equipment damage and downtime.
• When changing materials, flush the equipment
multiple times to ensure it is thoroughly clean.
• Always clean the fluid inlet strainers after
flushing.
• Check with your material manufacturer for
chemical compatibility.
• Keep the ISO pump wet cup or reservoir (if
installed) filled with appropriate lubricant. The
lubricant creates a barrier between the ISO and
the atmosphere.
• Use only moisture-proof hoses compatible with
ISO.
• Never use reclaimed solvents, which may
contain moisture. Always keep solvent
containers closed when not in use.
• Always lubricate threaded parts with an
appropriate lubricant when reassembling.
NOTE: The amount of film formation and rate of
crystallization varies depending on the blend of ISO,
the humidity, and the temperature.
Foam Resins with 245 fa Blowing
Agents
Some foam blowing agents will froth at temperatures
above 90°F (33°C) when not under pressure,
especially if agitated. To reduce frothing, minimize
preheating in a circulation system.
• When changing between epoxies and urethanes
or polyureas, disassemble and clean all fluid
components and change hoses. Epoxies often
have amines on the B (hardener) side. Polyureas
often have amines on the B (resin) side.
8
333024J
Models
Models
Reactor 2 E-30 and E-30 Elite
All elite systems include fluid inlet pressure and temperature sensors, Graco InSite™, and Xtreme-Wrap 50 ft
(15 m) head hose. For part numbers, see Accessories, page 11
E-30 Model
Model
Proportioner ★
10 kW
15 kW
10 kW
15kW
272010
272011
272110
272111
2000 (14, 140)
2000 (14, 140)
2000 (14, 140)
0.0272 (0.1034)
0.0272 (0.1034)
0.0272 (0.1034)
30 (13.5)
30 (13.5)
30 (13.5)
Maximum Fluid Working
2000 (14, 140)
Pressure psi (MPa, bar)
Approximate Output per Cycle 0.0272 (0.1034)
(A+B) gal. (liter)
Max Flow Rate lb/min (kg/min) 30 (13.5)
Total System Load † �(Watts) 17,900
Phase�
Configurable Voltage Phase
E-30 Elite Model
23,000
350–
415
VAC
3ØY
34
Fusion AP Package �
AP2010
AH2010
AP2011
AH2011
AP2110
AH2110
AP2111
AH2111
(Gun Part No.)
(246102)
(246102)
(246102)
(246102)
(246102)
(246102)
(246102)
(246102)
Fusion CS Package �
CS2010
CH2010
CS2011
CH2011
CS2110
CH2110
CS2111
CH2111
(Gun Part No.)
(CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD)
Probler P2 Package �
P22010
(Gun Part No.)
(GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2)
Heated Hose
50 ft (15 m)
24K240 (scuff guard)
24Y240 (Xtreme-Wrap)
Heated Whip Hose
10 ft (3 m)
Graco Insite™
24K240
24K240
24K240
24K240
24Y240
24Y240
24Y240
24Y240
Qty: 1
Qty: 5
Qty: 1
Qty: 5
Qty: 1
Qty: 5
Qty: 1
Qty: 5
PH2010
200–
240
VAC
1Ø
100
P22011
200–
240
VAC
3Ø∆
62
PH2011
246050
Fluid Inlet Sensors (2)
*
Full load amps with all devices operating at
maximum capabilities. Fuse requirements at
various flow rates and mix chamber sizes
may be less.
�
Total system watts used by system, based on
maximum heated hose length for each unit.
• E–30 and E–XP2 series: 310 ft (94.5 m)
maximum heated hose length, including
whip hose.
★
See Approvals, page 11.
333024J
350–
415
VAC
3ØY
35
200–
240
VAC
1Ø
78
23,000
Full Load Peak Current*
246050
200–
240
VAC
3Ø∆
50
17,900
200–
240
VAC
1Ø
78
P22110
200–
240
VAC
3Ø∆
50
350–
415
VAC
3ØY
34
PH2110
200–
240
VAC
1Ø
100
200–
240
VAC
3Ø∆
62
P22111
246050
246050
✓
✓
✓
✓
350–
415
VAC
3ØY
35
PH2111
�
Packages include gun, heated hose, and
whip hose. Elite packages also include Graco
InSite and fluid inlet sensors.
�
Low line input voltage will reduce power
available and heaters will not perform at full
capacity.
Voltage Configurations Key
Phase
Ø
∆
DELTA
Y
WYE
9
Models
Reactor 2 E-XP2 and E-XP2 Elite
All elite systems include fluid inlet pressure and temperature sensors, Graco InSite™, and Xtreme-Wrap 50 ft
(15 m) head hose. For part numbers, see Accessories, page 11
Model
E–XP2 Model
Proportioner ★
E–XP2 Elite Model
15 kW
15 kW
272012
272112
Maximum Fluid Working
3500 (24.1, 241)
Pressure psi (MPa, bar)
Approximate Output per Cycle 0.0203 (0.0771)
(A+B) gal. (liter)
Max Flow Rate gpm/min (l/min) 2 (7.6)
3500 (24.1, 241)
Total System Load † � (Watts) 23,000
23,000
Configurable Voltage Phase � 200–240 VAC
1Ø
100
Full Load Peak Current
(amps)*
(amps)
0.0203 (0.0771)
2 (7.6)
200–240 VAC
3Ø∆
62
350–415 VAC
3ØY
35
200–240 VAC
1Ø
100
Fusion AP Package �
AP2012
AP2112
(Gun Part No.)
(246100)
(246100)
Probler P2 Package �
P22012
P22112
(Gun Part No.)
(GCP2R0)
(GCP2R0)
Heated Hose
50 ft (15 m)
Heated Whip Hose
10 ft (3 m)
Graco InSite™
24K241
(scuff guard)
246055
24Y241
(Xtreme-Wrap)
246055
Full load amps with all devices operating at
maximum capabilities. Fuse requirements
at various flow rates and mix chamber sizes
may be less.
�
Total system watts used by system, based on
maximum heated hose length for each unit.
• E–30 and E–XP2 series: 310 ft (94.5 m)
maximum heated hose length, including
whip hose.
★
10
See Approvals, page 11.
350–415 VAC
3ØY
35
✓
Fluid Inlet Sensors (2)
*
200–240 VAC
3Ø∆
62
✓
�
Packages include gun, heated hose, and
whip hose. Elite packages also include
Graco InSite and fluid inlet sensors.
�
Low line input voltage will reduce power
available and heaters will not perform at full
capacity.
Voltage Configurations Key
Phase
Ø
∆
DELTA
Y
WYE
333024J
Approvals
Approvals
Accessories
Kit Number
Description
24U315
Air Manifold Kit (4 outlets)
24U314
Wheel and Handle Kit
24T280
Graco InSite Kit
16X521
Graco InSite Extension cable 24.6 ft
(7.5 m)
24N449
50 ft (15 m) CAN cable (for remote
display module)
9902471
24K207
Conforms to ANSI/UL Std. 499
Certified to CAN/CSA Std. C22.2 No. 88
Fluid Temperature Sensor (FTS)
with RTD
24U174
Remote Display Module Kit
24K337
Light Tower Kit
15V551
ADM Protective Covers (10 pack)
15M483
Remote Display Module Protective
Covers (10 pack)
24M174
Drum Level Sticks
121006
150 ft (45 m) CAN cable (for remote
display module)
24N365
RTD Test Cables (to aide resistance
measurements)
Intertek approvals apply to proportioners without
hoses.
Proportioner Approvals:
333024J
11
Supplied Manuals
Supplied Manuals
The following manuals are shipped with the Reactor
2. Refer to these manuals for detailed equipment
information.
Manuals are also available at www.graco.com.
Manual
333023
333091
333092
Description
Reactor 2 E-30 and E-XP2
Operation
Reactor 2 E-30 and E-XP2 Startup
Quick Guide
Reactor 2 E-30 and E-XP2
Shutdown Quick Guide
Related Manuals
The following manuals are for accessories used with
the Reactor.
Component Manuals in English:
Manuals are available at www.graco.com.
System Manuals
333023
Reactor 2 E-30 and E-XP2 Operation
Displacement Pump Manual
309577
Electric Reactor Displacement Pump,
Repair-Parts
Feed System Manuals
309572
Heated Hose, Instructions-Parts
309852
Circulation and Return Tube Kit,
Instructions-Parts
309815
Feed Pump Kits, Instructions-Parts
309827
Feed Pump Air Supply Kit,
Instructions-Parts
Spray Gun Manuals
309550
Fusion ™ AP Gun
312666
Fusion ™ CS Gun
313213
Probler® P2 Gun
Accessory Manuals
3A1905
Feed Pump Shutdown Kit,
Instructions-Parts
3A1906
Light Tower Kit, Instructions-Parts
3A1907
Remote Display Module Kit,
Instructions-Parts
332735
Air Manifold Kit, Instructions-Parts
332736
Handle and Wheel Kit,
Instructions-Parts
333276
Graco InSite ™ Kit, Instructions-Parts
12
333024J
Troubleshooting
Troubleshooting
1. Press the soft key for help with the active error.
Troubleshoot Errors
There are three types of errors that can occur. Errors
are indicated on the display as well as by the light
tower (optional).
Error
Description
Alarms
A parameter critical to
the process has reached
a level requiring the
system to stop. The
alarm needs to be
addressed immediately.
Deviations
A parameter critical
to the process has
reached a level requiring
attention, but not
sufficient enough to
stop the system at this
time.
Advisories
A parameter that is
not immediately critical
to the process. The
advisory needs attention
to prevent more serious
issues in the future.
Note
Press
or
to return to the
previously displayed screen.
2. The QR code screen will be displayed. Scan
the QR code with your smartphone to be sent
directly to online troubleshooting for the active
error code. Otherwise, manually navigate to
http://help.graco.com and search for the active
error.
See Error Codes, page 13 for causes and solutions
to each error code.
To troubleshoot the error:
3. If no internet connection is available, see
Error Codes, page 13 for causes and solutions
for each error code.
Error Codes
Note
When an error occurs be sure to determine the code before resetting it. If you forget which error code
occurred, see the Errors screen to view the last 200 errors, with date, time, and description.
333024J
13
Troubleshooting
Error
Location
A1NM
MCM
A4DA
A4DB
A4DH
Heater A
Heater B
Hose
Type
Description
Cause
Solution
Low Motor Current
Loose/broken
connection.
Check for loose wire
terminations at MCM motor
connector.
Bad Motor.
Disconnect motor output
connector from MCM.
Confirm less than 8 ohms
resistance between each
pair of motor power leads
(M1 to M2, M1 to M3, M2 to
M3). If any readings greater
than 8 ohms, check motor
wiring for damage and/or
loose terminations.
Short circuit in
heater wiring.
Check wiring for touching
wires.
Bad Heater.
Confirm resistance of
heater. Heater resistance
should be 18–21 Ω for
each heater element, 9–12
Ω combined for 10 kW
systems, and 6-8 Ω for
15 kW systems. If out of
tolerance, replace heater
element.
Short circuit in
heater wiring.
Check wiring for touching
wires.
Bad Heater.
Confirm resistance of
heater. Heater resistance
should be 9-12 Ω for 10
kW systems and 6-8 Ω for
15 kW systems. If out of
tolerance, replace heater.
Short circuit in
hose wiring.
Check continuity of
transformer windings.
Normal readings are about
0.2Ω on both primary and
secondary. If reading is 0Ω
replace transformer.
High Current A
High Current B
High Current Hose
Check for shorts between
the primary winding and the
support frame or enclosure.
14
333024J
Troubleshooting
Error
Location
A4NM
MCM
Type
Description
Cause
Solution
High Motor Current
Short circuit of
motor wiring.
Check wiring to the motor
to ensure no bare wires are
touching and that no wires
are shorted to ground.
Motor will not
rotate.
Remove pump gear
housings from motor
and check that motor shaft
rotates freely in direction
indicated on motor housing.
Damaged gear
train.
Check pump gear trains
for damage and repair or
replace as necessary.
Chemical pump is
stuck.
Repair or replace chemical
pump.
A7DA
Heater A
Unexpected Current
A
Shorted TCM
If error cannot be cleared
or regenerates consistently,
replace module.
A7DB
Heater B
Unexpected Current
B
Shorted TCM
If error cannot be cleared
or regenerates consistently,
replace module.
A7DH
Hose
Unexpected Current
Hose
Shorted TCM
If error cannot be cleared
or regenerates consistently,
replace module.
333024J
15
Troubleshooting
Error
Location
A8DA
Heater A
A8DB
A8DH
CACM
16
Heater B
Hose
MCM
Type
Description
Cause
Solution
No Current A
Tripped circuit
breaker.
Visually check circuit
breaker for a tripped
condition.
Loose/broken
connection.
Check heater wiring for
loose wires.
Tripped circuit
breaker.
Visually check circuit
breaker for a tripped
condition.
Loose/broken
connection.
Check heater wiring for
loose wires.
Tripped circuit
breaker.
Visually check circuit
breaker for a tripped
condition.
Loose/broken
connection.
Check heater wiring for
loose wires.
Module does not
have software.
Insert a system token into
the ADM module and cycle
the power. Wait until the
upload is complete before
removing the token.
Dial set to wrong
position.
Ensure the MCM dial is set
to the correct position: 2 for
E-30, 3 for E-XP2
No 24 VDC supply
to module.
Green light on each module
should be lit. If green light is
not lit, check to make sure
each CAN cable connection
is tight. Verify the power
supply is outputting 24
VDC. If not, check power
supply wiring. If wiring is
okay, replace the power
supply.
Loose or broken
CAN cable.
Check the CAN cables
running between GCA
modules and tighten of
needed. If the problem
still persists move each
cable around the connector
and watch the flashing
yellow light on the GCA
modules. If the yellow light
stops flashing, replace the
CAN cable.
No Current B
No Current Hose
MCM Communication Error
333024J
Troubleshooting
Error
Location
CACT
TCM
DADX
MCM
Type
Description
Cause
TCM Communication Module does not
have software.
Error
Pump Runaway
Solution
Insert a system token into
the ADM module and cycle
the power. Wait until the
upload is complete before
removing the token.
No 24 VDC supply
to module.
Green light on each module
should be lit. If green light is
not lit, check to make sure
each CAN cable connection
is tight. Verify the power
supply is outputting 24
VDC. If not, check power
supply wiring. If wiring is
okay, replace the power
supply.
Loose or broken
CAN cable.
Check the CAN cables
running between GCA
modules and tighten of
needed. If the problem
still persists move each
cable around the connector
and watch the flashing
yellow light on the GCA
modules. If the yellow light
stops flashing, replace the
CAN cable.
Flow rate is too
large.
Mix chamber too large for
system selected. Use mix
chamber rated for system.
Ensure the system has
chemical and the feed
pumps are operating
correctly.
No material in pumps.
Verify pumps are supplying
chemical. If necessary,
replace or refill drums.
Inlet ball valves are closed.
Open ball valves.
333024J
17
Troubleshooting
Error
Location
DE0X
MCM
18
Type
Description
Cause
Solution
Cycle Switch Error
Faulty or missing
cycle switch.
Check wiring between cycle
switch and MCM, Port 12.
Switch
disconnected
Measure resistance
between pin 3 and 4
at connector. Normal
resistance is 0.10 ohms.
Missing or out of
place cycle switch
magnet.
Check presence and
position of cycle switch
magnet on output crank
arm.
333024J
Troubleshooting
Error
Location
EVCH
Description
Cause
Solution
ADM
Manual Hose Mode
Enabled
Manual hose mode
has been enabled
in System Setup
screen.
Install a functioning fluid
temperature sensor (FTS)
on the hose. Manual hose
mode will automatically turn
off.
EAUX
ADM
USB Busy
USB drive has
been inserted to
the ADM.
Do not remove USB drive
until download/upload is
complete.
EVUX
ADM
USB disabled
USB
download/uploads
are disabled.
Enable USB download/uploads on the Advanced
Setup screen before inserting a USB drive.
F9DX
MCM
High Pressure/Flow
Cutback
Mix chamber is
too large for set
pressure.
Reference the pressure
flow curves and select a tip
size that is the correct size
for the set pressure.
H2MA
Heater A
Low Frequency A
Line frequency is
below 45 Hz
Ensure line frequency of
incoming power is between
45 and 65 Hz.
H2MB
Heater B
Low Frequency B
Line frequency is
below 45 Hz
Ensure line frequency of
incoming power is between
45 and 65 Hz.
H2MH
Hose
Low Frequency Hose Line frequency is
below 45 Hz
Ensure line frequency of
incoming power is between
45 and 65 Hz.
H3MA
Heater A
High Frequency A
Line frequency is
above 65 Hz
Ensure line frequency of
incoming power is between
45 and 65 Hz.
H3MB
Heater B
High Frequency B
Line frequency is
above 65 Hz
Ensure line frequency of
incoming power is between
45 and 65 Hz.
H3MH
Hose
High Frequency
Hose
Line frequency is
above 65 Hz
Ensure line frequency of
incoming power is between
45 and 65 Hz.
K8NM
MCM
Locked Rotor Motor
Motor will not
rotate.
Remove pump gear
housings from motor
and check that motor shaft
rotates freely in direction
indicated on motor housing.
Damaged gear
train.
Check motor/pump gear
trains for damage and repair
or replace as necessary.
Chemical pump is
stuck.
Repair or replace chemical
pump.
333024J
Type
19
Troubleshooting
Error
Location
L1AX
ADM
Type
Description
Cause
Solution
Low Chemical Level
A
Low material level.
Refill material and update
drum level on ADM
Maintenance screen.
Alarm can be disabled on
the System Setup screen.
L1BX
ADM
Low Chemical Level
B
Low material level.
Refill material and update
drum level on ADM
Maintenance screen.
Alarm can be disabled on
the System Setup screen.
MMUX
USB
Maintenance Due USB
Insert a USB drive into the
USB logs have
ADM and download all logs.
reached a level
where data loss
will occur if logs are
not downloaded.
P0AX
MCM
Pressure Imbalance
A High
Pressure
difference between
A and B material
is greater than the
defined value.
Ensure material flow is
equally restricted on both
material lines.
Pressure
imbalance is
defined too low.
Ensure that the pressure
imbalance value, on the
System Setup screen, is at
an acceptable maximum
pressure to prevent
unnecessary alarms and
abort dispenses.
Out of material.
Fill tanks with material
Fluid leaking from
heater inlet rupture
disk.
Check if heater
and PRESSURE
RELIEF/SPRAY valve are
plugged. Clear. Replace
rupture disk. Do not replace
with a pipe plug.
Feed system
defective.
Check feed pump and
hoses for blockage. Check
that feed pumps have
correct air pressure.
20
333024J
Troubleshooting
Error
Location
P0BX
MCM
P1FA
P1FB
P2FA
333024J
MCM
MCM
MCM
Type
Description
Cause
Solution
Pressure Imbalance
B High
Pressure
difference between
A and B material
is greater than the
defined value.
Ensure material flow is
equally restricted on both
material lines.
Pressure
imbalance is
defined too low.
Ensure that the pressure
imbalance value, on the
System Setup screen, is at
an acceptable maximum
pressure to prevent
unnecessary alarms and
abort dispenses.
Out of material.
Fill tanks with material
Fluid leaking from
heater inlet rupture
disk.
Check if heater
and PRESSURE
RELIEF/SPRAY valve are
plugged. Clear. Replace
rupture disk. Do not replace
with a pipe plug.
Feed system
defective.
Check feed pump and
hoses for blockage. Check
that feed pumps have
correct air pressure.
Inlet pressure
lower than defined
value.
Ensure that inlet pressure
to the pump is sufficient.
Value defined too
high.
Ensure that the low
pressure alarm level
defined on the System
Setup screen is acceptable.
Inlet pressure
lower than defined
value.
Ensure that inlet pressure
to the pump is sufficient.
Value defined too
high.
Ensure that the low
pressure alarm level
defined on the System
Setup screen is acceptable.
Inlet pressure
lower than defined
value.
Ensure that inlet pressure
to the pump is sufficient.
Value defined too
high.
Ensure that the low
pressure alarm level
defined on the System
Setup screen is acceptable.
Low Inlet Pressure A
Low Inlet Pressure B
Low Inlet Pressure A
21
Troubleshooting
Error
Location
P2FB
MCM
P4AX
MCM
Type
Description
Cause
Solution
Low Inlet Pressure B
Inlet pressure
lower than defined
value.
Ensure that inlet pressure
to the pump is sufficient.
Value defined too
high.
Ensure that the low
pressure alarm level
defined on the System
Setup screen is acceptable.
System
pressurized before
allowing heat to
reach setpoint.
Pressure in the hose and
pumps will increase as the
system heats up. Turn on
heat and allow all zones
to reach the temperature
setpoint before turning on
the pumps.
Bad pressure
transducer.
Verify the ADM pressure
reading and the analog
gauges at the manifold.
High Pressure A
E-XP2 system
Alarm level is lower for E-30
configured as E-30. than for E-XP2. Ensure dial
on MCM is set to position
"3" for E-XP2.
P4BX
MCM
High Pressure B
System
pressurized before
allowing heat to
reach setpoint.
Pressure in the hose and
pumps will increase as the
system heats up. Turn on
heat and allow all zones
to reach the temperature
setpoint before turning on
the pumps.
Bad pressure
transducer.
Verify the ADM pressure
reading and the analog
guages at the manifold.
E-XP2 system
Alarm level is lower for E-30
configured as E-30. than for E-XP2. Ensure dial
on MCM is set to position
"3" for E-XP2.
22
333024J
Troubleshooting
Error
Location
P6AX
MCM
P6BX
P6FA
333024J
MCM
MCM
Type
Description
Cause
Solution
Pressure Sensor
Error A
Loose/bad
connection.
Check to ensure the
pressure transducer is
properly installed and
all wires are properly
connected.
Bad sensor.
Check if the error follows
the transducer. Disconnect
transducer cables from
the MCM (connectors 6
and 7). Reverse A and B
connections and check if
the errors follows. If the
error follows the transducer,
replace the pressure
transducer.
Loose/bad
connection.
Check to ensure the
pressure transducer is
properly installed and
all wires are properly
connected.
Bad sensor.
Check if the error follows
the transducer. Disconnect
transducer cables from
the MCM (connectors 6
and 7). Reverse A and B
connections and check if
the errors follows. If the
error follows the transducer,
replace the pressure
transducer.
Inlet sensors not
installed.
If inlet sensors are not
installed, inlet sensors
should be disabled on the
System Setup screen.
Loose/bad
connection.
Check to ensure inlet
sensor is properly installed
and all wires are properly
connected.
Bad sensor.
Check if the error follows
the inlet sensor. Disconnect
inlet sensor cables from
the MCM (connectors 8
and 9). Reverse A and B
connections and check if
the errors follows. If the
error follows the sensor,
replace the inlet sensor.
Pressure Sensor
Error B
Pressure Sensor
Error Inlet A
23
Troubleshooting
Error
Location
P6FB
MCM
P7AX
24
MCM
Type
Description
Cause
Solution
Pressure Sensor
Error Inlet B
Inlet sensors not
installed.
If inlet sensors are not
installed, inlet sensors
should be disabled on the
System Setup screen.
Loose/bad
connection.
Check to ensure inlet
sensor is properly installed
and all wires are properly
connected.
Bad sensor.
Check if the error follows
the inlet sensor. Disconnect
inlet sensor cables from
the MCM (connectors 8
and 9). Reverse A and B
connections and check if
the errors follows. If the
error follows the sensor,
replace the inlet sensor.
Pressure
difference between
A and B material
is greater than the
defined value.
Ensure material flow is
equally restricted on both
material lines.
Pressure
imbalance is
defined too low.
Ensure that the pressure
imbalance value, on the
System Setup screen, is at
an acceptable maximum
pressure to prevent
unnecessary alarms and
abort dispenses.
Out of material.
Fill tanks with material
Fluid leaking from
heater inlet rupture
disk.
Check if heater
and PRESSURE
RELIEF/SPRAY valve are
plugged. Clear. Replace
rupture disk. Do not replace
with a pipe plug.
Feed system
defective.
Check feed pump and
hoses for blockage. Check
that feed pumps have
correct air pressure.
Pressure Imbalance
A High
333024J
Troubleshooting
Error
Location
P7BX
MCM
T2DA
333024J
Heater A
Type
Description
Cause
Solution
Pressure Imbalance
B High
Pressure
difference between
A and B material
is greater than the
defined value.
Ensure material flow is
equally restricted on both
material lines.
Pressure
imbalance is
defined too low.
Ensure that the pressure
imbalance value, on the
System Setup screen, is at
an acceptable maximum
pressure to prevent
unnecessary alarms and
abort dispenses.
Out of material.
Fill tanks with material
Fluid leaking from
heater inlet rupture
disk.
Check if heater
and PRESSURE
RELIEF/SPRAY valve are
plugged. Clear. Replace
rupture disk. Do not replace
with a pipe plug.
Feed system
defective.
Check feed pump and
hoses for blockage. Check
that feed pumps have
correct air pressure.
Flow is too high at
current setpoint.
Use a smaller mix chamber
that is rated for the unit
in use. If recirculating,
decrease flow or decrease
temperature setpoint.
Bad RTD or bad
RTD placement
against heater.
Swap A and B heater output
cables and RTD cables and
see if issue follows. If so,
replace RTD.
Bad heater rod or
loose heater wire.
Confirm resistance of
heater. Heater resistance
should be 9-12 Ω for 10
kW systems and 6-8 Ω
for 15 kW systems. If out
of tolerance, check for
loose heater rod wire(s).
Reconnect wires or replace
heater rod if necessary.
Low Temperature A
25
Troubleshooting
Error
Location
T2DB
Heater B
T2DH
T2FA
Hose
MCM
Type
Description
Cause
Solution
Low Temperature B
Flow is too high at
current setpoint.
Use a smaller mix chamber
that is rated for the unit
in use. If recirculating,
decrease flow or decrease
temperature setpoint.
Bad RTD or bad
RTD placement
against heater.
Swap A and B heater output
cables and RTD cables and
see if issue follows. If so,
replace RTD.
Bad heater rod or
loose heater wire.
Confirm resistance of
heater. Heater resistance
should be 9-12 Ω for 10
kW systems and 6-8 Ω
for 15 kW systems. If out
of tolerance, check for
loose heater rod wire(s).
Reconnect wires or replace
heater rod if necessary.
Flow is too high at
current setpoint.
Use a smaller mix chamber
that is rated for the unit
in use. If recirculating,
decrease flow or decrease
temperature setpoint.
Cold chemical in
unheated portion
of system passed
hose FTS at
startup.
Recirculate heated
chemical back to drum
in cold conditions before
startup.
Inlet fluid
temperature is
below the defined
level.
Recirculate fluid through
heaters until inlet fluid
temperature is above
defined error level.
Low Temperature
Hose
Low Temperature
Inlet A
Increase the low
temperature deviation
level on the System Setup
screen.
T2FB
MCM
Low Temperature
Inlet B
Inlet fluid
temperature is
below the defined
level.
Recirculate fluid through
heaters until inlet fluid
temperature is above
defined error level.
Increase the low
temperature deviation
level on the System Setup
screen.
26
333024J
Troubleshooting
Error
Location
T3CH
Hose
T3CT
T3NM
T3CM
TCM
MCM
MCM
Type
Description
Cause
Solution
Hose Cutback
Hose current has
been reduced
because hose
has been drawing
current for an
extended period.
Hose setpoint higher than A
and B setpoints. Decrease
hose setpoint.
High ambient
temperature.
Ensure ambient
temperature is below
120°F(48°C) before using
the system.
Enclosure fan not
operating.
Ensure fan in electrical
enclosure is spinning. If it
is not, check fan wiring or
replace fan.
Module fan not
operating.
If a TCM fan error (WMI0)
has occurred, fan inside
the module is not working
properly. Check TCM fan
for debris and clear with
forced air if necessary.
Motor is operating
outside of the
pressure flow
curve.
The system is running at a
lower setpoint to preserve
motor life. Run the system
at a lower duty cycle or with
a smaller mix chamber.
High ambient
temperature
Ensure ambient
temperature is below
120° F (48° C) before using
the system.
Motor control
temperature is
too high.
Ensure ambient
temperature is below
120°F(48°C).
TCM Cutback
Motor Temperature
Cutback
MCM Temperature
Cutback
Hose FTS is in a colder
environment than the rest
of the hose. Expose FTS to
the same environment as
the rest of the hose.
Verify that all fans are
working.
T4CM
333024J
MCM
High Temperature
MCM
High ambient
temperature.
Ensure ambient
temperature is below
120°F(48°C) before using
the system.
Enclosure fan not
operating.
Ensure fan in electrical
enclosure is spinning. If it
is not, check fan wiring or
replace fan.
27
Troubleshooting
Error
Location
T4CT
TCM
T4DA
Heater A
Type
Description
Cause
Solution
High Temperature
TCM
High ambient
temperature.
Ensure ambient
temperature is below
120°F(48°C) before using
the system.
Enclosure fan not
operating.
Ensure fan in electrical
enclosure is spinning. If it
is not, check fan wiring or
replace fan.
Module fan not
operating.
If a TCM fan error (WMI0)
has occurred, fan inside
the module is not working
properly. Check TCM fan
for debris and clear with
forced air if necessary.
Bad RTD or bad
RTD placement
against heater.
Swap A and B heater output
cables and RTD cables and
see if issue follows. If so,
replace RTD.
High Temperature A
Use a smaller mix chamber
Flow too high
that is rated for the unit in
for temperature
use.
setpoint, causing
temperature
overshoots when
gun is de-triggered.
T4DB
Heater B
High Temperature B
Bad RTD or bad
RTD placement
against heater.
Swap A and B heater output
cables and RTD cables and
see if issue follows. If so,
replace RTD.
Use a smaller mix chamber
Flow too high
that is rated for the unit in
for temperature
use.
setpoint, causing
temperature
overshoots when
gun is de-triggered.
28
333024J
Troubleshooting
Error
Location
T4DH
Hose
Type
Description
Cause
Solution
High Temperature
Hose
Hose portion
exposed to an
excessive heat
source, like hot
sun or coiled
hose, can pass
fluid more than
27°F (15°C) over
hose temperature
setting to the FTS.
Shade exposed hose from
hot sun or expose FTS to
same environment when
at rest. Uncoil entire hose
before heating to avoid
self-heating.
Increase hose setpoint
Setting the A or
so it is closer to A and B
B setpoint much
setpoints.
higher than hose
setpoint can cause
fluid more than
27°F (15°C) over
hose temperature
setting to reach the
FTS.
T4EA
333024J
Heater A
High Temperature
Switch A
Overtemperature
switch sensed a
fluid temperature
above 230°F
(110°C).
Heater was delivered too
much power, causing the
overtemperature switch to
open. RTD is not reading
properly. After the heater
cools down, replace RTD.
Switch closes and the error
can be cleared when the
heater temperature falls
below 190°F (87°C).
Disconnected
or loose
overtemperature
switch
cable/connection.
If heater is not actually
over temperature, check
all wiring and connections
between the TCM and the
overtemperature switches.
Overtemperature
switch failed in the
open position.
Replace overtemperature
switch.
29
Troubleshooting
Error
Location
T4EB
Heater B
T4NM
MCM
Type
Description
Cause
Solution
High Temperature
Switch B
Overtemperature
switch sensed a
fluid temperature
above 230°F
(110°C).
Heater was delivered too
much power, causing the
overtemperature switch to
open. RTD is not reading
properly. After the heater
cools down, replace RTD.
Switch closes and the error
can be cleared when the
heater temperature falls
below 190°F (87°C).
Disconnected
or loose
overtemperature
switch
cable/connection.
If heater is not actually
over temperature, check
all wiring and connections
between the TCM and the
overtemperature switches.
Overtemperature
switch failed in the
open position.
Replace overtemperature
switch.
Cooling fan is not
operating properly.
Check to see that the motor
fan is moving. Measure
voltage to fan. There should
be 24 VDC.
If no voltage is measured,
check fan wiring. If the
fan has voltage but is not
moving, replace fan.
If necessary use an air hose
to blow out around the fan
housings and remove any
built-up debris.
High ambient
temperature.
Ensure ambient
temperature is below
120°F(48°C) before using
the system.
High Temperature
Motor
Motor is operating Run the system at a lower
outside of the
duty cycle or with a smaller
pressure flow curve mix chamber.
Motor temperature
sensor wires are
shorted together
30
Measure resistance
between pins 2 and 4
on motor temperature cable
connector at MCM, port
2. A reading below 75
ohms indicates a wire short.
Replace motor.
333024J
Troubleshooting
Error
Location
T6DA
Heater A
Type
Description
Cause
Sensor Error A
Disconnected or
Check all wiring and
loose RTD cable or connection to RTD.
connection.
Bad RTD.
333024J
Solution
Switch the RTD with
another and see if the error
message follows the RTD.
Replace RTD if the error
follows the RTD.
31
Troubleshooting
Error
Location
T6DB
Heater B
Type
Description
Cause
Sensor Error B
Disconnected or
Check all wiring and
loose RTD cable or connection to RTD.
connection.
Bad RTD.
T6DH
Hose
Sensor Error Hose
Solution
Switch the RTD with
another and see if the error
message follows the RTD.
Replace RTD if the error
follows the RTD.
Disconnected or
Expose each hose RTD
shorted RTD cable connection to check and
in hose or bad FTS. retighten any loose connector. Measure hose RTD
cable and FTS continuity.
See Repair Heated Hose,
page 66. Order RTD Test
kit 24N365 for measurement.
Disconnect hose RTD and
use manual hose mode to
finish job until repair can be
completed.
T6DT
TCM
Sensor Error TCM
Shorted RTD cable Expose each hose RTD
connection to check for
in hose or FTS.
exposed and shorted RTD
wires. Measure hose RTD
cable and FTS continuity.
See Repair Heated Hose,
page 66. Order RTD Test
kit 24N365 for measurement.
Disconnect hose RTD and
use manual hose mode to
finish job until repair can be
completed.
Shorted A or B
Heater RTD
32
If the error still occurs with
the hose FTS unplugged,
one of the heater RTDs
is bad. Unplug the A or
B RTD from the TCM. If
unplugging an RTD fixes
the T6DT error, replace the
RTD.
333024J
Troubleshooting
Error
Location
T6NM
MCM
333024J
Type
Description
Cause
Solution
Sensor Error Motor
Disconnected
or loose motor
temperature cable
connector
Verify proper cable
connection at MCM, port
2. Measure resistance
between pins 2 and 4 on
motor temperature cable
connector. A correct ohm
reading will vary greatly
with temperature. An open
circuit reading indicates a
wire break. Replace motor.
33
Troubleshooting
Error
Location
T8DA
Heater A
T8DB
Heater B
Type
Description
Cause
Solution
No Temperature
Rise A
Bad RTD or bad
RTD placement
against heater.
Swap A and B heater output
cables and RTD cables and
see if issue follows. If so,
replace RTD.
Bad heater rod or
loose heater wire.
Confirm resistance of
heater. Heater resistance
should be 9-12 Ω for 10
kW systems and 6-8 Ω
for 15 kW systems. If out
of tolerance, check for
loose heater rod wire(s).
Reconnect wires or replace
heater rod if necessary.
Started spraying
before heater
reached operating
temperature.
Wait until operating
temperature has been
reached before spraying or
recirculating.
Bad RTD or bad
RTD placement
against heater.
Swap A and B heater output
cables and RTD cables and
see if issue follows. If so,
replace RTD.
Bad heater rod or
loose heater wire.
Confirm resistance of
heater. Heater resistance
should be 9-12 Ω for 10
kW systems and 6-8 Ω
for 15 kW systems. If out
of tolerance, check for
loose heater rod wire(s).
Reconnect wires or replace
heater rod if necessary.
Started spraying
before heater
reached operating
temperature.
Wait until operating
temperature has been
reached before spraying or
recirculating.
No Temperature
Rise B
T8DH
Hose
No Temperature
Rise Hose
Started spraying
before heater
reached operating
temperature.
Wait until operating
temperature has been
reached before spraying or
recirculating.
V1CM
MCM
Low Voltage MCM
Loose/bad
connection or
tripped circuit
breaker.
Check wiring for loose
connection or tripped circuit
breaker.
Low incoming line
voltage.
Measure voltage at circuit
breaker and ensure voltage
is greater than 195 VAC.
34
333024J
Troubleshooting
Error
Location
V1IT
Description
Cause
TCM
Low Voltage CAN
Bad 24 VDC power Check voltage of power
supply.
supply. Voltage should
be 23-25 VDC. If out of
tolerance, replace power
supply.
V2IT
TCM
Low Voltage CAN
Bad 24 VDC power Check voltage of power
supply.
supply. Voltage should
be 23-25 VDC. If out of
tolerance, replace power
supply.
V2MA
TCM
Low Voltage A
Loose connection
or tripped circuit
breaker.
Check wiring for loose
connection or tripped circuit
breaker.
Low incoming line
voltage.
Measure voltage at circuit
breaker and ensure voltage
is greater than 195 VAC.
Loose connection
or tripped circuit
breaker.
Check wiring for loose
connection or tripped circuit
breaker.
Low incoming line
voltage.
Measure voltage at circuit
breaker and ensure voltage
is greater than 195 VAC.
Loose connection
or tripped circuit
breaker.
Check wiring for loose
connection or tripped circuit
breaker.
Low incoming line
voltage.
Measure voltage at circuit
breaker and ensure voltage
is greater than 195 VAC.
V2MB
V2MH
TCM
TCM
Type
Low Voltage B
Low Voltage Hose
Solution
V3IT
TCM
High Voltage CAN
Bad 24 VDC power Check voltage of power
supply.
supply. Voltage should
be 23-25 VDC. If out of
tolerance, replace power
supply.
V3MA
TCM
High Voltage A
Incoming line
voltage is too high.
333024J
Ensure incoming system
power is wired properly.
Verify voltage at each circuit
breaker is between 195 and
264 VAC.
35
Troubleshooting
Error
Location
V3MB
Description
Cause
Solution
TCM
High Voltage B
Incoming line
voltage is too high.
Ensure incoming system
power is wired properly.
Verify voltage at each circuit
breaker is between 195 and
264 VAC.
V3MH
TCM
High Voltage Hose
Incoming line
voltage is too high.
Ensure incoming system
power is wired properly.
Verify voltage at each circuit
breaker is between 195 and
264 VAC.
V4CM
MCM
High Voltage MCM
Incoming line
voltage is too high.
Ensure incoming system
power is wired properly.
Verify voltage at each circuit
breaker is between 195 and
264 VAC.
V4IT
TCM
High Voltage CAN
Bad 24 VDC power Check voltage of power
supply.
supply. Voltage should
be 23-25 VDC. If out of
tolerance, replace power
supply.
V4MA
TCM
High Voltage A
Incoming line
voltage is too high.
Ensure incoming system
power is wired properly.
Verify voltage at each circuit
breaker is between 195 and
264 VAC.
V4MB
TCM
High Voltage B
Incoming line
voltage is too high.
Ensure incoming system
power is wired properly.
Verify voltage at each circuit
breaker is between 195 and
264 VAC.
V4MH
TCM
High Voltage Hose
Incoming line
voltage is too high.
Ensure incoming system
power is wired properly.
Verify voltage at each circuit
breaker is between 195 and
264 VAC.
36
Type
333024J
Troubleshooting
Error
Location
WBC0
MCM
Type
Description
Cause
Solution
Software Version
Error
Incorrect software
version.
Insert a system token into
the ADM module and cycle
the power. Wait until the
upload is complete before
removing the token.
MCM does not
have line voltage.
If V1CM also exists, see
troubleshooting for V1CM.
The software version
cannot be read if the MCM
does not have line voltage.
WMI0
TCM
TCM Fan Error
Fan inside TCM
is not operating
properly.
Check for debris in the TCM
fan and clear with forced air
if necessary.
WSUX
USB
Configuration Error
USB
A valid
configuration file
can't be found for
the USB.
Inset a system token into
the ADM and cycle power.
Wait until the lights on the
USB port stop flashing
before removing token.
WXUD
ADM
USB Download Error
Log download
failed.
Backup and reformat the
USB drive. Retry download.
WXUU
ADM
USB Upload Error
Custom language
Perform normal USB
file failed to upload. download and use the new
disptext.txt file to upload the
custom language.
333024J
37
Troubleshooting
System
Before performing any troubleshooting procedures:
1. Relieve Pressure. See Pressure Relief Procedure, page 46.
2. Turn main power switch OFF.
3. Allow equipment to cool.
Problem
Reactor ADM does not turn on.
Electric motor does not operate.
Electric motor runs erratically.
38
Cause
No power.
Solution
Turn main power switch ON.
Failed 24 V power supply.
Replace power supply.
Failed surge protector.
Replace surge protector.
Loose connections.
Check MCM connection 13.
Tripped circuit breaker (CB02).
Reset breaker, see Repair Circuit
Breaker Module, page 58. Check
240VAC at output of breaker.
Shorted windings.
Replace motor, see
Repair Electric Motor, page 57.
Failed motor bearing.
Replace motor, see
Repair Electric Motor, page 57.
333024J
Troubleshooting
Problem
Cause
Solution
Loose wire.
Check. See
Electrical Schematics, page 93.
Fan blade obstructed.
Remove obstruction.
Defective fan.
Replace. See
Replace Motor Fan, page 60.
Obstructed fluid hose or gun; fluid
hose ID too small.
Open, clear; use hose with larger
ID.
Worn piston valve or intake valve
in displacement pump.
See pump manual.
Pressure setpoint too high.
Reduce setpoint and output will
increase.
Fluid leak in pump packing nut
area.
Worn throat seals.
Replace. See pump manual.
No pressure on one side.
Fluid leaking from heater inlet
rupture disk (372).
Check if heater and PRESSURE
RELIEF/SPRAY valve (SA or SB)
are plugged. Clear. Replace
rupture disk (372) with a new one;
do not replace with a pipe plug.
Cooling fans not working.
Pump output low.
333024J
39
Troubleshooting
Hose Heat System
Before performing any troubleshooting procedures:
1. Relieve Pressure. See Pressure Relief Procedure, page 46.
2. Turn main power switch OFF.
3. Allow equipment to cool.
Problem
Hose heats but heats slower
than usual or it does not reach
temperature.
Hose does not maintain
temperature while spraying.
40
Cause
Solution
Ambient temperature is too cold.
Relocate hoses to a warmer area
or recirculate heated fluid through
the hose.
FTS failed or not installed correctly.
Check FTS, see Check RTD
Cables and FTS, page 67.
Low supply voltage.
Verify line voltage. Low line
voltage significantly reduces
power available to the hose heat
system, affecting longer hose
lengths.
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
temperature before spraying.
Low supply voltage.
Verify line voltage. Low line
voltage significantly reduces
power available to the hose heat
system, affecting longer hose
lengths.
333024J
Troubleshooting
Problem
Hose temperature exceeds
setpoint.
333024J
Cause
Solution
A and/or B heaters are overheating Check primary heaters for either
material.
a RTD problem or a failed
element attached to RTD, see
Electrical Schematics, page 93.
Faulty FTS connections.
Verify that all FTS connections are
snug and that pins of connectors
are clean. Unplug and re-plug
RTD wires, cleaning off any debris.
Ambient temperature is too high.
Cover hoses or move to a location
with a lower ambient temperature.
Missing or damaged insulation
around FTS, causing the hose
heat to be ON constantly.
Make sure the hose bundle
has adequate insulation evenly
covering the entire length and
connection joints.
41
Troubleshooting
Problem
Erratic hose temperature.
Hose does not heat.
Cause
Solution
Faulty FTS connections.
Verify that all FTS connections are
snug and that pins of connectors
are clean. Unplug and re-plug
FTS wires along length of hose,
cleaning off any debris.
FTS not installed correctly.
FTS should be installed close to
end of hose in same environment
as gun. Verify FTS installation,
see Repair Fluid Temperature
Sensor (FTS), page 68.
Missing or damaged insulation
around FTS, causing the hose
heat to be ON constantly.
Make sure the hose bundle
has adequate insulation evenly
covering the entire length and
connection joints.
FTS failed.
Check FTS, see Repair Fluid
Temperature Sensor (FTS), page
68.
FTS not installed correctly.
FTS should be installed close to
end of hose in same environment
as gun. Verify FTS installation,
see Repair Fluid Temperature
Sensor (FTS), page 68.
Loose hose electrical connections. Check connections. Repair as
necessary.
42
Circuit breakers tripped.
Reset breakers (CB01 ), see
Repair Circuit Breaker Module,
page 58.
Hose zone not turned on.
Turn on hose heat zone.
A and B temperature setpoints too
low.
Check. Increase if necessary.
333024J
Troubleshooting
Problem
Cause
Solution
Hoses near Reactor are warm, but Shorted connection or failed hose
hoses downstream are cold.
heating element.
With power off, check the hose
resistance with and without the
whip hose attached. With the
whip hose attached, the reading
should be less than 3 ohm. Without the whip hose attached, the
reading should be OL (open loop).
See Check Hose Heat Power
Connectors, page 66.
Low hose heat.
A and B temperature setpoints too
low.
Increase A and B setpoints. Hose
designed to maintain temperature,
not increase temperature.
Hose temperature setpoint too
low.
Check. Increase if necessary to
maintain heat.
Flow too high.
Use smaller mix chamber.
Decrease pressure.
Low current; FTS not installed.
Install FTS, see operation manual.
Hose heat zone not turned on long Allow hose to heat up, or preheat
enough to reach setpoint.
fluid.
Loose hose electrical connections. Check connections. Repair as
necessary.
Ambient temperature is to low
333024J
Relocate hoses to a warmer area
or increase A and B setpoints.
43
Troubleshooting
Primary Heater
Before performing any troubleshooting procedures:
1. Relieve Pressure. See Pressure Relief Procedure, page 46.
2. Turn main power switch 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 controls are properly set and wiring is correct before
assuming there is a problem.
Problem
Primary Heater(s) does not heat.
Control of primary heat is
abnormal; high temperature
overshoots (T4DA, T4DB) occurs
intermittently.
44
Cause
Solution
Heat turned off.
Turn on heat zones.
Temperature control alarm.
Check ADM for error codes.
Signal failure from RTD.
Signal failure from RTD.
Dirty RTD connections.
Examine RTD cables connected
to TCMs. Confirm RTDs are
not plugged into opposite heat
zone. Unplug and re-plug RTD
connectors. Unplug and re-plug
RTD connectors. Ensure RTD tip
contacts the heater element.
RTD not contacting heater
element.
Loosen ferrule nut, push in RTD
so tip contacts heater element.
Holding RTD tip against heater
element, tighten ferrule nut 1/4
turn past tight.
Failed heater element.
See
Replace Heater Element, page 62.
Signal failure from RTD.
See (T6DA, T6DB), Error Codes.
333024J
Troubleshooting
Graco InSite
Problem
No module status LEDs are
illuminated.
Has not identified GPS location
(green module status LED
flashing).
Cause
No power to cellular module.
Still identifying location.
Unable to identify location. In a
location where GPS lock cannot
occur. Buildings and warehouses
often prevent GPS locks.
Has not established cellular
connection (orange module status
LED flashing).
Still establishing cellular
connection.
Unable to establish cellular
connection.
Cannot view data for my unit(s) on
website.
Graco InSite unit has not been
activated.
Temperature data not displayed
on website.
Hose zone temperature data not
displayed on website.
Reactor temperature
measurement is not working.
The RTD or thermocouple is not
correctly installed on the hose or
is broken.
Reactor pressure measurement is
not working.
Pressure data not displayed on
website.
333024J
Solution
Turn Reactor ON.
Ensure unit is properly installed.
Verify 24V at output of the power
supply.
Make sure the M8, 4–pin to M12,
8–pin cable is installed between
cellular module and power supply.
Wait a few minutes for the unit to
identify the location.
Move system to a location with a
clear view of the sky.
Use extension cable 16X521 and
move cellular module to a location
with a clear view of the sky.
Wait a few minutes for the unit to
establish the connection.
Move system to a location with
cellular service to establish cellular
connection.
Use extension cable 16X521 and
move cellular module to a location
with a clear view of the sky.
Activate unit. See Registering
and Activating the Graco InSite
section.
See System troubleshooting
section.
See RTD or Thermocouple repair
section.
See System troubleshooting
section.
45
Pressure Relief Procedure
Pressure Relief Procedure
Follow the Pressure Relief Procedure
whenever you see this symbol.
4. Route fluid to waste containers or supply tanks.
Turn PRESSURE RELIEF/SPRAY valves (SA,
SB) to PRESSURE RELIEF/CIRCULATION
. Ensure gauges drop to 0.
GA
GB
SA
This equipment stays pressurized until pressure
is manually relieved. To help prevent serious
injury from pressurized fluid, such as skin injection,
splashing fluid and moving parts, follow the
Pressure Relief Procedure when you stop spraying
and before cleaning, checking, or servicing
equipment.
SB
5. Engage gun piston safety lock.
The Fusion AP gun is shown.
1. Relieve pressure in gun and perform gun
shutdown procedure. See gun manual.
2. Close gun fluid inlet valves A and B.
6. Disconnect gun air line and remove gun fluid
manifold.
3. Shut off feed pumps and agitator, if used.
46
333024J
Shutdown
Shutdown
4. Press
to park the Component A Pump. The
park operation is complete when green dot goes
out. Verify the park operation is complete before
moving to next step.
Shutdown system to avoid electric shock. All
electrical wiring must be done by a qualified
electrician and comply with all local codes and
regulations. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop spraying and before
cleaning, checking, or servicing equipment.
5. Press
to deactivate the system.
NOTICE
Proper system setup, startup, and shutdown
procedures are critical to electrical equipment
reliability. The following procedures ensure steady
voltage. Failure to follow these procedures will
cause voltage fluctuations that can damage
electrical equipment and void the warranty.
1. Press
to stop the pumps.
2. Turn off all heat zones.
3. Relieve pressure. See
Pressure Relief Procedure, page 46.
333024J
6. Turn off the air compressor, air dryer, and
breathing air.
7. Turn main power switch OFF.
To prevent electric shock do not remove any
shrouds or open the electrical enclosure door.
47
Shutdown
8. Close all fluid supply valves.
9. Engage gun piston safety lock then close fluid
inlet valves A and B.
Fusion
48
Probler
333024J
Flushing
Flushing
To flush feed hoses, pumps, and heaters
separately from heated hoses, set PRESSURE
RELIEF/SPRAY valves (SA, SB) to PRESSURE
RELIEF/CIRCULATION
lines (N).
To avoid fire and explosion:
GA
SA
. Flush through bleed
GB
SB
• Flush equipment only in a well-ventilated area.
• Do not turn on heaters until fluid lines are clear
of solvent.
• 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 wetted parts are compatible with common
solvents. Use only moisture-free solvents.
333024J
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 filled with a moisture-free
plasticizer or oil. Do not use water. Never leave the
system dry. See Important Isocyanate Information.
49
Repair
Repair
1. Close the fluid inlet valve on the y-strainer inlet
and shut off the appropriate feed pump. This
prevents material from being pumped while
cleaning the screen.
2. Place a container under the strainer base to catch
drain off when removing the strainer plug (C).
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.
Before Beginning Repair
NOTICE
Proper system setup, startup, and shutdown
procedures are critical to electrical equipment
reliability. The following procedures ensure steady
voltage. Failure to follow these procedures will
cause voltage fluctuations that can damage
electrical equipment and void the warranty.
3. Remove the screen (A) from the strainer
manifold. Thoroughly flush the screen with
compatible solvent and shake it dry. Inspect the
screen. No more than 25% of the mesh should
be restricted. If more than 25% of the mesh is
blocked, replace the screen. Inspect the o—ring
(B) and replace as required.
4. Ensure the pipe plug (D) is screwed into the
strainer plug (C). Install the strainer plug with the
screen (A) and o—ring (B) in place and tighten.
Do not overtighten. Let the gasket make the seal.
5. Open the fluid inlet valve, ensure that there are
no leaks, and wipe the equipment clean. Proceed
with operation.
1. Flush if necessary. See Flushing, page 49.
2. See Shutdown, page 47.
Flush Inlet Strainer Screen
The inlet strainers filter out particles that can plug the
pump inlet check valves. Inspect the screens daily as
part of the startup routine, and clean as required.
Isocyanate can crystallize from moisture
contamination or from freezing. If the chemicals used
are clean and proper storage, transfer, and operating
procedures are followed, there should be minimal
contamination of the A-side screen.
Figure 1
Note
Clean the A-side screen only during
daily startup. This minimizes moisture
contamination by immediately flushing
out any isocyanate residue at the start of
dispensing operations.
50
333024J
Repair
Change Pump Lubricant
Check the condition of the ISO pump lubricant daily.
Change the lubricant if it becomes a gel, its color
darkens, or it becomes diluted with isocyanate.
Gel formation is due to moisture absorption by the
pump lubricant. The interval between changes
depends on the environment in which the equipment
is operating. The pump lubrication system minimizes
exposure to moisture, but some contamination is still
possible.
5. Thread the reservoir onto the cap assembly and
place it in the bracket.
6. Manually prime the ISO pump. Plug the small
vent hole (H) between the tube grommets while
squeezing the bottle to force the lubricant up the
feed tube. Repeat until the fluid level reaches the
ISO pump to force the air out.
Lubricant discoloration is due to continual seepage of
small amounts of isocyanate past the pump packings
during operation. If the packings are operating
properly, lubricant replacement due to discoloration
should not be necessary more often than every 3 or
4 weeks.
To change pump lubricant:
1. Follow Pressure Relief Procedure, page 46.
2. Lift the lubricant reservoir (R) out of the bracket
and remove the container from the cap. Holding
the cap over a suitable container, remove the
check valve and allow the lubricant to drain.
Reattach the check valve to the inlet hose.
3. Drain the reservoir and flush it with clean
lubricant.
4. When the reservoir is flushed clean, fill with fresh
lubricant.
333024J
Pump Lubrication System
Figure 2
7. Verify that the ISO pump is operating correctly
by feeling the pulsation in the return tube during
normal proportioner pump operation.
8. Ensure the vent hole stays open.
51
Repair
Remove Pump
Pump rod and connecting rod move during
operation. Moving parts can cause serious injury
such as pinching or amputation. Keep hands and
fingers away from connecting rod during operation.
Note
See manual 309577 for pump repair
instructions.
1. Press
to stop the pumps.
2. Turn off heat zones.
3. Flush pump.
4. Press
5. Press
to park the pumps in the down position.
to deactivate the system.
8. Route fluid to waste containers or supply tanks.
Turn PRESSURE RELIEF/SPRAY valves (SA,
SB) to PRESSURE RELIEF/CIRCULATION
. Ensure gauges drop to 0.
6. Turn main power switch off.
GA
SA
GB
SB
7. Shut off both feed pumps. Close all fluid supply
valves.
52
333024J
Repair
Note
Use drop cloth or rags to protect Reactor
and surrounding areas from spills.
Note
Steps 9–11 apply to pump A. To
disconnect pump B, go to steps 12 and
13.
9. Disconnect fittings at fluid inlet (C) and outlet (D).
Also disconnect steel outlet tube from heater
inlet.
10. Disconnect tubes (T). Remove both tube fittings
(U) from wet-cup.
11. Loosen locknut (G) by hitting firmly with a
non-sparking hammer. Unscrew pump far
enough to expose rod retaining pin. Push
retaining wire clip up. Push pin out. Continue
unscrewing pump.
Pump B
Figure 4
1
Flat side faces up.
2
Lubricate threads with ISO oil or grease.
3
Pump top threads must be nearly flush with
bearing face (N).
Install Pump
Note
Steps 1–5 apply to pump B. To reconnect
pump A, proceed to step 6.
1. Ensure locknut (G) is screwed on pump with
flat side up. Screw pump into bearing housing
(M) until pin holes align. Push pin (F) in. Pull
retaining wire clip (E) down. See Fig. 4 for view
and assembly notes.
Pump A
Figure 3
1
Flat side faces up.
2
Lubricate threads with ISO oil or grease.
3
Pump top threads must be nearly flush with
bearing face (N).
2. Continue screwing pump into housing until fluid
outlet (D) is aligned with steel tube and top
threads are +/- 1/16 in. (2 mm) of bearing face
(N).
3. Tighten locknut (G) by hitting firmly with a
non-sparking hammer.
4. Reconnect fluid inlet (C) and outlet (D).
Note
Steps 12 and 13 apply to pump B.
12. Disconnect fluid inlet (C) and outlet (D). Also
disconnect steel outlet tube from heater inlet.
13. Push retaining wire clip (E) up. Push pin (F)
out. Loosen locknut (G) by hitting firmly with a
non-sparking hammer. Unscrew pump.
333024J
5. Go to step 13.
Note
Steps 6–12 apply to pump A only.
6. Ensure star-shaped locknut (G) is screwed on
pump with flat side up. Carefully twist and extend
displacement rod 2 in. (51 mm) above wet-cup.
53
Repair
11. Apply thin film of TSL to barbed fittings. Using
two hands, support tubes (T) while pushing
straight onto barbed fittings. Secure each tube
with a wire tie between two barbs.
Note
Do not let tubes kink or buckle.
12. Reconnect fluid inlet (C).
13. Purge air and prime the system. See Reactor
operation manual.
Repair Drive Housing
Removal
Figure 5
1. Press
to stop the pumps.
7. Start threading pump into bearing housing (M).
When pin holes align, insert pin. Pull retaining
wire clip down.
2. Turn off heat zones.
8. Continue threading pump into bearing housing
(M) until top threads are +/- 1/16 in. (2 mm) of
bearing face (N). Ensure that barbed fittings at
wet-cup flush ports are accessible.
4. Press
3. Flush pump.
5. Press
to park the pumps in the down position.
to deactivate the system.
6. Turn main power switch off.
9. Connect component A outlet tube loosely at
pump and at heater. Line up tube, then tighten
fittings securely.
10. Tighten star-shaped locknut (G) by hitting firmly
with a non-sparking hammer.
54
333024J
Repair
7. Perform Pressure Relief Procedure, page 46.
8. Remove the system frame from the floor and
L-brackets.
NOTICE
Do not drop gear cluster (104) when removing
drive housing (102). Gear cluster may stay
engaged in motor front end bell or drive
housing.
14. Remove screws (112, 119) and washers (114)
and pull drive housing (102) off motor (101).
Note
The A side drive housing includes cycle
counter switch (121). If replacing this
housing, remove screws (122) and
switch. Reinstall screws and switch on
new drive housing.
9. Remove two bolts and nuts and fold the electrical
enclosure backward.
10. Remove screws (21) and motor shroud (11).
Rest the motor shroud behind the motor without
straining the fan power cable.
Note
Examine bearing housing (103) and
connecting rod (105). If these parts need
replacing, first remove the pump (106),
see Remove Pump, page 52.
11. Remove cover (60) and screws (21).
12. Remove cycle counter (121) from housing by
removing screw (122).
13. Disconnect pump inlet and outlet lines. Remove
screws (113), washers (115), and bearing
housing (103).
333024J
Figure 6
55
Repair
Installation
1. Apply heavy duty extreme pressure grease
liberally to washers (107, 108, 118), all gears,
and inside drive housing (102).
2. Install one bronze washer (108) in drive housing,
then install steel washers (107, 118) as shown.
3. Install second bronze washer (108) on gear
cluster (104) and insert gear cluster in drive
housing.
Note
Drive housing crankshaft must be in line
with crankshaft at other end of motor.
4. Push drive housing (102) onto motor (101).
Install screws (112) and washers (114).
Note
If bearing housing (103), connecting rod
(105), or pump (106) were removed,
reassemble rod in housing and install
pump, see Install Pump, page 53 .
5. Route cycle counter switch cable (121) around
the motor fan and reattach to housing (102) with
screws (122).
6. Install bearing housing (103), screws (113), and
washers (114). Pumps must be in phase (both at
same position in stroke).
7. Install cover (60) and screws (21).
8. Install motor shield (11) and screws (21).
Figure 7
56
333024J
Repair
Repair Electric Motor
Removal
NOTICE
Be careful not to drop or damage the motor. The
motor is heavy and may require two people to lift.
1. Remove the system frame from the floor and
L-brackets.
Installation
1. Place motor on unit. Thread motor
cables into conduit as before. See
Electrical Schematics, page 93.
2. Remove drive housing and pump assemblies.
See Repair Drive Housing, page 54.
3. Disconnect electric motor (101) power cable from
port #15 on the MCM. Remove connector by
loosening four terminal screws.
4. Remove motor shroud (11). Rest the motor
shroud assembly behind the motor without
straining the fan power cable.
5. Disconnect over temperature cable from port
#2 on MCM. Cut tie wraps around harness to
remove cable.
6. Remove four screws (25) holding motor (101) to
bracket. Lift motor off unit.
333024J
2. Fasten motor with screws (25) until screws are
fully threaded in frame. Do not tighten screws
until drive housing and pumps are connected to
the motor.
3. Install drive housing and pump assemblies, see
Installation, page 56.
4. Route motor (101) power cord from motor
through conduit and connect to port #15 on
MCM. Route over temperature cable up from
motor and connect to port #2 on MCM. Insert
cables in conduit and use tie wraps to secure the
conduit together.
5. Connect motor shroud assembly to motor (101).
6. Install drive housing covers and motor cover.
7. Return to service.
57
Repair
Repair Circuit Breaker Module
new circuit breaker. Insert wires and tighten
down all screws.
1. See Before Beginning Repair, page 50.
2. Using an ohmmeter, check for continuity across
circuit breaker (top to bottom). If no continuity,
trip breaker, reset, and retest. If still no continuity,
replace breaker as follows:
Figure 8
Circuit Breakers
a. Refer to Electrical Schematics, page 93, and
circuit breaker table.
Circuit Breakers
b. Follow Shutdown instructions. See
Shutdown, page 47.
Ref.
Size
Component
CB01
50 A
Heated Hose
c.
CB02
20 A
Motor Control Module
(MCM)
CB03
40 A
ISO Heater
CB04
40 A
RES Heater
CB05
40 A
Hose Heat Transformer
Refer to circuit breaker identification table
and electrical diagrams in Reactor repair
manual.
d. Loosen two screws connecting wires and bus
bar to circuit breaker that will be replaced.
Disconnect wires.
e. Pull locking tab out 1/4 in. (6mm) and pull
circuit breaker away from the din rail. Install
58
333024J
Repair
Replace Fluid Inlet Sensor
5. Replace sensor (602).
Note
Replace Pressure Transducers
For Elite models only.
1. Perform Shutdown, page 47.
1. Perform Shutdown, page 47.
2. Perform Pressure Relief Procedure, page 46.
2. Perform Pressure Relief Procedure, page 46.
3. Disconnect transducer cables (405) from #6 and
#7 connectors on the MCM.
3. Disconnect inlet sensor cable from the fluid inlet
assembly. Inspect cable for damage and replace
if necessary. See Electrical Schematics, page 93.
4. Remove wire ties constraining transducer cable
and remove cable from cabinet.
5. Install o-ring (416) on new transducer (405).
6. Install transducer in manifold. Mark end of cable
with tape (red=transducer A, blue=transducer B).
7. Route new cable into cabinet and thread into
bundle as before. Attach cable ties to bundle
as before.
8. Connect A side pressure transducer cable
to MCM port #6. Connect B side pressure
transducer cable to MCM port #7.
405
Figure 9 Fluid Inlet Sensor
405
416
4. To replace sensor cable:
a. Open wire bundle and remove sensor cable.
b. Cut any wire ties and disconnect from MCM.
See Electrical Schematics, page 93.
401
NOTICE
To prevent damage to cable, route and secure
cable in wire bundle with wire ties.
333024J
59
Repair
Replace Fans
Replace Electrical Enclosure Fan
1. Perform Shutdown, page 47
2. Open electrical enclosure door (401). Loosen
four nuts (421) and remove fan (404).
Shutdown system to avoid electric shock. To avoid
burns, do not perform maintenance on the fan until
the system has reached ambient temperature.
3. Install new fan (404) in reverse order of
disassembly so that the fan blows out of the
electrical enclosure.
Replace Motor Fan
1. Perform Shutdown, page 47.
2. Open cabinet door and disconnect
fan cables from terminal blocks. See
Electrical Schematics, page 93.
3. Remove four screws (21) from motor cover (11).
If necessary, fold frame (1) to remove motor
cover (10). See Repair Drive Housing, page 54,
steps 1–10.
4. Cut tie wraps to remove cable.
5. Remove nuts (39), screws (22), washers (34)
and fan (32). Install new fan in reverse order.
Figure 11
Note
Ensure fan (32) blows onto motor.
Figure 10
60
333024J
Repair
Replace Transformer Fan
1. Perform Shutdown, page 47.
4. Disconnect fan and transformer connections
from terminal blocks. Connections are on left
side labeled: V+, V-, 1, 2, 3, and 4.
5. Remove four nuts (27) holding metal transformer
cover (8) to frame. Carefully remove cover while
sliding wires through hole in cover.
2. Remove four bolts (23) and shroud (10).
6. Remove four screws (23), washers (29), and fan
(32).
3. Remove bolt (20) on top of the heater junction
box (48).
7. Install fan in reverse order.
Figure 12
333024J
61
Repair
Repair Primary Heater
8. Wait for heater to cool.
Replace Heater Element
1. Press
9. Remove four bolts (23) and shroud (10).
to stop the pumps.
2. Turn off heat zones.
3. Flush pump.
4. Press
to park the pumps in the down position.
The park operation is complete when green dot
goes out. Verify the park operation is complete
before moving to next step.
10. Remove screw (20) and lower din rail cover (48).
11. Disconnect heater wires:
a. A Side: Disconnect A side heater wires,
transformer, and transformer fan wires from
lower din rail (33).
b. B Side: Disconnect B side heater wires and
remove lower din rail (33) from B side heater
(5).
5. Press
to deactivate the system.
6. Turn main power switch off.
12. Test heater wires with ohmmeter.
System
Total
Heater
Wattage
Element
Ohms
E-30 (10
kw)
10,200
2,550
18–21 per
element
E-XP2,
E-30 (15
kw)
15,300
2,550
18–21 per
element
NOTICE
7. Relieve pressure. See
Pressure Relief Procedure, page 46.
62
To prevent a short circuit or lowering the
transformer life, do not splash fluid on
transformer. Cover transformer with a plastic
sheet or piece of cardboard.
333024J
Repair
13. Remove nuts (27) and transformer cover
(8). Cover transformer with plastic sheet or
cardboard.
14. Disconnect overtemperature switches (209) from
cable.
15. Loosen ferrule nut (N). Remove RTD (212) from
heater housing. Do not remove adapter (206)
unless necessary. If adapter must be removed,
ensure that mixer (210) is out of the way when
replacing adapter.
16. Disconnect inlet and outlet fluid tubes from
heater.
17. Remove two bolts (23) and lift heater over
transformer.
18. Place heater block (201) in a vise. Use a wrench
to remove heater element (208).
19. Inspect element. It should be relatively smooth
and shiny. Replace element if there is a crusted,
burnt, ash-like material adhered to element, or
sheath shows pitting marks.
20. Install new heater element (208), holding mixer
(210) so it does not block RTD port.
21. Secure heater to frame with bolts (23).
22. Reinstall RTD (212),
Repair Primary Heater, page 62.
23. Reconnect cable to overtemperature switches
(209).
24. Reconnect wires to lower din rail. If necessary,
install lower din rail (33).
25. Install lower din rail cover (48).
Line Voltage
The heater outputs its rated wattage at 240 VAC.
Low line voltage will reduce power available and the
heater will not perform at full capacity.
Figure 13
333024J
63
Repair
Repair Overtemperature Switch
1. Perform Shutdown, page 47.
110009, install new switch in same location on
housing (201), and secure with screws (213).
Reconnect cables.
2. Wait for heaters to cool.
3. Remove heater cover (10).
4. Disconnect overtemperature switches (209) from
cable (46). Test across spade terminals with
ohmmeter.
a. If the resistance is not approximately 0 ohms,
the overtemperature switch needs to be
replaced. Go to step 5.
b. If the resistance is approximately 0 ohms,
inspect cable (46) to ensure it is not cut
or open. Reconnect the overtemperature
switch (209) and cable (46). Disconnect
cable from TCM. Test from pin 1 to 3 and
1 to 4. If resistance is not approximately 0,
and switches are 0. Replace cable in place
of original cable.
5. If switch fails test, remove screws. Discard failed
switch. Apply a thin layer of thermal compound
64
333024J
Repair
Replace RTD
1. Perform Shutdown, page 47.
2. Wait for heater to cool.
3. Remove heater cover (10).
4. Cut cable ties around the woven wrap with the
RTD cable (212).
5. Disconnect RTD cable(212) from TCM (453).
6. Loosen ferrule nut (N). Remove RTD (212) from
heater housing (201), then remove RTD housing
(H). Do not remove the adapter (206) unless
necessary. If adapter must be removed, ensure
that mixer (210) is out of the way when replacing
the adapter.
7. Remove RTD cable (212) from woven wrap.
8. Replace RTD (212).
a. Apply PTFE tape and thread sealant to male
pipe threads and tighten RTD housing (H)
into adapter (206).
b. Push in RTD (212) so tip contacts heater
element (208).
c.
Holding RTD (212) against heater element,
tighten ferrule nut (N) 3/4 turn past
finger-tight.
9. Route wires (S) as before through woven wrap
and reconnect RTD cable (212) to the TCM.
10. Replace heater shroud (10).
11. Follow startup instructions in the operation
manual. Turn on A and B heat simultaneously to
test. Temperatures should rise at same rate. If
one is low, loosen ferrule nut (N) and tighten RTD
housing (H) to ensure RTD tip contacts element
(212) when ferrule nut (N) is retightened.
ti22870a
Figure 14
333024J
65
Repair
Repair Heated Hose
3. For Series A only: Disconnect hose connector
(D) at Reactor.
Refer to the heated hose manual 309572 for hose
replacement parts.
Check Hose Heat Power Connectors
1. Perform Shutdown, page 47.
Note
Whip hose must be connected.
2. Disconnect power harness (PM) from hose
termination box terminal block (TB).
Figure 16
4. Using an ohmmeter, check between the
connectors (D). There should be continuity.
5. If hose fails test, retest at each length of hose,
including whip hose, until failure is isolated.
Figure 15
66
333024J
Repair
Check RTD Cables and FTS
1. Perform Shutdown, page 47.
2. Disconnect RTD cable (C) at Reactor.
3. Test with an ohmmeter between pins of cable
connector C.
Note
Do not touch outer ring with test probe.
Pins
Result
3 to 1
approximately 1090
ohms
3 to 4
approximately 1090
ohms
1 to 4
0.2 - 0.4 ohms
2 to any
infinity (open)
4. Retest at each length of hose, including whip
hose, until failure is located.
5. If the FTS is not reading properly at the end of
the hose, connect FTS directly to RTD cable (C)
at the manifold.
6. If the FTS reads properly at the manifold but
not at the end of the hose, check cable (C)
connections. Verify they are tight.
333024J
Heated Hose
Figure 17
Note
To assist in taking readings, order RTD
Test Kit 24N365. Kit includes two cables:
one cable with a compatible female M8
connector and another cable with a male
M8 connector. Both cables have stripped
wire at the other end for easy test probe
access.
Pins / Wire Color
Result
3 to 1 / brown to blue
approximately 1090
ohms
3 to 4 / blue to black
approximately 1090
ohms
1 to 4 / brown to black
0.2 - 0.4 ohms
2 to any / N/A
infinity (open)
67
Repair
Repair Fluid Temperature Sensor
(FTS)
Installation
The Fluid Temperature Sensor (FTS) is supplied with
the system. Install FTS between main hose and
whip hose. See Heated Hose manual 309572 for
instructions.
B
D
K
H
F
W
B
A
L
ti18511a
C
A
Figure 18
Test/Removal
1. Perform Shutdown, page 47.
a. Disconnect air hoses (C,L) and electrical
connectors (D).
b. Disconnect FTS from whip hose (W) and
fluid hoses (A, B).
2. Remove tape and protective covering from FTS.
Disconnect hose cable (F).
c.
Remove ground wire (K) from ground screw
on underside of FTS.
3. If FTS is not reading properly at the end of the
hose, see Check RTD Cables and FTS, page 67.
d. Remove FTS probe (H) from component A
(ISO) side of hose.
4. If FTS fails, replace FTS.
68
333024J
Repair
Transformer Primary Check
indicator on the circuit breaker GREEN. Use
an ohmmeter to test for continuity between
two transformer wires in terminal blocks
TB17 and TB18; there should be continuity.
See Electrical Schematics, page 93.
1. Check wires and transformer:
a. See Shutdown, page 47.
c.
Close the circuit breaker CB01.
b. Shut off CB05.
c.
Use an ohmmeter to test for continuity
between terminals 2 and 4 of CB05. If there
is no continuity, check transformer.
2. Check transformer:
a. See Shutdown, page 47.
Figure 19
b. Remove lower shroud.
c.
Locate the two smaller (10 AWG) wires,
labeled 1 and 2, coming out of transformer.
Trace these wires back to terminal blocks
TB15 and TB16.
d. Use an ohmmeter to test for continuity
between two wires; there should be
continuity.
Transformer Secondary Check
See Electrical Schematics, page 93.
1. Check wires and transformer:
d. Apply incoming power to system.
e. To verify voltage on the secondary leads
of the transformer, measure between the
terminals terminals 3 and 4 on TB17 and
TB18. Verify voltage is approximately 90
VAC for 240 VAC input.
f.
See the Diagnostic Run Screen on the
ADM. The Diagnostic Run Screen displays
the incoming (90 Vac) to the TCM “Hose
Voltage”. The diagnostic screen will show if
the circuit breaker has been tripped for the
incoming power to the TCM.
a. Disconnect 7 pin green connector from TCM.
b. Use an ohmmeter to test for continuity
between terminals 6 and 7 on the TCM 7 pin
green connector. There should be continuity.
If there is no continuity, check transformer.
c.
Reconnect 7 pin green connector to TCM
2. Check transformer:
a. Remove lower shroud.
b. Locate the two larger (6 AWG) wires,
labeled 3 and 4, coming out of transformer.
Trace these wires back to TB17 and TB18.
Open circuit breaker CB01 to turn the color
333024J
69
Repair
Replace Transformer
1. Perform Shutdown, page 47.
2. Remove four bolts (23) and shroud (10).
3. Remove lower dinrail cover (48).
4. Disconnect fan and transformer connections
from terminal blocks. Connections are on left
side labeled: V+, V-, 1, 2, 3, and 4.
5. Remove four nuts (27) holding metal transformer
cover (8) to frame. Carefully remove cover while
sliding wires through hole in cover.
6. Remove nuts (27) and transformer (17).
7. Install transformer (17) in reverse order.
Figure 20
70
333024J
Repair
Replace Power Supply
1. Perform Shutdown, page 47.
2. Disconnect input and output cables from
both sides of the power supply. See
Electrical Schematics, page 93.
3. Insert a flat head screw driver in the mounting
tab on the bottom of the power supply to remove
from the din rail.
4. Install new power supply (535) in reverse order.
Figure 22 Surge Protector
Replace Advanced Display Module
(ADM)
1.
Loosen four screws (70) on inside of electrical
enclosure door (61). Lift up and pull out to
remove ADM (88).
2. Disconnect CAN cable (475).
3. Inspect ADM (88) for damage. Replace if
necessary.
Figure 21 24 VDC Power Supply
Replace Surge Protector
1. Loosen connections on terminals 1 and 3 on
CB02.
2. Loosen connections on input to power supply
(535) on N and L connections.
3. Remove two screws (413) and surge protector
(505) from enclosure.
Figure 23
4. Install new surge protector (505) in reverse order.
Note
Wire on both the circuit breaker and power
supply are interchangeable.
333024J
71
Repair
Replace Motor Control Module (MCM)
Replace Temperature Control Module
(TCM)
1. Perform Shutdown, page 47.
2. Disconnect connectors from MCM (63).
Disconnect two power cables. See
Electrical Schematics, page 93.
3. Remove nuts (91) and MCM (63).
4. Set rotary switch. 2= E–30 and 3= E-XP2.
5. Replace MCM in enclosure.
1. Perform Shutdown, page 47.
2. Open electrical enclosure door (61).
3. Disconnect all connectors from the TCM (453).
4. Remove four nuts (461) and TCM (453).
5. Install new TCM module (453). Reassemble
parts in reverse order.
6. Connect cables to MCM. See
Electrical Schematics, page 93.
Figure 25 Replace TCM
Figure 24 Replace MCM
Software Update Procedure
NOTICE
Repair kit GCA modules are shipped
pre-programmed and software loading is not
necessary. If software version upgrade is
necessary, follow the procedure in the manual
provided.
72
333024J
Parts
Parts
Proportioners
333024J
73
Parts
1
2
3
74
Apply anaerobic polyacrylate pipe sealant to all
non-swiveling pipe threads.
Apply grease to tube fitting threads. Torque to
43 ft-lbs (58 N•m).
Safety and warning labels are from label sheet
(68).
333024J
Parts
Ref
Part
Description
Quantity
272010
272011
272012
272110
272111
272112
1
- - -
FRAME
1
1
1
1
1
1
2
- - -
ENCLOSURE, electrical;
see Electrical Enclosure,
page 86
1
1
1
1
1
1
3
246995
BOTTLE, assembly,
complete
1
1
1
1
1
1
4
16X531
BRACKET, tsl, bottle
1
1
1
1
1
1
5
24U843
HEATER, 10kw, 2
zone, RTD; see
Fluid Heater, page 82
1
24U842
HEATER, 7.5kw,
1 zone, RTD; see
Fluid Heater, page 82
2
2
6
24U704
MANIFOLD, fluid; see
Fluid Manifold, page 84
7
16W654
8
1
2
2
1
1
1
1
1
1
INSULATOR, foam,
heater
2
4
4
2
4
4
24R684
COVER, transformer
1
1
1
1
1
1
9+
261821
CONNECTOR, wire,
6awg
1
1
1
1
1
1
10
24U841
COVER, heater
1
1
1
1
1
1
11
16W765
COVER, motor
1
1
1
1
1
1
12
16W764
COVER, heater, rear
1
1
1
1
1
1
13
24U837
TUBE, b-side, inlet, 15
kW
1
1
1
1
24U838
TUBE, b-side, inlet, 10kw
24U839
TUBE, b-side, outlet, 15
kW
1
1
24U840
TUBE, b-side, outlet,
10kw
1
1
24U834
TUBE, a-side, inlet, 10
kW
1
1
24U833
TUBE, a-side, inlet, 15
kW
1
1
24U836
TUBE, a-side, outlet, 10
kW
24U835
TUBE, a-side, outlet, 15
kW
1
1
17
15K742
TRANSFORMER,
4090va, 230/90
18
15B456
GASKET, manifold
14
15
16
333024J
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
75
Parts
Ref
Part
Description
Quantity
272010
272011
272012
272110
272111
272112
19
125643
FITTING, elbow, 3/8 npt
x #8 jic
2
2
2
2
2
2
20
119865
SCREW, mch, hex
serrated; 3/8 in. x 1/4–20
9
9
9
9
9
9
21
118444
SCREW, mch, slot hex
wash hd; 1/2 in. x #10–24
12
12
12
12
12
12
22
117683
SCREW, mch, phil pan
hd; 1.5 in. x #6–32
8
8
8
8
8
8
23
113796
SCREW, flanged, hex hd;
3/4 in. x 1/4–20
11
13
13
11
13
13
24
112731
NUT, hex, flanged
6
6
6
6
6
6
25
111800
SCREW, cap, hex hd;
7/32 in. x 5/16–18
4
4
4
4
4
4
26
111218
CAP, tube, square
2
2
2
2
2
2
27
110996
NUT, hex, flange head
8
8
8
8
8
8
28
104859
SCREW, tapping pnhd;
5/16 in. x #10–16
2
2
2
2
2
2
29
103181
WASHER, lock ext
4
4
4
4
4
4
30
100020
WASHER, lock
2
2
2
2
2
2
31
115836
GUARD, finger
1
1
1
1
1
1
32
24U847
FAN, cooling, 120mm,
24vdc
2
2
2
2
2
2
33
24R685
ENCLOSURE, lower,
dinrail; includes 33a-33d
1
1
1
1
1
1
33a
24U849
KIT, module, din rail,
heater; see Heater and
Transformer Terminal
Block Module, page 89
1
1
1
1
1
1
33b
16W667
INSULATOR, FOAM
1
1
1
1
1
1
33c
- - -
COVER, bottom, dinrail
1
1
1
1
1
1
33d
113505
NUT, keps, hex hd
1
1
1
1
1
1
34
151395
WASHER, flat
4
4
4
4
4
4
35
120685
GROMMET
2
2
2
2
2
2
36
114269
GROMMET, rubber
1
1
1
1
1
1
37
125625
TIE, cable, fir tree
5
6
6
5
6
6
38
127277
BOLT, carriage, 1/2-13 x
3.5 l
4
4
4
4
4
4
39
127278
NUT, keps, hex
4
4
4
4
4
4
40
127282
GROMMET, rubber
4
4
4
4
4
4
76
333024J
Parts
Ref
Part
Description
Quantity
272010
272011
272012
272110
272111
272112
41
16X095
CONNECTOR, power,
male, 4 pin
1
1
1
1
1
1
42
125871
TIE, cable, 7.5 in.
25
25
25
25
25
25
43
24K207
KIT, fts, rtd, single hose
1
1
1
1
1
1
44
24R725
BRIDGE, plug-in jumper,
ut35
4
4
4
4
4
4
45
106569
TAPE, electrical
1
1
1
1
1
1
46�
24T242
CABLE, over-temp, 10
kW Reactor
1
24P970
CABLE, over-temp, 15
kW Reactor
1
1
47
104765
PLUG, pipe headless
48
16V268
49
50
1
1
1
2
2
2
2
2
1
COVER, top, dinrail
1
1
1
1
1
1
15Y118
LABEL, made in the USA
1
1
1
1
1
1
24V150
PROPORTIONER,
module, E-30; see
Proportioner Module,
page 80
1
1
1
1
24V151
PROPORTIONER,
module, E-XP2; see
Proportioner Module,
page 80
24U321
KIT, asm, pair,
elite, reactor; see
Fluid Inlet Kits, page 91
24U320
KIT, assembly, pair,
std, reactor; see
Fluid Inlet Kits, page 91
52��
16X118
53��
51
1
1
1
1
1
MODULE, cellular, gps,
temp
1
1
1
24T050
CABLE, m8 4p f to m12
8p m 1.5m
1
1
1
54�
16W130
CABLE, m12 5p, fem male, 2.0m
2
2
2
55
24U845
TUBE, pressure relief
2
2
2
2
2
2
56
191892
FITTING, elbow, street,
90 deg; 1/8 npt
2
2
2
2
2
2
57
116746
FITTING, barbed, plated;
1/8–27 npt x 1/4 in. hose
I.D.
2
2
2
2
2
2
333024J
1
1
1
77
Parts
Ref
58
Part
Description
Quantity
272010
272011
1
1
272012
272110
272111
1
1
272112
16W218
LABEL, branding, e-30
16W321
LABEL, branding, e-30,
elite
16W215
LABEL, branding, e-xp2
16W322
LABEL, branding, e-xp2,
elite
59
16U530
MODULE, system surge
protector (spare)
1
1
1
1
1
1
60
15G349
COVER, drive, plastic
2
2
2
2
2
2
61
16W766
COVER, control, box
1
1
1
1
1
1
62
16W596
LATCH, door
2
2
2
2
2
2
63
24U832
MODULE, MCM
1
1
1
24U831
MODULE, MCM
1
1
1
64
206995
FLUID, tsl, 1 qt.
1
1
1
1
1
1
65
206994
FLUID, tsl 8 oz bottle
1
1
1
1
1
1
67
114225
TRIM, edge protection;
1.6 ft (0.48 m)
1
1
1
1
1
1
68
16X250
LABEL, identification
1
1
1
1
1
1
70
127296
SCREW, mchn, pnh,
w/ext tooth wash; M4 x
0.7
4
4
4
4
4
4
71
16X129
SCREW, mach, phillips,
tooth wash; 5/16 x 8–32
10
10
10
10
10
10
72
117502
FITTING, reducer #5 x #8
(JIC)
1
1
1
1
1
1
73
117677
FITTING, reducer #6 x
#10 (JIC)
1
1
1
1
1
1
74
299521
CAP, 1/2-20 jic
cap-aluminum
1
1
1
1
1
1
75
299520
CAP, 9/16-18 JIC
cap-aluminum
1
1
1
1
1
1
79+
261843
FLUID, oxide inhibitor
1
1
1
1
1
1
81
16V806
BRACKET, wall, mount
2
2
2
2
2
2
82
15V551
SHIELD, membrane,
ADM (10 pack)
1
1
1
1
1
1
83
24K409
BAR, 55 gal chem.
measure; A side
1
1
1
1
1
1
84
24K411
BAR, 55 gal chem.
measure. B side
1
1
1
1
1
1
78
1
1
333024J
Parts
Ref
Part
Description
Quantity
272010
272011
272012
272110
272111
272112
85
127276
BOLT, carriage, 1/2-13 x
2.5 l
2
2
2
2
2
2
88
24U854
MODULE, ADM
1
1
1
1
1
1
89
16W967
FITTING, swivel, 3/4 npt
x 1 npsm
2
2
2
2
118459
FITTING, union, swivel,
3/4 in.
90
16W213
LABEL, branding, reactor
2
2
2
2
2
2
91
115942
NUT, hex, flange head
4
4
4
4
4
4
92�
15D906
SUPPRESSOR, round
snap ferrite .260
1
1
1
1
1
1
93
127368
SLEEVE, split, wire, 1.50
ID
2
2
2
2
2
2
94
127377
TIE, cable, 6 in.
1
1
1
95
16X154
LABEL, InSite
1
1
1
96
333091
MANUAL, quick guide,
startup
1
1
1
1
1
1
97
333092
MANUAL, quick guide,
shutdown
1
1
1
1
1
1
98*
24W204
ENCLOSURE, terminal
block
1
1
1
1
1
1
99*
25A234
ENCLOSURE, cover
1
1
1
1
1
1
100*
189930
LABEL, caution
1
1
1
1
1
1
101*
172953
LABEL, ground
1
1
1
1
1
1
102*
17D955
BRACKET, mounting
1
1
1
1
1
1
103*
113161
SCREW, flange, hex hd
2
2
2
2
2
2
Replacement Warning labels, signs, tags, and
cards are available at no cost.
Not shown.
� Parts included in Graco Insite Kit 24T280.
333024J
2
2
� See Electrical Schematics, page 93.
+ Part applies to Series A only.
*
Part applies to Series B only.
79
Parts
Proportioner Module
24V150, Module for E-30
24V151, Module for E-XP2
1
Torque to 190–120 in-lbs (21–24 N•m).
2
Lubricate threads with ISO oil or grease. Assemble pump cylinders flush to one full thread under-flush of
housing surface.
3
Apply grease to all gear teeth proportionally, motor pinion and drive housing.
4
Torque to 20–30 ft-lbs (27–40.6 N•m).
5
Crankshaft must be in line with crankshaft at other end of motor.
6
Torque to 70–80 ft-lbs (95–108 N•m).
7
Flat side faces up.
80
333024J
Parts
24V150
E-30
24V151
E-XP2
MOTOR, brushless, double ended, 2 HP
1
1
24M417
HOUSING, drive, Mark VII
2
2
257355
HOUSING, bearing
245927
HOUSING, bearing
2
104�
287290
KIT, repair, gear
2
2
105�
241279
KIT, rod, connecting
2
2
106
245971
PUMP, displacement B
245972
PUMP, displacement B
1
107�
114699
WASHER, thrust; steel colored
2
2
108�
114672
WASHER, thrust; copper colored
4
4
110�
183169
SPRING, retaining
2
2
111
183210
PIN, str, hdls
2
2
112�
15C753
SCREW, machine, hex wash hd; 1.25 in. x
5/16–18
10
10
113
114666
SCREW, cap, socket head; 2.25 x 3/8–16
8
8
114
106115
WASHER, lock (hi-collar)
8
8
115
246831
PUMP, displacement, A
246832
PUMP, displacement, A
193031
NUT, retaining
193394
NUT, retaining
2
118�
116192
WASHER, thrust (1595)
2
2
120
116618
MAGNET
1
1
121
24P728
SWITCH, reed, M8 4-pin
1
1
122
127301
SCREW, hexhead, thread cut, 4-40 x 0.375
2
2
125
187437
LABEL, torque
2
2
126
192840
LABEL, warning
2
2
Ref
Part
Description
101
24U050
102�
103
116
Replacement Warning labels, signs, tags, and
cards are available at no cost.
See pump repair manual 309577 for repair kits.
� Spring (110) included in Connecting Rod Kit
241279.
333024J
2
1
1
1
2
� Gear Repair Kit includes washers (107) and
(108).
� Drive Housing Repair Kit includes housing (1),
screws (5), and washer (1) to replace one end.
81
Parts
Fluid Heater
24U843 — 10kW, 2–zone
24U842 — 7.5 kW, 1–zone
1
Torque to 120 ft-lbs (163 N•m).
2
Torque to 23 ft-lbs (31 N•m).
3
Torque to 40 ft-lbs (54 N•m).
4
Apply thermal paste.
5
Apply pipe sealant and PTFE tape to all non-swiveling threads and threads without o-rings.
6
Apply lithium grease lubricant to o-rings before assembling in block (1).
7
Remove tape from probe tip and Orientate sensor as shown. Insert probe until it bottoms on heating element.
Tighten ferrule on sensor probe one turn past finger tight or 16 ft-lbs (21.6 N•m).
82
333024J
Parts
Ref
201
Part
15J090
15K825
124132
202
203
204
205
206
207
208
209
210
15H305
121309
15H304
15H306
120336
16A110
15B137
15B135
- - - - -
211*
212*
213
214
*
124131
247520
Description
HEATER, machined, 1 zone
HEATER, machined, dual zone
O-RING
FITTING, plug, hollow, hex, 1-3/16 sae
FITTING, adapter, sae-orb x jic
FITTING, plug 9/16 sae
ADAPTER, 9/16 x 1/8
24U843
1
4
4
4
2
2
24U842
1
3
5
2
3
1
2
4
1
1
3
1
FITTING, compression
SENSOR, RTD
SCREW, machine, pnhd; 5/16 in. x #6–32
4
2
2
2
3
1
1
2
HOUSING, rupture disc
2
1
O-RING, packing
HEATER, immersion, 2550W, 230V
SWITCH, over temperature
MIXER, immersion heater
Included in 24L973 Heater RTD Repair Kit.
333024J
83
Parts
Fluid Manifold
24U844
1
Torque to 355–395 in.-lbs (40–44.6 N●m)
2
Apply sealant (113500) to threads.
3
Valve must be closed with handle position as
shown on drawing.
84
4
Apply PTFE tape and thread sealant to gauge
threads.
5
Apply grease on valve.
**
Apply PTFE tape or thread sealant to tapered
threads.
333024J
Parts
24U844, Fluid Manifold
Ref
401
402
402a
402b
403
404
405
406
407
408
411
412
Part
255228
247824
158674
247779
102814
162453
Description
MANIFOLD, fluid
KIT, valve, cartridge, drain
O-RING, BUNA-N
SEAL, seat, valve
GAUGE, press, fluid
FITTING, 1/4 NPSM X 1/4
NPT
15M669 SENSOR, pressure, fluid
outlet
247788 HANDLE, red
247789 HANDLE, blue
112309 NUT, hex, jam
117556 NIPPLE, #8 JIC x 1/2 NPT
121312 FITTING, elbow, 3/4 SAE
x 1/2 JIC
333024J
Qty
1
2
1
1
2
2
2
1
1
2
1
1
Ref
413
414
415
416
419
Part
100840
111457
189285
150829
117557
Description
FITTING, elbow, street
O-RING, PTFE
LABEL, caution
SPRING, compression
NIPPLE, #10 JIC x 1/2
NPT
Qty
2
2
1
2
1
Replacement Warning labels, signs, tags,
and cards are available at no cost.
Included in the following complete valve kits:
ISO Valve Kit (left/red) handle 255149.
Resin Valve Kit (right/blue handle) 255150.
Valve Set Kit (both handles and grease gun)
255148.
85
Parts
Electrical Enclosure
PE
86
333024J
Parts
Electrical Enclosure
Ref
451
453
454
Part
24U087
24U855
24U848
455
24R736
457
458
459
460
461
462
463
464
466
117666
120859
120858
123967
115942
103181
124131
194337
113505
Description
ENCLOSURE
MODULE, TCM
FAN, cooling, 80 mm,
24VDC
SWITCH, disconnect,
door mounted
TERMINAL, ground
Qty
NUT, strain relief, M40
thread
BUSHING, strain relief,
M40 thread
KNOB, operator
disconnect
NUT, hex, flange head
WASHER, lock external
SCREW, machine, pan
head; 5/16 in. x #6–32
WIRE, grounding, door
NUT, keps, hex head
Ref
468
469
470
471
472
Part
111218
114269
127282
127278
Description
CAP, tube, square
GROMMET, rubber
GROMMET, rubber
NUT, keps, hex
16W925
473
16W926
1
474
24R735
1
475
127068
1
5
2
476
477
24U850
127290
2
1
6
478
16X050
GASKET, enclosure,
foam
GASKET, enclosure,
foam
CABLE, CAN power, M12
female, pigtail
CABLE, CAN,
female/female 1.0 meter
MODULE, breaker
CABLE, 4-pin,
male/female, 1.3 meter,
molded (hose RTD)
LABEL, safety; enclosure
479
16X049
LABEL, safety; multi
1
1
1
1
1
Qty
2
1
2
4
2
2
1
2
1
1
1
1
Replacement Warning labels, signs, tags, and
cards are available at no cost.
See Electrical Schematics, page 93.
333024J
87
Parts
System DIN Rail and Harness Module Kit
24U850, System DIN Rail and Harness Module Kit
See Electrical Schematics, page 93.
1
Torque to 6–8 in.-lbs (0.7–1 N●m)
2
Torque to 28–33 in.-lbs (3–3.8 N●m)
3
Torque to 23–26 in.-lbs (2.6–3 N●m)
88
333024J
Parts
Ref
501
Part
16U529
502
503
16V515
16U522
Description
HARNESS, breaker
module
HARNESS, hose out
MODULE, din rail, term
blk, power sup; see
System Circuit Breaker
Module, page 90
Qty
Ref
504
Part
16U526
505
16U530
1
1
1
Description
MODULE, din rail,
circuit breakers; see
Power Supply and
Terminal Block Module,
page 90
MODULE, sys surge
protector
Qty
Description
BLOCK, terminal
BLOCK, terminal,
UT-2.5, red
BLOCK, terminal,
UT-2.5, black
Qty
6
1
1
1
Heater and Transformer Terminal Block Module
24U849
Ref
511
Part
24T315
512
513
514
126811
126383
126382
333024J
Description
RAIL, DIN; 35 mm x 7.5
mm x 7 in.
BLOCK, clamp, end
COVER, end
BLOCK, terminal
Qty
1
2
1
2
Ref
515
516
Part
120570
24R758
517
24R759
1
89
Parts
System Circuit Breaker Module
16U526
Ref
521
Part
514014
522
523
120838
17A319
Description
RAIL, DIN; 35 mm x
7.5 mm x 8.625 in.
TERMINAL, end stop
CIRCUIT, breaker, 1
pole, 50A, C Curve
Qty
1
Ref
524
Part
17A314
2
1
525
17A317
Description
CIRCUIT, breaker, 2P,
20A, UL489
CIRCUIT, breaker, 2P,
40A, UL489
Qty
1
Description
BLOCK, terminal, quad
M4, ABB
POWER SUPPLY, 24V
BLOCK, terminal, UT35
Qty
2
3
Power Supply and Terminal Block Module
16U522
Ref
531
Part
514014
532
533
120838
90
24R722
Description
RAIL, DIN; 35 mm x 7.5
mm x 8.625 in.
TERMINAL, end stop
BLOCK, terminal PE,
quad, ABB
Qty
1
Ref
534
Part
24R723
3
1
535
126453
536
24R724
1
6
333024J
Parts
Fluid Inlet Kits
24U320, Standard
24U321, Elite
1
2
Apply sealant to all tapered pipe threads. Apply
sealant to female threads. Apply to at least the
first four threads and approximately 1/4 turn wide.
Apply thermal paste to the stem of dial before
assembling into housing.
333024J
91
Parts
Ref
Part
Description
Quantity
24U320
24U321
601
160327
FITTING, union adapter, 90°
2
2
602
118459
FITTING, union, swivel, 3/4 in.
2
2
603�
247503
MANIFOLD, strainer, inlet
2
2
604
24U852
THERMOMETER, dial
2
2
605
24U853
GAUGE, press, fluid
2
2
606
- - -
FILTER, replacement
2
2
607 �
C20203
PACKING, o-ring, 1.17, fluoroelastomer
2
2
608�
16V879
CAP, filter
2
2
609�
555808
PLUG, 1/4mp w/ hex hd
2
2
610
15D757
HOUSING, thermometer, viscon hp
2
2
613
109077
VALVE, ball 3/4 npt
1
2
614
C20487
FITTING, nipple, hex
2
614
624545
FITTING, tee 3/4m run x 1/4f branc
2
615
24U851
TRANSDUCER, pressure, temperature (includes foam)
2
Optional 80 mesh filter 255082 (2 pack)
★ Included in 24V020 Inlet Filter and Seal Kit, 20
mesh (2 pack).
� Included in 247503 Manifold Repair Kit.
*
92
333024J
Electrical Schematics
Electrical Schematics
Reactor 2 E-30
Reactor 2 E-XP2
To TCM
24P728
24U831
24U832
16X118
ti22679b
333024J
93
Electrical Schematics
PS-L
PS-N
CB-B
CB-A
ti22680b
94
333024J
Electrical Schematics
16U526
16U529
1
15D906
24U855
16V515
ELEC ENCL
GND STUD
2
TO HTD HOSE
ti22678b
1
Locate near TCM.
2
Heated hose wire termination enclosure (series
B only).
333024J
95
Reactor 2 Repair Spare Parts Reference
Reactor 2 Repair Spare
Parts Reference
Recommended Common Spare Parts
Ref
Part
Description
Part of Assembly
106,
115
15C852
E-30 Pump Repair Kit
Pump
106,
115
15C851
E-XP2 Pump Repair Kit
Pump
106,
115
246963
E-XP2 Wet Cup Repair Kit
Pump
106,
115
246964
E-30 Wet Cup Repair Kit
Pump
606,
607
24V020
Y-Strainer Filter and Gasket Kit
(pack of two each)
Y-Strainer
402
247824
Drain Valve Cartridge
Fluid Manifold
403
102814
Fluid Pressure Gauge
Fluid Manifold
405
15M669
Pressure Sensor
Fluid Manifold
211,
212
24L973
RTD Repair Kit
Heater
--
24K207
Hose FTS
Hose
--
24N450
RTD Cable (50 ft. replacement)
Hose
--
24N365
RTD Cable Test Kit (To assist measureing Hose
RTDs and RTD cable resistances)
96
333024J
Performance Charts
Performance Charts
Use these charts to help identify the proportioner that will work most efficiently with each mix chamber. Flow
rates are based on a material viscosity of 60 cps.
NOTICE
To prevent system damage, do not pressurize the
system above the line for the gun tip size being used.
Proportioners For Foam
2000
(138)
AR4242
(01)
AR5252
(02)
1500
(103)
PRESSURE
psi (bar)
AR6060
(03)
1000
(69)
AR7070
(04)
E-30
500
(34) 0
5
10
15
20
25
30
35
40
(2.3)
(4.5)
(6.8)
(9.1)
(11.3)
(13.6)
(15.9)
(18.1)
FLOW lbs/min (kg/min)
333024J
97
Performance Charts
Proportioners For Coatings
Table 1 Fusion Air Purge, Round Pattern
3500
(241)
3000
(207)
2500
PRESSURE
psi (bar)
E-XP2
AR2020
(000)
(172)
AR2929
(00)
2000
(138)
1500
(103)
AR4242
(01)
1000
(69)
500
(34) 0
0.5
1.0
1.5
2.0
(1.9)
(3.8)
(5.7)
(7.6)
FLOW gal./min (l/min)
Table 2 Fusion Air Purge, Flat Pattern
3500
(241, 24.1)
3000
(207, 20.7)
AF2929
(FTXX38 TIP)
2500
(174, 17.4)
PRESSURE
psi (bar)
AF2020
(FTXX24 TIP)
2000
(138, 13.8)
E-XP2
AF4242
(FTXX38 TIP)
1500
(103, 10.3)
AF5252
(FTXX48 TIP)
1000
(69,6.9)
500
(35, 3.5)
0
0.5
1.0
1.5
2.0
(1.9)
(3.8)
(5.7)
(7.6)
FLOW gal./min (l/min)
98
333024J
Performance Charts
Table 3 Fusion Mechanical Purge, Round Pattern
3500
(241, 24.1)
E-XP2
3000
(207, 20.7)
XR2323
(RTM040)
2500
(174, 17.4)
PRESSURE
psi (bar)
XR2929
(RTM040)
2000
(138, 13.8)
MR3535
(RTM040)
1500
MR4747
(RTM055)
(103, 10.3)
XR3535
(RTM055)
1000
XR4747
(RTM055)
(69, 6.9)
500
(35, 3.5)
0
0.5
1
1.5
2.0
(1.9)
(3.8)
(5.7)
(7.6)
FLOW gal./min (l/min)
Table 4 Fusion Mechanical Purge, Flat Pattern
3500
(241, 24.1)
XF2323
(FTM424)
XF1313
(FTM424)
3000
(207, 20.7)
MF2929
(FTM424)
2500
MF4747
(FTM638)
(174, 17.4)
PRESSURE
psi (bar)
MF1818
(FTM424)
2000
(138, 13.8)
XF2929
(FTM424)
XF1818
(FTM424)
1500
(103, 10.3)
XF5757
(FTM638)
XF3535
(FTM638)
1000
E-XP2
MF5757
(FTM638)
MF3535
(FTM638)
(69, 6.9)
500
(35, 3.5)
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
2.0
(0.7)
(1.5)
(2.3)
(3.0)
(3.8)
(4.5)
(5.3)
(6.0)
(6.8)
(7.6)
FLOW gal./min (l/min)
333024J
99
Technical Specifications
Technical Specifications
Reactor 2 E-30 and E-XP2 Proportioning System
Maximum Fluid Working Pressure
E-30
E-XP2
Maximum Fluid Temperature
E-30
E-XP2
Maximum Flow Rate
E-30
E-XP2
Maximum Heated Hose Length
Length
Cycle, ISO and RES
Output per Cycle
E-30
E-XP2
Operating Ambient Temperature Range
Temperature
Line Voltage Requirement
Nominal 200–240 VAC, 1 Phase,
50/60 Hz
Nominal 200–240 VAC, 3 phase,
DELTA, 50/60 Hz
Nominal 350–415 VAC, 3 phase,
WYE, 50/60 Hz
Power, (at 230 VAC rated voltage)
Heater Power
E-30 10 kW
E-30, 15 kW
E-XP2 15 kW
100
U.S.
Metric
2000 psi
3500 psi
14 MPa, 140 bar
24.1 MPa, 241 bar
190°F
190°F
88°C
88°C
30 lb/min
2 gpm
13.5 kg/min
7.6 lpm
310 ft
94 m
0.0272 gal.
0.0203 gal.
0.1034 liter
0.0771 liter
20° to 120°F
-7° to 49°C
195–265 VAC
195–265 VAC
340–455 VAC
10,200 Watts
15,300 Watts
15,300 Watts
333024J
Technical Specifications
Pressure, Sound Pressure measured per ISO-9614–2.
Sound Pressure
E-30, Measured from 3.1 ft (1 m),
87.3 dBA
at 1000 psi (7 MPa, 70 bar), 3 gpm
(11.4 lpm)
79.6 dBA
E-XP2, Measured from 3.1 ft (1
m), at 3000 psi (21 MPa, 207 bar),
1 gpm (3.8 lpm)
Sound Power
E-30, Measured from 3.1 ft (1 m),
at 1000 psi (7 MPa, 70 bar), 3 gpm
(11.4 lpm)
E-XP2, Measured from 3.1 ft (1
m), at 3000 psi (21 MPa, 207 bar),
1 gpm (3.8 lpm)
Fluid Inlets
Component A ISO) and
Component B (RES)
Fluid Outlets
Component A (ISO)
Component B (RES)
Fluid Circulation Ports
Size
Maximum Pressure
Dimensions
Width
Height
Depth
Weight
E-30, 10 kW
E-30, 15 kW
E-30, 10 kW Elite
E-30, 15 kW Elite
E-XP2
E-XP Elite
Wetted Parts
Material
333024J
93.7 dBA
86.6 dBA
3/4 NPT(f) with 3/4 NPSM(f) union
#8 (1/2 in.) JIC, with #5 (5/16 in.) JIC adapter
#10 (5/8 in.) JIC, with #6 (3/8 in.) JIC adapter
1/4 NPSM(m)
250 psi
1.75 MPa, 17.5 bar
26.3 in.
63 in.
15 in.
668 mm
1600 mm
381 mm
315
350
320
355
345
350
lb
lb
lb
lb
lb
lb
143
159
145
161
156
159
kg
kg
kg
kg
kg
kg
Aluminum, stainless steel, zinc plated carbon steel, brass, carbide,
chrome, chemically resistant o-rings, PTFE, ultra-high molecular weight
polyethylene
101
Notes
Notes
102
333024J
Graco Extended Warranty for Reactor® 2
Components
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.
Graco Part Number
Description
Warranty Period
24U050
24U051
24U831
Electric Motor
36 Months or 3 Million Cycles
Motor Control Module
36 Months or 3 Million Cycles
24U832
Motor Control Module
36 Months or 3 Million Cycles
24U855
Heater Control Module
36 Months or 3 Million Cycles
24U854
Advanced Display Module
All other Reactor 2 parts
36 Months or 3 Million Cycles
12 Months
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 hereunder must be brought within the latter of two (2) years of the date of
sale, or one (1) year the warranty period expires.
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 www.graco.com.
To place an order, contact your Graco Distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
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 www.graco.com/patents.
Original Instructions. This manual contains English. MM 333024
Graco Headquarters: Minneapolis
International Offices:
Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision J, September 2016

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