Graco DVD Player 333024F User manual

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Graco DVD Player 333024F User manual | Manualzz
Repair-Parts
Reactor 2 E-30 and E-XP2
Proportioning System
333024F
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.
WLE
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 .................................. 43
Shutdown........................................................... 44
Flushing............................................................. 46
Repair................................................................ 47
Before Beginning Repair............................... 47
Flush Inlet Strainer Screen ........................... 47
Change Pump Lubricant............................... 48
Remove Pump............................................. 49
Install Pump ................................................ 50
Repair Drive Housing ................................... 51
Repair Electric Motor.................................... 54
Repair Circuit Breaker Module ...................... 55
Replace Fluid Inlet Sensor............................ 56
2
Replace Pressure Transducers..................... 56
Replace Fans .............................................. 57
Repair Primary Heater.................................. 60
Repair Heated Hose..................................... 64
Repair Fluid Temperature Sensor
(FTS)............................................. 66
Replace Power Supply ................................. 69
Replace Surge Protector .............................. 69
Replace Advanced Display Module
(ADM)............................................ 69
Replace Motor Control Module (MCM)........... 70
Software Update Procedure.......................... 70
Replace Temperature Control Module
(TCM)............................................ 70
Parts.................................................................. 71
Electrical Schematics.......................................... 91
Reactor 2 Repair Spare Parts Reference ............. 94
Performance Charts............................................ 95
Technical Specifications...................................... 98
Notes ............................................................. 100
Graco Extended Warranty for Reactor® 2
Components ....................................... 101
333024F
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 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
warnings in this manual.
• Store hazardous fluid in approved containers, and dispose of it according to applicable
guidelines.
TOXIC FLUID OR FUMES
Personal
Protective Equipment
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.
333024F
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.
.
• 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
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.
Get immediate surgical
treatment
Pressure Relief Procedure
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in
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
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.
•
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.
work area
Grounding
Stop operation immediately
.
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
333024F
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
in this and all other equipment instruction manuals. Read fluid and
solvent manufacturer’s MSDSs and recommendations.
Technical Data
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
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
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.
Technical Data
Pressure Relief Procedure
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
and disconnect all power sources.
Pressure Relief Procedure
333024F
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
333024F
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:
333024F
7
Important Isocyanate Information
Material Self-Ignition
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.
store ISO in an open container.
• 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.
The amount of film formation and rate of
crystallization varies depending on the blend of ISO,
the humidity, and the temperature.
Never
Cross-contamination can result in cured
material in fluid lines which could cause serious
injury or damage to equipment. To prevent
cross-contamination:
•
interchange component A and component
B wetted parts.
• Never use solvent on one side if it has been
contaminated from the other side.
Never
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.
• 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
NOTE:
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.
333024F
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
10 kW
15 kW
10 kW
15kW
272010
2000 (14, 140)
0.0272 (0.1034)
30 (13.5)
17,900
230 230 400
1Ø 3Ø∆ 3ØY
78 50 34
272011
2000 (14, 140)
0.0272 (0.1034)
30 (13.5)
23,000
230 230 400
1Ø 3Ø∆ 3ØY
100 62 35
272110
2000 (14, 140)
0.0272 (0.1034)
30 (13.5)
17,900
230 230 400
1Ø 3Ø∆ 3ØY
78 50 34
272111
2000 (14, 140)
0.0272 (0.1034)
30 (13.5)
23,000
230 230 400
1Ø 3Ø∆ 3ØY
100 62 35
Fusion AP Package 
AP2010
AH2010
AP2011
AH2011
AP2110
AH2110
AP2111
AH2111
(Gun Part No.)
(246102)
(246102)
(246102)
(246102)
(246102)
(246102)
(246102)
(246102)
(Gun Part No.)
(CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD)
(CS02RD) (CS02RD)
(Gun Part No.)
(GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2)
(GCP2R2) (GCP2R2)
Proportioner
★
E-30 Elite Model
Maximum Fluid Working
Pressure psi (MPa, bar)
Approximate Output per
Cycle (A+B) gal. (liter)
Max Flow Rate lb/min
(kg/min)
Total System Load †
(Watts)
Configurable Voltage

Phase
Full Load Peak Current*
Fusion CS Package 
Probler P2 Package 
Heated Hose
50 ft (15 m)
24K240 (scuff guard)
24Y240 (Xtreme-Wrap)
Heated Whip Hose
10 ft (3 m)
Graco Insite™
Fluid Inlet Sensors (2)
CS2010
P22010
24K240
Qty: 1
246050
CH2010
PH2010
24K240
Qty: 5
CS2011
P22011
24K240
Qty: 1
333024F
PH2011
24K240
Qty: 5
246050
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.
*
CH2011


CS2110
P22110
24Y240
Qty: 1
CH2110
PH2110
24Y240
Qty: 5
CS2111
P22111
24Y240
Qty: 1
246050
246050
✓
✓
✓
✓
CH2111
PH2111
24Y240
Qty: 5
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
Ø Phase
∆ 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
15 kW
★
Proportioner
Maximum Fluid Working
Pressure psi (MPa, bar)
Approximate Output per
Cycle (A+B) gal. (liter)
Max Flow Rate gpm/min
(l/min)
Total System Load †

(Watts)
Configurable Voltage

Phase
E–XP2 Elite Model
*
Full Load Peak Current
272012
3500 (24.1, 241)
0.0203 (0.0771)
2 (7.6)
23,000
230 1Ø
230 3Ø∆
100
62
15 kW
400 3ØY
35
272112
3500 (24.1, 241)
0.0203 (0.0771)
2 (7.6)
23,000
230 1Ø
230 3Ø∆
100
62
400 3ØY
35
(amps)
Fusion AP Package

Probler P2 Package

(Gun Part No.)
(Gun Part No.)
Heated Hose
50 ft (15 m)
Heated Whip Hose
10 ft (3 m)
AP2012
(246100)
P22012
(GCP2R0)
24K241
(scuff guard)
246055
™
Graco InSite
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.
*
10


AP2112
(246100)
P22112
(GCP2R0)
24Y241
(Xtreme-Wrap)
246055
✓
✓
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
Ø Phase
∆ DELTA
Y WYE
333024F
Approvals
Approvals
Accessories
Intertek approvals apply to proportioners without
hoses.
Proportioner Approvals:
Kit Number
24U315
24U314
24T280
16X521
24N449
9902471
Conforms to ANSI/UL Std. 499
Certified to CAN/CSA Std. C22.2 No. 88
24K207
24U174
24K337
15V551
15M483
24M174
121006
24N365
333024F
Description
Air Manifold Kit (4 outlets)
Wheel and Handle Kit
Graco InSite Kit
Graco InSite Extension cable 24.6 ft
(7.5 m)
50 ft (15 m) CAN cable (for remote
display module)
Fluid Temperature Sensor (FTS)
with RTD
Remote Display Module Kit
Light Tower Kit
ADM Protective Covers (10 pack)
Remote Display Module Protective
Covers (10 pack)
Drum Level Sticks
150 ft (45 m) CAN cable (for remote
display module)
RTD Test Cables (to aide resistance
measurements)
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
Heated Hose, Instructions-Parts
Circulation and Return Tube Kit,
Instructions-Parts
Feed Pump Kits, Instructions-Parts
Feed Pump Air Supply Kit,
Instructions-Parts
Fusion ™ AP Gun
Fusion ™ CS Gun
Probler® P2 Gun
Feed System Manuals
309572
309852
309815
309827
Spray Gun Manuals
309550
312666
313213
Accessory Manuals
3A1905
3A1906
3A1907
332735
332736
333276
12
Feed Pump Shutdown Kit,
Instructions-Parts
Light Tower Kit, Instructions-Parts
Remote Display Module Kit,
Instructions-Parts
Air Manifold Kit, Instructions-Parts
Handle and Wheel Kit,
Instructions-Parts
Graco InSite ™ Kit, Instructions-Parts
333024F
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
A parameter critical to
the process has reached
a level requiring the
system to stop. The
alarm needs to be
addressed immediately.
A parameter critical
to the process has
reached a level requiring
attention, but not
sufficient enough to
stop the system at this
time.
A parameter that is
not immediately critical
to the process. The
advisory needs attention
to prevent more serious
issues in the future.
See Error Codes, page 13 for causes and solutions
to each error code.
To troubleshoot the error:
Alarms
Deviations
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.
Advisories
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.
333024F
13
Troubleshooting
Error
Location
A1NM MCM
Type
Description
Low Motor Current
Cause
Loose/broken
connection.
Bad Motor.
A4DA
Heater A
High Current A
Short circuit in
heater wiring.
Bad Heater.
A4DB
Heater B
High Current B
Short circuit in
heater wiring.
Bad Heater.
High Current Hose
Short circuit in
hose wiring.
A4DH Hose
14
Solution
Check for loose wire
terminations at MCM motor
connector.
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.
Check wiring for touching
wires.
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.
Check wiring for touching
wires.
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.
Check continuity of
transformer windings.
Normal readings are about
0.2Ω on both primary and
secondary. If reading is 0Ω
replace transformer.
Check for shorts between
the primary winding and the
support frame or enclosure.
333024F
Troubleshooting
Error
Location
A7DA
Heater A
A7DB
Heater B
A4NM MCM
A7DH Hose
333024F
Type
Description
Cause
High Motor Current Short circuit of
motor wiring.
Solution
Check wiring to the motor
to ensure no bare wires are
touching and that no wires
are shorted to ground.
Motor will not
Remove pump gear
rotate.
housings from motor
and check that motor shaft
rotates freely in direction
indicated on motor housing.
Damaged gear Check pump gear trains
train.
for damage and repair or
replace as necessary.
Chemical pump is Repair or replace chemical
stuck.
pump.
Unexpected Current Shorted TCM
If error cannot be cleared
A
or regenerates consistently,
replace module.
Unexpected Current Shorted TCM
If error cannot be cleared
B
or regenerates consistently,
replace module.
Unexpected Current Shorted TCM
If error cannot be cleared
Hose
or regenerates consistently,
replace module.
15
Troubleshooting
Error
Location
A8DA
Heater A
A8DB
Heater B
Type
Description
No Current A
No Current B
A8DH Hose
No Current Hose
CACM MCM
MCM Communication Error
16
Cause
Tripped circuit
breaker.
Solution
Visually check circuit
breaker for a tripped
condition.
Loose/broken
Check heater wiring for
connection.
loose wires.
Tripped circuit
Visually check circuit
breaker.
breaker for a tripped
condition.
Loose/broken
Check heater wiring for
connection.
loose wires.
Tripped circuit
Visually check circuit
breaker.
breaker for a tripped
condition.
Loose/broken
Check heater wiring for
connection.
loose wires.
Module does not Insert a system token into
have software.
the ADM module and cycle
the power. Wait until the
upload is complete before
removing the token.
Dial set to wrong Ensure the MCM dial is set
position.
to the correct position: 2 for
E-30, 3 for E-XP2
No 24 VDC supply Green light on each module
to 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 Check the CAN cables
CAN cable.
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.
333024F
Troubleshooting
Error
Location
CACT TCM
Type
Description
TCM Communication Module does not
have software.
Error
DADX MCM
Pump Runaway
DE0X
Cycle Switch Error
333024F
MCM
Cause
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 Green light on each module
to 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 Check the CAN cables
CAN cable.
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 Mix chamber too large for
large.
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.
Faulty or missing Check wiring between cycle
cycle switch.
switch and MCM.
Missing or out of Check presence and
place cycle switch position of cycle switch
magnet on output crank
magnet.
arm.
17
Troubleshooting
Error
Location
Description
Cause
EAUX ADM
USB Busy
EVUX ADM
USB disabled
USB drive has
been inserted to
the ADM.
USB
download/uploads
are disabled.
F9DX
High Pressure/Flow Mix chamber is
Cutback
too large for set
pressure.
EVCH ADM
MCM
Type
Manual Hose Mode Manual hose mode
Enabled
has been enabled
in System Setup
screen.
H2MA Heater A
Low Frequency A
Line frequency is
below 45 Hz
H2MB Heater B
Low Frequency B
Line frequency is
below 45 Hz
H2MH Hose
Low Frequency Hose Line frequency is
below 45 Hz
H3MA Heater A
High Frequency A
Line frequency is
above 65 Hz
H3MB Heater B
High Frequency B
Line frequency is
above 65 Hz
H3MH Hose
High Frequency
Hose
Line frequency is
above 65 Hz
K8NM MCM
Locked Rotor Motor Motor will not
rotate.
Damaged gear
train.
Chemical pump is
stuck.
18
Solution
Install a functioning fluid
temperature sensor (FTS)
on the hose. Manual hose
mode will automatically turn
off.
Do not remove USB drive
until download/upload is
complete.
Enable USB download/uploads on the Advanced
Setup screen before inserting a USB drive.
Reference the pressure
flow curves and select a tip
size that is the correct size
for the set pressure.
Ensure line frequency of
incoming power is between
45 and 65 Hz.
Ensure line frequency of
incoming power is between
45 and 65 Hz.
Ensure line frequency of
incoming power is between
45 and 65 Hz.
Ensure line frequency of
incoming power is between
45 and 65 Hz.
Ensure line frequency of
incoming power is between
45 and 65 Hz.
Ensure line frequency of
incoming power is between
45 and 65 Hz.
Remove pump gear
housings from motor
and check that motor shaft
rotates freely in direction
indicated on motor housing.
Check motor/pump gear
trains for damage and repair
or replace as necessary.
Repair or replace chemical
pump.
333024F
Troubleshooting
Error
Location
L1BX
ADM
L1AX
ADM
MMUX USB
P0AX
333024F
MCM
Type
Description
Cause
Solution
Low Chemical Level Low material level. Refill material and update
A
drum level on ADM
Maintenance screen.
Alarm can be disabled on
the System Setup screen.
Low Chemical Level Low material level. Refill material and update
B
drum level on ADM
Maintenance screen.
Alarm can be disabled on
the System Setup screen.
Maintenance Due - USB logs have Insert a USB drive into the
USB
reached a level ADM and download all logs.
where data loss
will occur if logs are
not downloaded.
Pressure Imbalance Pressure
Ensure material flow is
A High
difference between equally restricted on both
A and B material material lines.
is greater than the
defined value.
Ensure that the pressure
Pressure
imbalance value, on the
imbalance is
defined too low. 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 Check if heater
heater inlet rupture and PRESSURE
RELIEF/SPRAY valve are
disk.
plugged. Clear. Replace
rupture disk. Do not replace
with a pipe plug.
Feed system
Check feed pump and
defective.
hoses for blockage. Check
that feed pumps have
correct air pressure.
19
Troubleshooting
Error
P0BX
Location
MCM
P1FA
MCM
P1FB
MCM
P2FA
MCM
20
Type
Description
Cause
Pressure Imbalance Pressure
B High
difference between
A and B material
is greater than the
defined value.
Pressure
imbalance is
defined too low.
Solution
Ensure material flow is
equally restricted on both
material lines.
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 Check if heater
heater inlet rupture and PRESSURE
RELIEF/SPRAY valve are
disk.
plugged. Clear. Replace
rupture disk. Do not replace
with a pipe plug.
Feed system
Check feed pump and
defective.
hoses for blockage. Check
that feed pumps have
correct air pressure.
Ensure that inlet pressure
Low Inlet Pressure A Inlet pressure
lower than defined to the pump is sufficient.
value.
Value defined too Ensure that the low
pressure alarm level
high.
defined on the System
Setup screen is acceptable.
Ensure that inlet pressure
Low Inlet Pressure B Inlet pressure
lower than defined to the pump is sufficient.
value.
Value defined too Ensure that the low
pressure alarm level
high.
defined on the System
Setup screen is acceptable.
Ensure that inlet pressure
Low Inlet Pressure A Inlet pressure
lower than defined to the pump is sufficient.
value.
Value defined too Ensure that the low
pressure alarm level
high.
defined on the System
Setup screen is acceptable.
333024F
Troubleshooting
Error
P2FB
P4AX
Location
MCM
MCM
Type
Description
Cause
Low Inlet Pressure B Inlet pressure
lower than defined
value.
Value defined too
high.
High Pressure A
System
pressurized before
allowing heat to
reach setpoint.
Bad pressure
transducer.
E-XP2 system
configured as E-30.
P4BX
MCM
High Pressure B
System
pressurized before
allowing heat to
reach setpoint.
Bad pressure
transducer.
E-XP2 system
configured as E-30.
333024F
Solution
Ensure that inlet pressure
to the pump is sufficient.
Ensure that the low
pressure alarm level
defined on the System
Setup screen is acceptable.
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.
Verify the ADM pressure
reading and the analog
gauges at the manifold.
Alarm level is lower for E-30
than for E-XP2. Ensure dial
on MCM is set to position
"3" for E-XP2.
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.
Verify the ADM pressure
reading and the analog
guages at the manifold.
Alarm level is lower for E-30
than for E-XP2. Ensure dial
on MCM is set to position
"3" for E-XP2.
21
Troubleshooting
Error
P6AX
Location
MCM
Type
Description
Pressure Sensor
Error A
Cause
Loose/bad
connection.
Bad sensor.
P6BX
MCM
Pressure Sensor
Error B
Loose/bad
connection.
Bad sensor.
P6FA
MCM
Pressure Sensor
Error Inlet A
Inlet sensors not
installed.
Loose/bad
connection.
Bad sensor.
22
Solution
Check to ensure the
pressure transducer is
properly installed and
all wires are properly
connected.
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.
Check to ensure the
pressure transducer is
properly installed and
all wires are properly
connected.
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.
If inlet sensors are not
installed, inlet sensors
should be disabled on the
System Setup screen.
Check to ensure inlet
sensor is properly installed
and all wires are properly
connected.
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.
333024F
Troubleshooting
Error
Location
P6FB
MCM
P7AX
MCM
333024F
Type
Description
Cause
Inlet sensors not
installed.
Solution
If inlet sensors are not
installed, inlet sensors
should be disabled on the
System Setup screen.
Loose/bad
Check to ensure inlet
connection.
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 Imbalance Pressure
Ensure material flow is
A High
difference between equally restricted on both
A and B material material lines.
is greater than the
defined value.
Ensure that the pressure
Pressure
imbalance value, on the
imbalance is
defined too low. 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 Check if heater
heater inlet rupture and PRESSURE
RELIEF/SPRAY valve are
disk.
plugged. Clear. Replace
rupture disk. Do not replace
with a pipe plug.
Feed system
Check feed pump and
defective.
hoses for blockage. Check
that feed pumps have
correct air pressure.
Pressure Sensor
Error Inlet B
23
Troubleshooting
Error
P7BX
Location
MCM
Type
Description
Cause
Pressure Imbalance Pressure
B High
difference between
A and B material
is greater than the
defined value.
Pressure
imbalance is
defined too low.
Out of material.
Fluid leaking from
heater inlet rupture
disk.
Feed system
defective.
T2DA
Heater A
Low Temperature A Flow is too high at
current setpoint.
Bad RTD or bad
RTD placement
against heater.
Bad heater rod or
loose heater wire.
24
Solution
Ensure material flow is
equally restricted on both
material lines.
Ensure that the pressure
imbalance value, on the
System Setup screen, is at
an acceptable maximum
pressure to prevent
unnecessary alarms and
abort dispenses.
Fill tanks with material
Check if heater
and PRESSURE
RELIEF/SPRAY valve are
plugged. Clear. Replace
rupture disk. Do not replace
with a pipe plug.
Check feed pump and
hoses for blockage. Check
that feed pumps have
correct air pressure.
Use a smaller mix chamber
that is rated for the unit
in use. If recirculating,
decrease flow or decrease
temperature setpoint.
Swap A and B heater output
cables and RTD cables and
see if issue follows. If so,
replace RTD.
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.
333024F
Troubleshooting
Error
Location
T2DB
Heater B
T2DH
Hose
T2FA
MCM
T2FB
MCM
333024F
Type
Description
Cause
Solution
Low Temperature B Flow is too high at Use a smaller mix chamber
current setpoint. that is rated for the unit
in use. If recirculating,
decrease flow or decrease
temperature setpoint.
Bad RTD or bad Swap A and B heater output
RTD placement cables and RTD cables and
against heater.
see if issue follows. If so,
replace RTD.
Bad heater rod or Confirm resistance of
loose heater wire. 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 Flow is too high at Use a smaller mix chamber
Hose
current setpoint. that is rated for the unit
in use. If recirculating,
decrease flow or decrease
temperature setpoint.
Cold chemical in Recirculate heated
unheated portion chemical back to drum
of system passed in cold conditions before
startup.
hose FTS at
startup.
Low Temperature Inlet fluid
Recirculate fluid through
Inlet A
temperature is
heaters until inlet fluid
below the defined temperature is above
level.
defined error level.
Increase the low
temperature deviation
level on the System Setup
screen.
Low Temperature Inlet fluid
Recirculate fluid through
Inlet B
temperature is
heaters until inlet fluid
below the defined temperature is above
level.
defined error level.
Increase the low
temperature deviation
level on the System Setup
screen.
25
Troubleshooting
Error
Location
T3CH
Hose
T3CT
TCM
Type
Description
Cause
Hose Cutback
Hose current has
been reduced
because hose
has been drawing
current for an
extended period.
TCM Cutback
High ambient
temperature.
Enclosure fan not
operating.
Module fan not
operating.
T3NM MCM
Motor Temperature Motor is operating
Cutback
outside of the
pressure flow
curve.
Motor temperature
is too high.
T3CM MCM
MCM Temperature
Cutback
Motor control
temperature is
too high.
T4CM MCM
High Temperature
MCM
High ambient
temperature.
Enclosure fan not
operating.
26
Solution
Hose setpoint higher than A
and B setpoints. Decrease
hose setpoint.
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.
Ensure ambient
temperature is below
120°F(48°C) before using
the system.
Ensure fan in electrical
enclosure is spinning. If it
is not, check fan wiring or
replace fan.
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.
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.
Ensure ambient
temperature is below
120°F(48°C).
Verify that all fans are
working.
Ensure ambient
temperature is below
120°F(48°C).
Verify that all fans are
working.
Ensure ambient
temperature is below
120°F(48°C) before using
the system.
Ensure fan in electrical
enclosure is spinning. If it
is not, check fan wiring or
replace fan.
333024F
Troubleshooting
Error
Location
T4DA
Heater A
T4DB
Heater B
T4CT
333024F
TCM
Type
Description
High Temperature
TCM
Cause
High ambient
temperature.
Solution
Ensure ambient
temperature is below
120°F(48°C) before using
the system.
Enclosure fan not Ensure fan in electrical
operating.
enclosure is spinning. If it
is not, check fan wiring or
replace fan.
Module fan not If a TCM fan error (WMI0)
operating.
has occurred, fan inside
the module is not working
properly. Check TCM fan
for debris and clear with
forced air if necessary.
High Temperature A Bad RTD or bad Swap A and B heater output
RTD placement cables and RTD cables and
see if issue follows. If so,
against heater.
replace RTD.
Use a smaller mix chamber
Flow too high
for temperature that is rated for the unit in
setpoint, causing use.
temperature
overshoots when
gun is de-triggered.
High Temperature B Bad RTD or bad Swap A and B heater output
RTD placement cables and RTD cables and
against heater.
see if issue follows. If so,
replace RTD.
Use a smaller mix chamber
Flow too high
for temperature that is rated for the unit in
setpoint, causing use.
temperature
overshoots when
gun is de-triggered.
27
Troubleshooting
Error
T4DH
T4EA
28
Location
Hose
Heater A
Type
Description
High Temperature
Hose
High Temperature
Switch A
Cause
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.
Setting the A or
B setpoint much
higher than hose
setpoint can cause
fluid more than
27°F (15°C) over
hose temperature
setting to reach the
FTS.
Overtemperature
switch sensed a
fluid temperature
above 230°F
(110°C).
Solution
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
so it is closer to A and B
setpoints.
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
If heater is not actually
or loose
over temperature, check
overtemperature all wiring and connections
switch
between the TCM and the
cable/connection. overtemperature switches.
Overtemperature Replace overtemperature
switch failed in the switch.
open position.
333024F
Troubleshooting
Error
T4EB
Location
Heater B
Type
Description
High Temperature
Switch B
T4NM MCM
High Temperature
Motor
T6DA
Sensor Error A
333024F
Heater A
Cause
Solution
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
If heater is not actually
or loose
over temperature, check
overtemperature all wiring and connections
switch
between the TCM and the
cable/connection. overtemperature switches.
Overtemperature Replace overtemperature
switch failed in the switch.
open position.
Cooling fan is not Check to see that the motor
operating properly. 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.
Disconnected
Verify wiring between the
or loose motor
motor temperature sensor
temperature cable. and the MCM.
High ambient
Ensure ambient
temperature.
temperature is below
120°F(48°C) before using
the system.
Bad electric motor. Replace electric motor.
Disconnected or Check all wiring and
loose RTD cable or connection to RTD.
connection.
Bad RTD.
Switch the RTD with
another and see if the error
message follows the RTD.
Replace RTD if the error
follows the RTD.
Overtemperature
switch sensed a
fluid temperature
above 230°F
(110°C).
29
Troubleshooting
Error
Location
Type
Description
T6DB
Heater B
T6DH
Hose
Sensor Error Hose
T6DT
TCM
Sensor Error TCM
30
Sensor Error B
Cause
Solution
Disconnected or Check all wiring and
loose RTD cable or connection to RTD.
connection.
Bad RTD.
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 64. Order RTD Test
kit 24N365 for measurement.
Disconnect hose RTD and
use manual hose mode to
finish job until repair can be
completed.
Shorted RTD cable Expose each hose RTD
in hose or FTS. connection to check for
exposed and shorted RTD
wires. Measure hose RTD
cable and FTS continuity.
See Repair Heated Hose,
page 64. 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 If the error still occurs with
Heater RTD
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.
333024F
Troubleshooting
Error
T8DA
Location
Heater A
Type
Description
No Temperature
Rise A
Cause
Bad RTD or bad
RTD placement
against heater.
Bad heater rod or
loose heater wire.
T8DB
Heater B
No Temperature
Rise B
Started spraying
before heater
reached operating
temperature.
Bad RTD or bad
RTD placement
against heater.
Bad heater rod or
loose heater wire.
T8DH
Hose
V1CM MCM
333024F
No Temperature
Rise Hose
Low Voltage MCM
Solution
Swap A and B heater output
cables and RTD cables and
see if issue follows. If so,
replace RTD.
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.
Wait until operating
temperature has been
reached before spraying or
recirculating.
Swap A and B heater output
cables and RTD cables and
see if issue follows. If so,
replace RTD.
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.
Wait until operating
temperature has been
reached before spraying or
recirculating.
Wait until operating
temperature has been
reached before spraying or
recirculating.
Check wiring for loose
connection or tripped circuit
breaker.
Started spraying
before heater
reached operating
temperature.
Started spraying
before heater
reached operating
temperature.
Loose/bad
connection or
tripped circuit
breaker.
Low incoming line Measure voltage at circuit
voltage.
breaker and ensure voltage
is greater than 195 VAC.
31
Troubleshooting
Error
Location
V1IT
TCM
V2IT
TCM
Type
Description
Low Voltage CAN
Low Voltage CAN
V2MA TCM
Low Voltage A
V2MB TCM
Low Voltage B
V2MH TCM
Low Voltage Hose
V3IT
High Voltage CAN
TCM
V3MA TCM
32
High Voltage A
Cause
Solution
Bad 24 VDC power Check voltage of power
supply.
supply. Voltage should
be 23-25 VDC. If out of
tolerance, replace power
supply.
Bad 24 VDC power Check voltage of power
supply.
supply. Voltage should
be 23-25 VDC. If out of
tolerance, replace power
supply.
Loose connection Check wiring for loose
or tripped circuit connection or tripped circuit
breaker.
breaker.
Low incoming line Measure voltage at circuit
voltage.
breaker and ensure voltage
is greater than 195 VAC.
Loose connection Check wiring for loose
or tripped circuit connection or tripped circuit
breaker.
breaker.
Low incoming line Measure voltage at circuit
voltage.
breaker and ensure voltage
is greater than 195 VAC.
Loose connection Check wiring for loose
or tripped circuit connection or tripped circuit
breaker.
breaker.
Low incoming line Measure voltage at circuit
voltage.
breaker and ensure voltage
is greater than 195 VAC.
Bad 24 VDC power Check voltage of power
supply.
supply. Voltage should
be 23-25 VDC. If out of
tolerance, replace power
supply.
Incoming line
Ensure incoming system
voltage is too high. power is wired properly.
Verify voltage at each circuit
breaker is between 195 and
264 VAC.
333024F
Troubleshooting
Error
Location
V3MB TCM
Type
Description
High Voltage B
V3MH TCM
High Voltage Hose
V4CM MCM
High Voltage MCM
V4IT
High Voltage CAN
TCM
V4MA TCM
High Voltage A
V4MB TCM
High Voltage B
V4MH TCM
High Voltage Hose
333024F
Cause
Solution
Incoming line
Ensure incoming system
voltage is too high. power is wired properly.
Verify voltage at each circuit
breaker is between 195 and
264 VAC.
Incoming line
Ensure incoming system
voltage is too high. power is wired properly.
Verify voltage at each circuit
breaker is between 195 and
264 VAC.
Incoming line
Ensure incoming system
voltage is too high. power is wired properly.
Verify voltage at each circuit
breaker is between 195 and
264 VAC.
Bad 24 VDC power Check voltage of power
supply.
supply. Voltage should
be 23-25 VDC. If out of
tolerance, replace power
supply.
Incoming line
Ensure incoming system
voltage is too high. power is wired properly.
Verify voltage at each circuit
breaker is between 195 and
264 VAC.
Incoming line
Ensure incoming system
voltage is too high. power is wired properly.
Verify voltage at each circuit
breaker is between 195 and
264 VAC.
Incoming line
Ensure incoming system
voltage is too high. power is wired properly.
Verify voltage at each circuit
breaker is between 195 and
264 VAC.
33
Troubleshooting
Error
Location
WMI0
TCM
WBC0 MCM
WSUX USB
WXUD ADM
WXUU ADM
34
Type
Description
Cause
Solution
Incorrect software Insert a system token into
the ADM module and cycle
version.
the power. Wait until the
upload is complete before
removing the token.
MCM does not If V1CM also exists, see
have line voltage. troubleshooting for V1CM.
The software version
cannot be read if the MCM
does not have line voltage.
TCM Fan Error
Fan inside TCM Check for debris in the TCM
is not operating fan and clear with forced air
if necessary.
properly.
Inset a system token into
Configuration Error A valid
USB
configuration file the ADM and cycle power.
can't be found for Wait until the lights on the
USB port stop flashing
the USB.
before removing token.
Backup and reformat the
USB Download Error Log download
failed.
USB drive. Retry download.
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.
Software Version
Error
333024F
Troubleshooting
System
Before performing any troubleshooting procedures:
1. Relieve Pressure. See Pressure Relief Procedure, page 43.
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.
333024F
Cause
No power.
Failed 24 V power supply.
Failed surge protector.
Loose connections.
Tripped circuit breaker (CB02).
Shorted windings.
Failed motor bearing.
Solution
Turn main power switch ON.
Replace power supply.
Replace surge protector.
Check MCM connection 13.
Reset breaker, see Repair Circuit
Breaker Module, page 55. Check
240VAC at output of breaker.
Replace motor, see
Repair Electric Motor, page 54.
Replace motor, see
Repair Electric Motor, page 54.
35
Troubleshooting
Problem
Cooling fans not working.
Pump output low.
Fluid leak in pump packing nut
area.
No pressure on one side.
36
Cause
Loose wire.
Fan blade obstructed.
Defective fan.
Obstructed fluid hose or gun; fluid
hose ID too small.
Worn piston valve or intake valve
in displacement pump.
Pressure setpoint too high.
Worn throat seals.
Fluid leaking from heater inlet
rupture disk (372).
Solution
Check. See
Electrical Schematics, page 91.
Remove obstruction.
Replace. See
Replace Motor Fan, page 57.
Open, clear; use hose with larger
ID.
See pump manual.
Reduce setpoint and output will
increase.
Replace. See pump manual.
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.
333024F
Troubleshooting
Hose Heat System
Before performing any troubleshooting procedures:
1. Relieve Pressure. See Pressure Relief Procedure, page 43.
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.
333024F
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 65.
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.
37
Troubleshooting
Problem
Hose temperature exceeds
setpoint.
38
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 91.
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 Make sure the hose bundle
around FTS, causing the hose has adequate insulation evenly
covering the entire length and
heat to be ON constantly.
connection joints.
333024F
Troubleshooting
Problem
Erratic hose temperature.
Hose does not heat.
333024F
Cause
Faulty FTS connections.
Solution
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 66.
Missing or damaged insulation Make sure the hose bundle
around FTS, causing the hose has adequate insulation evenly
covering the entire length and
heat to be ON constantly.
connection joints.
FTS failed.
Check FTS, see Repair Fluid
Temperature Sensor (FTS), page
66.
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 66.
Loose hose electrical connections. Check connections. Repair as
necessary.
Circuit breakers tripped.
Reset breakers (CB01 ), see
Repair Circuit Breaker Module,
page 55.
Hose zone not turned on.
Turn on hose heat zone.
A and B temperature setpoints too Check. Increase if necessary.
low.
39
Troubleshooting
Problem
Cause
Solution
Hoses near Reactor are warm, but Shorted connection or failed hose With power off, check the hose
hoses downstream are cold.
heating element.
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 64.
Low hose heat.
A and B temperature setpoints too Increase A and B setpoints. Hose
low.
designed to maintain temperature,
not increase temperature.
Hose temperature setpoint too Check. Increase if necessary to
low.
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
Relocate hoses to a warmer area
or increase A and B setpoints.
40
333024F
Troubleshooting
Primary Heater
Before performing any troubleshooting procedures:
1. Relieve Pressure. See Pressure Relief Procedure, page 43.
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
Cause
Primary Heater(s) does not heat. Heat turned off.
Temperature control alarm.
Signal failure from RTD.
Dirty RTD connections.
Control of primary heat is
abnormal; high temperature
overshoots (T4DA, T4DB) occurs
intermittently.
RTD not contacting heater
element.
Failed heater element.
Signal failure from RTD.
333024F
Solution
Turn on heat zones.
Check ADM for error codes.
Signal failure from RTD.
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.
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.
See
Replace Heater Element, page 60.
See (T6DA, T6DB), Error Codes.
41
Troubleshooting
Graco InSite
Problem
No module status LEDs are
illuminated.
Cause
No power to cellular module.
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.
Has not identified GPS location Still identifying location.
Wait a few minutes for the unit to
(green module status LED
identify the location.
Unable to identify location. In a Move system to a location with a
flashing).
location where GPS lock cannot clear view of the sky.
occur. Buildings and warehouses Use extension cable 16X521 and
move cellular module to a location
often prevent GPS locks.
with a clear view of the sky.
Has not established cellular
Still establishing cellular
Wait a few minutes for the unit to
connection (orange module status connection.
establish the connection.
Unable to establish cellular
Move system to a location with
LED flashing).
connection.
cellular service to establish cellular
connection.
Use extension cable 16X521 and
move cellular module to a location
with a clear view of the sky.
Cannot view data for my unit(s) on Graco InSite unit has not been Activate unit. See Registering
website.
activated.
and Activating the Graco InSite
section.
Temperature data not displayed Reactor temperature
See System troubleshooting
on website.
measurement is not working.
section.
Hose zone temperature data not The RTD or thermocouple is not See RTD or Thermocouple repair
displayed on website.
correctly installed on the hose or section.
is broken.
Pressure data not displayed on Reactor pressure measurement is See System troubleshooting
website.
not working.
section.
42
333024F
Pressure Relief Procedure
Route fluid to waste containers or supply tanks.
Pressure Relief Procedure 4. Turn
PRESSURE RELIEF/SPRAY valves (SA,
Follow the Pressure Relief Procedure
whenever you see this symbol.
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) to PRESSURE RELIEF/CIRCULATION
. Ensure gauges drop to 0.
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.
333024F
43
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.
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 deactivate the system.
6. Turn off the air compressor, air dryer, and
breathing air.
to stop the pumps.
2. Turn off all heat zones.
3. Relieve pressure. See
Pressure Relief Procedure, page 43.
44
5. Press
7. Turn main power switch OFF.
To prevent electric shock do not remove any
shrouds or open the electrical enclosure door.
333024F
Shutdown
8. Close all fluid supply valves.
9. Engage gun piston safety lock then close fluid
inlet valves A and B.
Fusion
333024F
Probler
45
Flushing
Flushing
To avoid fire and explosion:
• 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.
46
To flush feed hoses, pumps, and heaters
separately from heated hoses, set PRESSURE
RELIEF/SPRAY valves (SA, SB) to PRESSURE
RELIEF/CIRCULATION
lines (N).
. Flush through bleed
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.
333024F
Repair
Repair
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.
1. Flush if necessary. See Flushing, page 46.
2. See Shutdown, page 44.
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).
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.
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.
333024F
47
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.
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 43.
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.
48
4. When the reservoir is flushed clean, fill with fresh
lubricant.
5. Thread the reservoir onto the cap assembly and
place it in the bracket.
6. The lubrication system is ready for operation. No
priming is required.
Pump Lubrication System
Figure 2
333024F
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
1.
2.
3.
4.
5.
6.
See manual 309577 for pump repair
instructions.
Press to stop the pumps.
Turn off heat zones.
8. Route fluid to waste containers or supply tanks.
Flush pump.
Turn PRESSURE RELIEF/SPRAY valves (SA,
SB) to PRESSURE RELIEF/CIRCULATION
Press to park the pumps in the down position.
. Ensure gauges drop to 0.
Press to deactivate the system.
Turn main power switch off.
7. Shut off both feed pumps. Close all fluid supply
valves.
333024F
49
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
Flat side faces up.
Lubricate threads with ISO oil or grease.
Pump top threads must be nearly flush with
bearing face (N).
1
2
3
Install Pump
Note
1.
Pump A
Figure 3
1
2
3
2.
Flat side faces up.
Lubricate threads with ISO oil or grease.
Pump top threads must be nearly flush with
bearing face (N).
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.
50
3.
4.
5.
Steps 1–5 apply to pump B. To reconnect
pump A, proceed to step 6.
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.
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).
Tighten locknut (G) by hitting firmly with a
non-sparking hammer.
Reconnect fluid inlet (C) and outlet (D).
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.
333024F
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
7. Start threading pump into bearing housing (M).
When pin holes align, insert pin. Pull retaining
wire clip down.
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.
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.
333024F
1.
2.
3.
4.
5.
6.
Press to stop the pumps.
Turn off heat zones.
Flush pump.
Press to park the pumps in the down position.
Press to deactivate the system.
Turn main power switch off.
51
Repair
7. Perform Pressure Relief Procedure, page 43.
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 49.
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).
52
Figure 6
333024F
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
5.
6.
7.
8.
If bearing housing (103), connecting rod
(105), or pump (106) were removed,
reassemble rod in housing and install
pump, see Install Pump, page 50 .
Route cycle counter switch cable (121) around
the motor fan and reattach to housing (102) with
screws (122).
Install bearing housing (103), screws (113), and
washers (114). Pumps must be in phase (both at
same position in stroke).
Install cover (60) and screws (21).
Install motor shield (11) and screws (21).
Figure 7
333024F
53
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
2.
3.
4.
5.
6.
54
1. Place motor on unit. Thread motor
cables into conduit as before. See
Electrical Schematics, page 91.
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
Remove drive housing and pump assemblies.
the motor.
See Repair Drive Housing, page 51.
Install drive housing and pump assemblies, see
Disconnect electric motor (101) power cable from 3. Installation,
page 53.
port #15 on the MCM. Remove connector by
loosening four terminal screws.
4. Route motor (101) power cord from motor
through conduit and connect to port #15 on
Remove motor shroud (11). Rest the motor
MCM. Route over temperature cable up from
shroud assembly behind the motor without
motor and connect to port #2 on MCM. Insert
straining the fan power cable.
cables in conduit and use tie wraps to secure the
Disconnect over temperature cable from port
conduit together.
#2 on MCM. Cut tie wraps around harness to
5. Connect motor shroud assembly to motor (101).
remove cable.
Remove four screws (25) holding motor (101) to 6. Install drive housing covers and motor cover.
7. Return to service.
bracket. Lift motor off unit.
333024F
Repair
new circuit breaker. Insert wires and tighten
down all screws.
Repair Circuit Breaker Module
1. See Before Beginning Repair, page 47.
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:
a. Refer to Electrical Schematics, page 91, and
circuit breaker table.
b. Follow Shutdown instructions. See
Shutdown, page 44.
c. 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
333024F
Figure 8
Circuit Breakers
Circuit Breakers
Ref.
Size
CB01
CB02
50 A
20 A
CB03
CB04
CB05
40 A
40 A
40 A
Component
Heated Hose
Motor Control Module
(MCM)
ISO Heater
RES Heater
Hose Heat Transformer
55
Repair
Replace Fluid Inlet Sensor
5. Replace sensor (602).
Replace Pressure Transducers
Note
For Elite models only.
1. Perform Shutdown, page 44.
2. Perform Pressure Relief Procedure, page 43.
3. Disconnect inlet sensor cable from the fluid inlet
assembly. Inspect cable for damage and replace
if necessary. See Electrical Schematics, page 91.
1. Perform Shutdown, page 44.
2. Perform Pressure Relief Procedure, page 43.
3. Disconnect transducer cables (405) from #6 and
#7 connectors on the MCM.
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.
Figure 9 Fluid Inlet Sensor
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 91.
NOTICE
To prevent damage to cable, route and secure
cable in wire bundle with wire ties.
56
333024F
Repair
Replace Fans
Shutdown system to avoid electric shock. To avoid
burns, do not perform maintenance on the fan until
the system has reached ambient temperature.
Replace Motor Fan
1. Perform Shutdown, page 44.
2. Open cabinet door and disconnect
fan cables from terminal blocks. See
Electrical Schematics, page 91.
3. Remove four screws (21) from motor cover (11).
If necessary, fold frame (1) to remove motor
cover (10). See Repair Drive Housing, page 51,
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.
Note
Ensure fan (32) blows onto motor.
Figure 10
Replace Electrical Enclosure Fan
1. Perform
2. Open electrical enclosure door (401). Loosen
four nuts (421) and remove fan (404).
3. Install new fan (404) in reverse order of
disassembly so that the fan blows out of the
electrical enclosure.
333024F
57
Repair
Figure 11
58
333024F
Repair
Replace Transformer Fan
1. Perform Shutdown, page 44.
2. Remove four bolts (23) and shroud (10).
3. Remove bolt (20) on top of the heater junction
box (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 four screws (23), washers (29), and fan
(32).
7. Install fan in reverse order.
Figure 12
333024F
59
Repair
Repair Primary Heater
Replace Heater Element
8. Wait for heater to cool.
9. Remove four bolts (23) and shroud (10).
1. Press to stop the pumps.
2. Turn off heat zones.
3. Flush pump.
4. Press to park the pumps in the down position. 10. Remove screw (20) and lower din rail cover (48).
The park operation is complete when green dot 11. Disconnect heater wires:
goes out. Verify the park operation is complete
a. A Side: Disconnect A side heater wires,
before moving to next step.
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).
12. Test heater wires with ohmmeter.
5. Press to deactivate the system.
System
Total
Element
Ohms
2,550
18–21 per
element
18–21 per
element
Heater
Wattage
6. Turn main power switch off.
7. Relieve pressure. See
Pressure Relief Procedure, page 43.
60
E-30 (10 10,200
kw)
E-XP2, 15,300
E-30 (15
kw)
2,550
NOTICE
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.
333024F
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 60.
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
333024F
61
Repair
Repair Overtemperature Switch
1.
2.
3.
4.
Perform Shutdown, page 44.
Wait for heaters to cool.
Remove heater cover (10).
Disconnect overtemperature switches (209) from
cable (46). Test across spade terminals with
ohmmeter.
a. If the resistance
approximately 0 ohms,
the overtemperature switch needs to be
replaced. Go to step 5.
b. If the resistance 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
110009, install new switch in same location on
housing (201), and secure with screws (213).
Reconnect cables.
is not
is
62
333024F
Repair
Replace RTD
1.
2.
3.
4.
5.
6.
7.
8.
Perform Shutdown, page 44.
Wait for heater to cool.
Remove heater cover (10).
Cut cable ties around the woven wrap with the
RTD cable (212).
Disconnect RTD cable(212) from TCM (453).
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.
Remove RTD cable (212) from woven wrap.
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.
Figure 14
333024F
63
Repair
Repair Heated Hose
Refer to the heated hose manual 309572 for hose
replacement parts.
3. For Series A only: Disconnect hose connector
(D) at Reactor.
Check Hose Heat Power Connectors
1. Perform Shutdown, page 44.
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
64
333024F
Repair
Check RTD Cables and FTS
1. Perform Shutdown, page 44.
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
3 to 1
Result
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.
333024F
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)
65
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.
Figure 18
Test/Removal
1. Perform Shutdown, page 44.
2. Remove tape and protective covering from FTS.
Disconnect hose cable (F).
3. If FTS is not reading properly at the end of the
hose, see Check RTD Cables and FTS, page 65.
4. If FTS fails, replace FTS.
66
a. Disconnect air hoses (C,L) and electrical
connectors (D).
b. Disconnect FTS from whip hose (W) and
fluid hoses (A, B).
c. Remove ground wire (K) from ground screw
on underside of FTS.
d. Remove FTS probe (H) from component A
(ISO) side of hose.
333024F
Repair
Transformer Primary Check
See Electrical Schematics, page 91.
1. Check wires and transformer:
a. See Shutdown, page 44.
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 44.
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 91.
1. Check wires and transformer:
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
333024F
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.
c. Close the circuit breaker CB01.
Figure 19
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.
67
Repair
Replace Transformer
1.
2.
3.
4.
Perform Shutdown, page 44.
Remove four bolts (23) and shroud (10).
Remove lower dinrail cover (48).
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
68
333024F
Repair
Replace Power Supply
1. Perform Shutdown, page 44.
2. Disconnect input and output cables from
both sides of the power supply. See
Electrical Schematics, page 91.
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.
333024F
69
Repair
Replace Motor Control Module (MCM)
1. Perform Shutdown, page 44.
2. Disconnect connectors from MCM (63).
Disconnect two power cables. See
Electrical Schematics, page 91.
3. Remove nuts (91) and MCM (63).
4. Set rotary switch. 2= E–30 and 3= E-XP2.
5. Replace MCM in enclosure.
6. Connect cables to MCM. See
Electrical Schematics, page 91.
Figure 24 Replace MCM
Replace Temperature Control Module
(TCM)
1.
2.
3.
4.
5.
Perform Shutdown, page 44.
Open electrical enclosure door (61).
Disconnect all connectors from the TCM (453).
Remove four nuts (461) and TCM (453).
Install new TCM module (453). Reassemble
parts in reverse order.
Figure 25 Replace TCM
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.
70
333024F
Parts
Parts
Proportioners
333024F
71
Parts
1
2
3
72
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).
333024F
Parts
Ref
1
2
Part
- - - - -
3
246995
4
5
16X531
24U843
24U842
6
24U704
7
16W654
8
9+
24R684
261821
10
11
12
13
24U841
16W765
16W764
24U837
24U838
24U839
24U840
14
15
17
24U834
24U833
24U836
24U835
15K742
18
19
15B456
125643
20
119865
16
333024F
Description
FRAME
ENCLOSURE, electrical;
see Electrical Enclosure,
page 84
BOTTLE, assembly,
complete
BRACKET, tsl, bottle
HEATER, 10kw, 2
zone, RTD; see
Fluid Heater, page 80
HEATER, 7.5kw,
1 zone, RTD; see
Fluid Heater, page 80
MANIFOLD, fluid; see
Fluid Manifold, page 82
INSULATOR, foam,
heater
COVER, transformer
CONNECTOR, wire,
6awg
COVER, heater
COVER, motor
COVER, heater, rear
TUBE, b-side, inlet
TUBE, b-side, inlet, 10kw
TUBE, b-side, outlet
TUBE, b-side, outlet,
10kw
TUBE, a-side, inlet
TUBE, a-side, inlet
TUBE, a-side, outlet
TUBE, a-side, outlet
TRANSFORMER,
4090va, 230/90
GASKET, manifold
FITTING, elbow, 3/8 npt
x #8 jic
SCREW, mch, hex
serrated; 3/8 in. x 1/4–20
Quantity
272010
272011
272012
272110
272111
272112
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
1
1
1
1
1
1
2
4
4
2
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
1
2
1
2
1
2
1
2
9
9
9
9
9
9
1
1
73
Parts
Ref
21
22
23
24
25
26
27
28
29
30
31
32
33
33a
33b
33c
33d
34
35
36
37
38
39
40
41
42★
43★
74
Part
Description
118444 SCREW, mch, slot hex
wash hd; 1/2 in. x #10–24
117683 SCREW, mch, phil pan
hd; 1.5 in. x #6–32
113796 SCREW, flanged, hex hd;
3/4 in. x 1/4–20
112731 NUT, hex, flanged
111800 SCREW, cap, hex hd;
7/32 in. x 5/16–18
111218 CAP, tube, square
110996 NUT, hex, flange head
104859 SCREW, tapping pnhd;
5/16 in. x #10–16
103181 WASHER, lock ext
100020 WASHER, lock
115836 GUARD, finger
24U847 FAN, cooling, 120mm,
24vdc
24R685 ENCLOSURE, lower,
dinrail; includes 33a-33d
24U849
KIT, module, din rail,
heater; see Heater and
Transformer Terminal
Block Module, page 87
16W667 INSULATOR, FOAM
- - COVER, bottom, dinrail
113505
NUT, keps, hex hd
151395 WASHER, flat
120685 GROMMET
114269 GROMMET, rubber
125625 TIE, cable, fir tree
127277 BOLT, carriage, 1/2-13 x
3.5 l
127278 NUT, keps, hex
127282 GROMMET, rubber
16X095 CONNECTOR, power,
male, 4 pin
125871 TIE, cable, 7.5 in.
24K207 KIT, fts, rtd, single hose
Quantity
272010
272011
272012
272110
272111
272112
8
8
8
8
8
8
11
13
13
11
13
13
6
4
6
4
6
4
6
4
6
4
6
4
2
8
2
2
8
2
2
8
2
2
8
2
2
8
2
2
8
2
4
2
1
2
4
2
1
2
4
2
1
2
4
2
1
2
4
2
1
2
4
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
1
4
4
1
4
4
1
4
4
1
4
4
1
4
4
1
25
1
25
1
25
1
25
1
25
1
25
1
12
4
2
1
5
4
12
4
2
1
6
4
12
4
2
1
6
4
12
4
2
1
5
4
12
4
2
1
6
4
12
4
2
1
6
4
333024F
Parts
Ref
44★
45★
46
47
48
49
50
51
52
53
54
55
56
57
58
333024F
Part
Description
24R725 BRIDGE, plug-in jumper,
ut35
106569 TAPE, electrical
24T242 CABLE, over-temp, 10
kW Reactor
24P970 CABLE, over-temp, 15
kW Reactor
104765 PLUG, pipe headless
16V268 COVER, top, dinrail
15Y118 LABEL, made in the USA
24V150 PROPORTIONER,
module, E-30; see
Proportioner Module,
page 78
24V151 PROPORTIONER,
module, E-XP2; see
Proportioner Module,
page 78
24U321 KIT, asm, pair,
elite, reactor; see
Fluid Inlet Kits, page 89
24U320 KIT, assembly, pair,
std, reactor; see
Fluid Inlet Kits, page 89
16X118 MODULE, cellular, gps,
temp
24T050 CABLE, m8 4p f to m12
8p m 1.5m
16W130 CABLE, m12 5p, fem male, 2.0m
24U845 TUBE, pressure relief
191892 FITTING, elbow, street,
90 deg; 1/8 npt
116746 FITTING, barbed, plated;
1/8–27 npt x 1/4 in. hose
I.D.
16W218 LABEL, branding, e-30
16W321 LABEL, branding, e-30,
elite
16W215 LABEL, branding, e-xp2
16W322 LABEL, branding, e-xp2,
elite
Quantity
272010
272011
272012
272110
272111
272112
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
2
1
1
2
1
1
1
1
1
1
4
2
1
1
1
4
4
4
2
1
1
1
4
1
1
1
4
1
1
1
1
1
1
1
1
1
1
2
2
2
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
75
Parts
Ref
59★
60
61
62
63
64★
65★
67★
68
70
71
72
73
74
75
79+★
81
82
83★
84★
85
88
89
76
Part
Description
16U530 MODULE, system surge
protector (spare)
15G349 COVER, drive, plastic
16W766 COVER, control, box
16W596 LATCH, door
24U832 MODULE, MCM
24U831 MODULE, MCM
206995 FLUID, tsl, 1 qt.
206994 FLUID, tsl 8 oz bottle
114225 TRIM, edge protection;
1.6 ft (0.48 m)
16X250 LABEL, identification
127296 SCREW, mchn, pnh,
w/ext tooth wash; M4 x
0.7
16X129 SCREW, mach, phillips,
tooth wash; 5/16 x 8–32
117502 FITTING, reducer #5 x #8
(JIC)
117677 FITTING, reducer #6 x
#10 (JIC)
299521 CAP, 1/2-20 jic
cap-aluminum
299520 CAP, 9/16-18 JIC
cap-aluminum
261843 FLUID, oxide inhibitor
16V806 BRACKET, wall, mount
15V551 SHIELD, membrane,
ADM (10 pack)
24K409 BAR, 55 gal chem.
measure; A side
24K411 BAR, 55 gal chem.
measure. B side
127276 BOLT, carriage, 1/2-13 x
2.5 l
24U854 MODULE, ADM
16W967 FITTING, swivel, 3/4 npt
x 1 npsm
118459 FITTING, union, swivel,
3/4 in.
Quantity
272010
272011
272012
272110
272111
272112
2
1
2
2
1
2
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
1
2
1
2
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
4
1
4
1
4
1
4
1
4
1
4
10
10
10
10
10
10
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
1
1
2
1
1
2
1
1
2
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
1
2
1
2
1
1
2
1
2
1
1
1
1
2
1
1
1
2
333024F
Parts
Ref
90
91
92
93★
94
95
96★
97★
98*
99*
100*▲
101*▲
102*
103*
Part
Description
16W213 LABEL, branding, reactor
115942 NUT, hex, flange head
15D906 SUPPRESSOR, round
snap ferrite .260
127368 SLEEVE, split, wire, 1.50
ID
127377 TIE, cable, 6 in.
16X154 LABEL, InSite
333091 MANUAL, quick guide,
startup
333092 MANUAL, quick guide,
shutdown
24W204 ENCLOSURE, terminal
block
17C258 ENCLOSURE, cover
189930 LABEL, caution
172953 LABEL, ground
17D955 BRACKET, mounting
113161 SCREW, flange, hex hd
Quantity
272010
272011
272012
272110
272111
272112
2
2
2
2
2
2
1
1
1
1
1
1
▲ Replacement Warning labels, signs, tags, and
cards are available at no cost.
★ Not shown.
 Parts included in Graco Insite Kit 24T280.
333024F
2
4
1
2
4
1
2
4
1
2
4
1
2
4
1
2
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
1
1
1
2
1
1
1
1
2
1
1
1
1
2
1
1
1
1
2
 See Electrical Schematics, page 91.
+
*
Part applies to Series A only.
Part applies to Series B only.
77
Parts
Proportioner Module
24V150, Module for E-30
24V151, Module for E-XP2
1
2
Torque to 190–120 in-lbs (21–24 N•m).
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.
78
333024F
Parts
24V150
E-30
24V151
E-XP2
MOTOR, brushless, double ended, 2 HP
1
1
---
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; copper colored
2
2
108
114672
WASHER, thrust; steel 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.
333024F
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.
79
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).
4
Torque to 40 ft-lbs (54 N•m).
Apply thermal paste.
5
Apply pipe sealant and PTFE tape to all non-swiveling threads and threads without o-rings.
3
6
7
80
Apply lithium grease lubricant to o-rings before assembling in block (1).
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).
333024F
Parts
Ref
201
Part
15J090
Description
HEATER, machined, 1 zone
HEATER, machined, dual zone
1
202
15K825
124132
O-RING
4
FITTING, plug, hollow, hex, 1-3/16 sae
4
3
5
FITTING, adapter, sae-orb x jic
4
2
3
203
204
15H305
121309
24U843
24U842
1
205
15H304
FITTING, plug 9/16 sae
2
206
ADAPTER, 9/16 x 1/8
2
1
207
15H306
120336
2
1
208
16A110
O-RING, packing
HEATER, immersion, 2550W, 230V
4
3
SWITCH, over temperature
MIXER, immersion heater
1
1
4
3
FITTING, compression
2
1
209
15B137
210
15B135
-----
211*
212*
213
214
*
SENSOR, RTD
124131
SCREW, machine, pnhd; 5/16 in. x #6–32
15M178 HOUSING, rupture disc
2
1
2
2
2
1
Included in 24L973 Heater RTD Repair Kit.
333024F
81
Parts
Fluid Manifold
24U844
1
2
3
82
Torque to 355–395 in.-lbs (40–44.6 N●m)
Apply sealant (113500) to threads.
Valve must be closed with handle position as
shown on drawing.
4
5
**
Apply PTFE tape and thread sealant to gauge
threads.
Apply grease on valve.
Apply PTFE tape or thread sealant to tapered
threads.
333024F
Parts
24U844, Fluid Manifold
Ref
401
402★
402a★
402b★
403
404
405
406
407
408
411
412
Part
255228
247824
158674
247779
102814
162453
15M669
247788
247789
112309
117556
121312
333024F
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
SENSOR, pressure, fluid
outlet
HANDLE, red
HANDLE, blue
NUT, hex, jam
NIPPLE, #8 JIC x 1/2 NPT
FITTING, elbow, 3/4 SAE
x 1/2 JIC
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.
83
Parts
Electrical Enclosure
84
333024F
Parts
Electrical Enclosure
451
Part
Description
24U087
ENCLOSURE
453
24U855
454
24U848
MODULE, TCM
FAN, cooling, 80 mm,
24VDC
SWITCH, disconnect,
door mounted
TERMINAL, ground
Ref
455
24R736
457
117666
458
120859
Qty
Part
Description
1
468
111218
CAP, tube, square
2
1
469
114269
GROMMET, rubber
1
470
127282
2
471
127278
GROMMET, rubber
NUT, keps, hex
472
16W925
1
473
16W926
1
1
GASKET, enclosure,
foam
GASKET, enclosure,
foam
CABLE, CAN power, M12
female, pigtail
CABLE, CAN,
female/female 1.0 meter
MODULE, breaker
461
115942
NUT, strain relief, M40
thread
BUSHING, strain relief,
M40 thread
KNOB, operator
disconnect
NUT, hex, flange head
462
103181
WASHER, lock external
2
463
124131
2
478▲
16X050
CABLE, 4-pin,
male/female, 1.3 meter,
molded (hose RTD)
LABEL, safety; enclosure
1
479▲
16X049
LABEL, safety; multi
6
459
460
120858
123967
464
194337
SCREW, machine, pan
head; 5/16 in. x #6–32
WIRE, grounding, door
466
113505
NUT, keps, hex head
Qty
Ref
1
474
24R735
1
475
127068
1
476
5
24U850
477
127290
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 91.
333024F
85
Parts
System DIN Rail and Harness Module Kit
24U850, System DIN Rail and Harness Module Kit
See Electrical Schematics, page 91.
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)
86
333024F
Parts
Ref
501
Part
16U529
502
16V515
503
16U522
Description
HARNESS, breaker
module
HARNESS, hose out
MODULE, din rail, term
blk, power sup; see
System Circuit Breaker
Module, page 88
Qty
Ref
504
Part
16U526
505
16U530
1
1
1
Description
MODULE, din rail,
circuit breakers; see
Power Supply and
Terminal Block Module,
page 88
MODULE, sys surge
protector
Qty
Qty
6
1
1
Heater and Transformer Terminal Block Module
24U849
Ref
511
Part
24T315
512
126811
Description
RAIL, DIN; 35 mm x 7.5
mm x 7 in.
BLOCK, clamp, end
513
126383
COVER, end
1
514
126382
BLOCK, terminal
2
333024F
Qty
1
2
Ref
515
Part
120570
Description
BLOCK, terminal
516
24R758
517
24R759
BLOCK, terminal,
UT-2.5, red
BLOCK, terminal,
UT-2.5, black
1
1
87
Parts
System Circuit Breaker Module
16U526
Ref
521
Part
514014
522
120838
523
17A319
Description
RAIL, DIN; 35 mm x
7.5 mm x 8.625 in.
TERMINAL, end stop
Qty
1
Ref
524
Part
17A314
2
525
17A317
CIRCUIT, breaker, 1
pole, 50A, C Curve
1
Description
CIRCUIT, breaker, 2P,
20A, UL489
CIRCUIT, breaker, 2P,
40A, UL489
Qty
1
3
Power Supply and Terminal Block Module
16U522
Ref
531
Part
514014
532
120838
533
88
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
Qty
2
126453
Description
BLOCK, terminal, quad
M4, ABB
POWER SUPPLY, 24V
3
535
1
536
24R724
BLOCK, terminal, UT35
6
1
333024F
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.
333024F
89
Parts
Ref
Part
Description
601 160327 FITTING, union adapter, 90°
602 118459 FITTING, union, swivel, 3/4 in.
603 247503 MANIFOLD, strainer, inlet
604 24U852 THERMOMETER, dial
605 24U853 GAUGE, press, fluid
- - - FILTER, replacement
606★
607★ C20203 PACKING, o-ring, 1.17, fluoroelastomer
608 16V879 CAP, filter
609 555808 PLUG, 1/4mp w/ hex hd
610 15D757 HOUSING, thermometer, viscon hp
613 109077 VALVE, ball 3/4 npt
614 C20487 FITTING, nipple, hex
614 624545 FITTING, tee 3/4m run x 1/4f branc
615 24U851 TRANSDUCER, pressure, temperature (includes foam)
* Optional 80 mesh filter 255082 (2 pack)
★
Quantity
24U320
2
2
2
2
2
2
2
2
2
2
1
2
24U321
2
2
2
2
2
2
2
2
2
2
2
2
2
Included in 24V020 Inlet Filter and Seal Kit, 20
mesh (2 pack).
 Included in 247503 Manifold Repair Kit.
90
333024F
Electrical Schematics
Electrical Schematics
Reactor 2 E-30
Reactor 2 E-XP2
To TCM
24U831
24U832
16X118
333024F
91
Electrical Schematics
PS-L
PS-N
CB-B
CB-A
ti22680b
92
333024F
Electrical Schematics
16U526
16U529
1
15D906
24U855
16V515
ELEC ENCL
GND STUD
2
TO HTD HOSE
ti22678b
1
2
Locate near TCM.
Heated hose wire termination enclosure (series
B only).
333024F
93
Reactor 2 Repair Spare Parts Reference
Reactor 2 Repair Spare
Parts Reference
Recommended Common Spare Parts
Ref
106,
115
106,
115
106,
115
106,
115
606,
607
402
403
405
211,
212
----
94
Part
Description
15C852 E-30 Pump Repair Kit
Part of Assembly
Pump
15C851 E-XP2 Pump Repair Kit
Pump
246963 E-XP2 Wet Cup Repair Kit
Pump
246964 E-30 Wet Cup Repair Kit
Pump
24V020 Y-Strainer Filter and Gasket Kit
(pack of two each)
247824 Drain Valve Cartridge
102814 Fluid Pressure Gauge
15M669 Pressure Sensor
24L973 RTD Repair Kit
Y-Strainer
Fluid Manifold
Fluid Manifold
Fluid Manifold
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)
333024F
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
333024F
5
(2.3)
10
(4.5)
15
(6.8)
20
(9.1)
25
(11.3)
FLOW lbs/min (kg/min)
30
(13.6)
35
(15.9)
40
(18.1)
95
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
(1.9)
1.5
(3.8)
FLOW gal./min (l/min)
2.0
(5.7)
(7.6)
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
96
0.5
(1.9)
1.0
(3.8)
FLOW gal./min (l/min)
1.5
(5.7)
2.0
(7.6)
333024F
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
(103, 10.3)
XR3535
(RTM055)
1000
(69, 6.9)
MR4747
(RTM055)
XR4747
(RTM055)
500
(35, 3.5)
0
0.5
(1.9)
1
1.5
(3.8)
2.0
(5.7)
FLOW gal./min (l/min)
(7.6)
Table 4 Fusion Mechanical Purge, Flat Pattern
3500
(241, 24.1)
XF2323
(FTM424)
XF1313
(FTM424)
3000
(207, 20.7)
MF2929
(FTM424)
2500
(174, 17.4)
PRESSURE
psi (bar)
MF1818
(FTM424)
2000
(138, 13.8)
XF1818
(FTM424)
1500
MF4747
(FTM638)
XF2929
(FTM424)
(103, 10.3)
XF5757
(FTM638)
XF3535
(FTM638)
1000
(69, 6.9)
E-XP2
MF5757
(FTM638)
MF3535
(FTM638)
500
(35, 3.5)
0
333024F
0.2
(0.7)
0.4
(1.5)
0.6
(2.3)
0.8
(3.0)
1
(3.8)
1.2
(4.5)
FLOW gal./min (l/min)
1.4
(5.3)
1.6
(6.0)
1.8
(6.8)
2.0
(7.6)
97
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 Inlet Temperature
E-30
E-XP2
Maximum Inlet Fluid Pressure
E-30
E-XP2
Maximum Heated Hose Length
Length
ISO and RES
E-30
E-XP2
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
150°F
150°F
66°C
66°C
300 psi
300 psi
2.1 MPa, 21 bar
2.1 MPa, 21 bar
310 ft
94 m
0.0272 gal.
0.0203 gal.
0.1034 liter
0.0771 liter
20° to 120°F
-7° to 49°C
Output per Cycle
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
(at 230 VAC rated voltage)
E-30 10 kW
E-30, 15 kW
E-XP2 15 kW
195–265 VAC
195–265 VAC
340–455 VAC
Heater Power
98
10,200 Watts
15,300 Watts
15,300 Watts
333024F
Technical Specifications
Sound Pressure
Sound Pressure measured per ISO-9614–2.
E-30
87.3 dBA
E-XP2
Measured from 3.1 ft (1 m), at
3000 psi (21 MPa, 207 bar), 1 gpm
(3.8 lpm)
79.6 dBA
Sound Power
93.7 dBA
Measured from 3.1 ft (1 m), at
1000 psi (7 MPa, 70 bar), 3 gpm
(11.4 lpm)
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)
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
Fluid Circulation Ports
Size
Maximum Pressure
Dimensions
250 psi
1/4 NPSM(m)
1.75 MPa, 17.5 bar
Width
Height
Depth
26.3 in.
63 in.
15 in.
668 mm
1600 mm
381 mm
Weight
315 lb
350 lb
320 lb
355 lb
345 lb
350 lb
143 kg
159 kg
145 kg
161 kg
156 kg
159 kg
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
333024F
Aluminum, stainless steel, zinc plated carbon steel, brass,
carbide, chrome, chemically resistant o-rings, PTFE, ultra-high
molecular weight polyethylene
99
Notes
Notes
100
333024F
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
24U050
24U051
24U831
24U832
24U855
24U854
All other Reactor 2 parts
Description
Warranty Period
Electric Motor
36 Months or 3 Million Cycles
Motor Control Module
Motor Control Module
Heater Control Module
Advanced Display Module
36 Months or 3 Million Cycles
36 Months or 3 Million Cycles
36 Months or 3 Million Cycles
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: 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 F, July 2015

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