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

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

Repair-Parts

Reactor 2 E-30 and E-XP2

Proportioning System

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.

PROVEN QUALITY. LEADING TECHNOLOGY.

WLE

2

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

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.

ELECTRIC SHOCK HAZARD

WARNING

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing or installing equipment.

• Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

• Do not expose to rain. Store indoors.

TOXIC FLUID OR FUMES

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled or swallowed.

• Read Safety Data Sheet (SDS) for handling instructions and to know the specific hazards of the fluids you are using, including the effects of long-term exposure.

• When spraying, servicing equipment, or when in the work area, always keep work area well ventilated and always wear appropriate personal protective equipment. See Personal

Protective Equipment warnings in this manual.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

PERSONAL PROTECTIVE EQUIPMENT

Always wear appropriate personal protective equipment and cover all skin when spraying, servicing equipment, or when in the work area. Protective equipment helps prevent serious injury, including long-term exposure; inhalation of toxic fumes, mists or vapors; allergic reaction; burns; eye injury and hearing loss. This protective equipment includes but is not limited to:

• A properly fitting respirator, which may include a supplied-air respirator, chemically impermeable gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory authority.

• Protective eyewear and hearing protection.

333024F 3

4

Warnings

WARNING

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are antistatic or conductive.

• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

THERMAL EXPANSION HAZARD

Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure due to the thermal expansion. Over-pressurization can result in equipment rupture and serious injury.

• Open a valve to relieve the fluid expansion during heating.

• Replace hoses proactively at regular intervals based on your operating conditions.

333024F

Warnings

333024F

WARNING

PRESSURIZED ALUMINUM PARTS HAZARD

Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents.

• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for compatibility.

PLASTIC PARTS CLEANING SOLVENT HAZARD

Many solvents can degrade plastic parts and cause them to fail, which could cause serious injury or property damage.

• Use only compatible water-based solvents to clean plastic structural or pressure-containing parts.

• See Technical Data in this and all other equipment instruction manuals. Read fluid and solvent manufacturer’s MSDSs and recommendations.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

MOVING PARTS HAZARD

Moving parts can pinch, cut or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.

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

Isocyanates (ISO) are catalysts used in two component materials.

Isocyanate Conditions

Important Isocyanate Information

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

Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage to equipment. To prevent cross-contamination:

• Never interchange component A and component

B wetted parts.

• Never use solvent on one side if it has been contaminated from the other side.

Changing Materials

NOTICE

Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime.

• When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical compatibility.

• 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.

Moisture Sensitivity of Isocyanates

Exposure to moisture (such as humidity) will cause

ISO to partially cure, forming small, hard, abrasive crystals that become suspended in the fluid.

Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity.

NOTICE

Partially cured ISO will reduce performance and the life of all wetted parts.

• Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere.

Never store ISO in an open container.

• Keep the ISO pump wet cup or reservoir (if installed) filled with appropriate lubricant. The lubricant creates a barrier between the ISO and the atmosphere.

• Use only moisture-proof hoses compatible with

ISO.

• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.

• Always lubricate threaded parts with an appropriate lubricant when reassembling.

NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature.

Foam Resins with 245 fa Blowing

Agents

Some foam blowing agents will froth at temperatures above 90°F (33°C) when not under pressure, especially if agitated. To reduce frothing, minimize preheating in a circulation system.

8 333024F

Models

Models

Reactor 2E-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

Model

Proportioner ★

10 kW

272010

E-30 Model

15 kW

272011

2000 (14, 140) Maximum Fluid Working

Pressure psi (MPa, bar)

2000 (14, 140)

Approximate Output per

Cycle (A+B) gal. (liter)

Max Flow Rate lb/min

(kg/min)

0.0272 (0.1034)

30 (13.5)

Total System Load †

 (Watts)

Configurable Voltage

Phase 

17,900

230

Full Load Peak Current* 78

230

3Ø∆

50

400

3ØY

34

0.0272 (0.1034)

30 (13.5)

23,000

230

230

3Ø∆

100 62

400

3ØY

35

10 kW

272110

30 (13.5)

17,900

230

78

230

3Ø∆

50

E-30 Elite Model

2000 (14, 140)

0.0272 (0.1034)

400

3ØY

34

15kW

272111

2000 (14, 140)

0.0272 (0.1034)

30 (13.5)

23,000

230

230

3Ø∆

100 62

400

3ØY

35

Fusion AP Package 

(Gun Part No.)

Fusion CS Package 

(Gun Part No.)

Probler P2 Package 

(Gun Part No.)

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)

AP2010

(246102)

CS2010

(CS02RD)

P22010

(GCP2R2)

AH2010

(246102)

CH2010

(CS02RD)

PH2010

(GCP2R2)

AP2011

(246102)

CS2011

(CS02RD)

P22011

(GCP2R2)

AH2011

(246102)

CH2011

(CS02RD)

PH2011

(GCP2R2)

AP2110

(246102)

CS2110

(CS02RD)

P22110

(GCP2R2)

AH2110

(246102)

CH2110

(CS02RD)

PH2110

(GCP2R2)

24K240 24K240 24K240 24K240 24Y240 24Y240

Qty: 1 Qty: 5 Qty: 1 Qty: 5 Qty: 1 Qty: 5

AP2111

(246102)

CS2111

(CS02RD)

P22111

(GCP2R2)

AH2111

(246102)

CH2111

(CS02RD)

PH2111

(GCP2R2)

24Y240 24Y240

Qty: 1 Qty: 5

246050 246050 246050

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

.

 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

Y

DELTA

WYE

333024F 9

Models

Reactor 2E-XP2and E-XP2Elite

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

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 

Full Load Peak Current

(amps)*

E–XP2 Model

15 kW

272012

3500 (24.1, 241)

0.0203 (0.0771)

2 (7.6)

23,000

230 1Ø

100

230 3Ø∆

62

400 3ØY

35

E–XP2 Elite Model

15 kW

272112

3500 (24.1, 241)

0.0203 (0.0771)

2 (7.6)

23,000

230 1Ø

100

230 3Ø∆

62

400 3ØY

35

Fusion AP Package 

(Gun Part No.)

Probler P2 Package 

(Gun Part No.)

Heated Hose

50 ft (15 m)

Heated Whip Hose

10 ft (3 m)

Graco InSite ™

Fluid Inlet Sensors (2)

AP2012

(246100)

P22012

(GCP2R0)

24K241

(scuff guard)

246055

*

Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix chamber sizes may be less.

Total system watts used by system, based on maximum heated hose length for each unit.

• E–30 and E–XP2 series: 310 ft (94.5 m) maximum heated hose length, including whip hose.

★ See

Approvals, page 11 .

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

Y

Phase

DELTA

WYE

10 333024F

Approvals

Intertek approvals apply to proportioners without hoses.

Proportioner Approvals:

9902471

Conforms to ANSI/UL Std. 499

Certified to CAN/CSA Std. C22.2 No. 88

Approvals

Accessories

Kit Number Description

24U315 Air Manifold Kit (4 outlets)

24U314

24T280

16X521

Wheel and Handle Kit

Graco InSite Kit

24N449

Graco InSite Extension cable 24.6 ft

(7.5 m)

50 ft (15 m) CAN cable (for remote display module)

24K207

24U174

24K337

15V551

15M483

Fluid Temperature Sensor (FTS) with RTD

Remote Display Module Kit

Light Tower Kit

24M174

121006

24N365

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)

333024F 11

Supplied Manuals

Supplied Manuals

The following manuals are shipped with the Reactor

2. Refer to these manuals for detailed equipment information.

Manuals are also available at www.graco.com.

Manual

333023

333091

333092

Description

Reactor 2 E-30 and E-XP2

Operation

Reactor 2 E-30 and E-XP2 Startup

Quick Guide

Reactor 2 E-30 and E-XP2

Shutdown Quick Guide

Related Manuals

The following manuals are for accessories used with the Reactor.

Component Manuals in English:

Manuals are available at www.graco.com.

System Manuals

333023 Reactor 2 E-30 and E-XP2 Operation

Displacement Pump Manual

309577 Electric Reactor Displacement Pump,

Repair-Parts

Feed System Manuals

309572 Heated Hose, Instructions-Parts

309852

309815

Circulation and Return Tube Kit,

Instructions-Parts

Feed Pump Kits, Instructions-Parts

309827 Feed Pump Air Supply Kit,

Instructions-Parts

Spray Gun Manuals

309550

312666

313213 Probler ® P2 Gun

Accessory Manuals

3A1905

Fusion ™ AP Gun

Fusion ™ CS Gun

3A1906

3A1907

332735

332736

333276

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

12 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

Alarms

Deviations

Advisories

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:

Note

Press or to return to the previously displayed screen.

2. The QR code screen will b e displayed. Scan the QR code with your smartphone to b e sent directly to online troubleshooting for the active error code. Otherwise, manually navigate to http://help.graco.com and search for the active error.

3. If no internet connection is available, see

Error Codes, page 13

for causes and solutions for each error code.

Error Codes

Note

When an error occurs be sure to determine the code before resetting it. If you forget which error code occurred, see the Errors screen to view the last 200 errors, with date, time, and description.

333024F 13

Troubleshooting

Error Location

A1NM MCM

Type

A4DA

A4DB

A4DH

Heater A

Heater B

Hose

Description

Low Motor Current

High Current A

High Current B

High Current Hose

Cause

Loose/broken connection.

Bad Motor.

Short circuit in heater wiring.

Bad Heater.

Short circuit in heater wiring.

Bad Heater.

Short circuit in hose wiring.

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.

14 333024F

Error Location

A4NM MCM

Type

A7DA

A7DB

A7DH

Heater A

Heater B

Hose

Troubleshooting

Description

High Motor Current

Cause

Short circuit of motor wiring.

Motor will not rotate.

Damaged gear train.

Unexpected Current

A

Chemical pump is stuck.

Shorted TCM

Unexpected Current

B

Unexpected Current

Hose

Shorted TCM

Shorted TCM

Solution

Check wiring to the motor to ensure no bare wires are touching and that no wires are shorted to ground.

Remove pump gear housings from motor and check that motor shaft rotates freely in direction indicated on motor housing.

Check pump gear trains for damage and repair or replace as necessary.

Repair or replace chemical pump.

If error cannot be cleared or regenerates consistently, replace module.

If error cannot be cleared or regenerates consistently, replace module.

If error cannot be cleared or regenerates consistently, replace module.

333024F 15

Troubleshooting

Error

A8DA

Location

Heater A

Type

A8DB

A8DH

CACM

Heater B

Hose

MCM

Description

No Current A

No Current B

No Current Hose

MCM Communication Error

Cause

Tripped circuit breaker.

Loose/broken connection.

Tripped circuit breaker.

Loose/broken connection.

Tripped circuit breaker.

Loose/broken connection.

Module does not have software.

Dial set to wrong position.

No 24 VDC supply to module.

Loose or broken

CAN cable.

Solution

Visually check circuit breaker for a tripped condition.

Check heater wiring for loose wires.

Visually check circuit breaker for a tripped condition.

Check heater wiring for loose wires.

Visually check circuit breaker for a tripped condition.

Check heater wiring for loose wires.

Insert a system token into the ADM module and cycle the power. Wait until the upload is complete before removing the token.

Ensure the MCM dial is set to the correct position: 2 for

E-30, 3 for E-XP2

Green light on each module should be lit. If green light is not lit, check to make sure each CAN cable connection is tight. Verify the power supply is outputting 24

VDC. If not, check power supply wiring. If wiring is okay, replace the power supply.

Check the CAN cables running between GCA modules and tighten of needed. If the problem still persists move each cable around the connector and watch the flashing yellow light on the GCA modules. If the yellow light stops flashing, replace the

CAN cable.

16 333024F

Error Location

CACT TCM

Type

DADX

DE0X

MCM

MCM

Troubleshooting

Description

TCM Communication

Error

Pump Runaway

Cycle Switch Error

Cause

Module does not have software.

No 24 VDC supply to module.

Loose or broken

CAN cable.

Flow rate is too large.

Faulty or missing cycle switch.

Missing or out of place cycle switch magnet.

Solution

Insert a system token into the ADM module and cycle the power. Wait until the upload is complete before removing the token.

Green light on each module should be lit. If green light is not lit, check to make sure each CAN cable connection is tight. Verify the power supply is outputting 24

VDC. If not, check power supply wiring. If wiring is okay, replace the power supply.

Check the CAN cables running between GCA modules and tighten of needed. If the problem still persists move each cable around the connector and watch the flashing yellow light on the GCA modules. If the yellow light stops flashing, replace the

CAN cable.

Mix chamber too large for system selected. Use mix chamber rated for system.

Ensure the system has chemical and the feed pumps are operating correctly.

No material in pumps.

Verify pumps are supplying chemical. If necessary, replace or refill drums.

Inlet ball valves are closed.

Open ball valves.

Check wiring between cycle switch and MCM.

Check presence and position of cycle switch magnet on output crank arm.

333024F 17

Troubleshooting

Error Location

EVCH ADM

Type

EAUX

EVUX

F9DX

H2MA

H2MB

H2MH

H3MA

H3MB

H3MH

K8NM

ADM

ADM

MCM

Heater A

Heater B

Hose

Heater A

Heater B

Hose

MCM

Description

Manual Hose Mode

Enabled

USB Busy

USB disabled

High Pressure/Flow

Cutback

Low Frequency A

Low Frequency B

USB drive has been inserted to the ADM.

USB download/uploads are disabled.

Mix chamber is too large for set pressure.

Low Frequency Hose Line frequency is

High Frequency A

High Frequency B

High Frequency

Hose

Locked Rotor Motor

Cause

Manual hose mode has been enabled in System Setup screen.

Line frequency is below 45 Hz

Line frequency is below 45 Hz below 45 Hz

Line frequency is ab ove 65 Hz

Line frequency is ab ove 65 Hz

Line frequency is ab ove 65 Hz

Motor will not rotate.

Damaged gear train.

Chemical pump is stuck.

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 b efore 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.

18 333024F

Error

L1AX

Location

ADM

Type

L1BX

MMUX

P0AX

ADM

USB

MCM

Troubleshooting

Description

Low Chemical Level

A

Low Chemical Level

B

Maintenance Due -

USB

Pressure Imbalance

A High

Cause Solution

Low material level. Refill material and update drum level on ADM

Maintenance screen.

Alarm can be disabled on the System Setup screen.

Low material level. Refill material and update drum level on ADM

Maintenance screen.

USB logs have reached a level where data loss will occur if logs are not downloaded.

Pressure difference between

A and B material is greater than the defined value.

Pressure imbalance is defined too low.

Alarm can be disabled on the System Setup screen.

Insert a USB drive into the

ADM and download all logs.

Ensure material flow is equally restricted on both material lines.

Out of material.

Fluid leaking from heater inlet rupture disk.

Feed system defective.

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.

333024F 19

Troubleshooting

Error

P0BX

Location

MCM

Type

P1FA

P1FB

P2FA

MCM

MCM

MCM

Description

Pressure Imbalance

B High

Low Inlet Pressure A

Low Inlet Pressure B

Low Inlet Pressure A

Cause

Pressure 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.

Inlet pressure lower than defined value.

Value defined too high.

Inlet pressure lower than defined value.

Value defined too high.

Inlet pressure lower than defined value.

Value defined too high.

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.

Ensure that inlet pressure to the pump is sufficient.

Ensure that the low pressure alarm level defined on the System

Setup screen is acceptable.

Ensure that inlet pressure to the pump is sufficient.

Ensure that the low pressure alarm level defined on the System

Setup screen is acceptable.

Ensure that inlet pressure to the pump is sufficient.

Ensure that the low pressure alarm level defined on the System

Setup screen is acceptable.

20 333024F

Error

P2FB

Location

MCM

Type

P4AX

P4BX

MCM

MCM

Troubleshooting

Description

Low Inlet Pressure B

High Pressure A

High Pressure B

Cause

Inlet pressure lower than defined value.

Value defined too high.

Solution

Ensure that inlet pressure to the pump is sufficient.

System pressurized before allowing heat to reach setpoint.

Bad pressure transducer.

E-XP2 system configured as E-30.

System pressurized before allowing heat to reach setpoint.

Bad pressure transducer.

E-XP2 system configured as E-30.

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.

333024F 21

Troubleshooting

Error

P6AX

Location

MCM

Type

P6BX

P6FA

MCM

MCM

Description

Pressure Sensor

Error A

Pressure Sensor

Error B

Pressure Sensor

Error Inlet A

Cause

Loose/bad connection.

Bad sensor.

Loose/bad connection.

Bad sensor.

Inlet sensors not installed.

Loose/bad connection.

Bad sensor.

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.

22 333024F

Error

P6FB

Location

MCM

Type

P7AX MCM

Troubleshooting

Description

Pressure Sensor

Error Inlet B

Pressure Imbalance

A High

Cause

Inlet sensors not installed.

Loose/bad connection.

Bad sensor.

Solution

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.

Ensure material flow is equally restricted on both material lines.

Pressure 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.

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.

333024F 23

Troubleshooting

Error

P7BX

Location

MCM

Type

T2DA Heater A

Description

Pressure Imbalance

B High

Low Temperature A

Cause

Pressure 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.

Flow is too high at current setpoint.

Bad RTD or bad

RTD placement against heater.

Bad heater rod or loose heater wire.

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.

24 333024F

Error

T2DB

Location

Heater B

Type

T2DH

T2FA

T2FB

Hose

MCM

MCM

Troubleshooting

Description

Low Temperature B

Low Temperature

Hose

Low Temperature

Inlet A

Low Temperature

Inlet B

Cause

Flow is too high at current setpoint.

Bad RTD or bad

RTD placement against heater.

Bad heater rod or loose heater wire.

Flow is too high at current setpoint.

Cold chemical in unheated portion of system passed hose FTS at startup.

Inlet fluid temperature is below the defined level.

Solution

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 b e 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.

Use a smaller mix chamber that is rated for the unit in use. If recirculating, decrease flow or decrease temperature setpoint.

Recirculate heated chemical back to drum in cold conditions before startup.

Inlet fluid temperature is below the defined level.

Recirculate fluid through heaters until inlet fluid temperature is above defined error level.

Increase the low temperature deviation level on the System Setup screen.

Recirculate fluid through heaters until inlet fluid temperature is above defined error level.

Increase the low temperature deviation level on the System Setup screen.

333024F 25

Troubleshooting

Error

T3CH

Location

Hose

Type

T3CT

T3NM

T3CM

T4CM

TCM

MCM

MCM

MCM

Description

Hose Cutback

TCM Cutback

Motor Temperature

Cutback

MCM Temperature

Cutback

High Temperature

MCM

Cause

Hose current has been reduced because hose has been drawing current for an extended period.

High ambient temperature.

Enclosure fan not operating.

Module fan not operating.

Motor is operating outside of the pressure flow curve.

Motor temperature is too high.

Motor control temperature is too high.

High ambient temperature.

Enclosure fan not operating.

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.

26 333024F

Error

T4CT

Location

TCM

Type

T4DA

T4DB

Heater A

Heater B

Troubleshooting

Description

High Temperature

TCM

High Temperature A

High Temperature B

Cause

High ambient temperature.

Enclosure fan not operating.

Module fan not operating.

Bad RTD or bad

RTD placement against heater.

Solution

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.

Swap A and B heater output cables and RTD cables and see if issue follows. If so, replace RTD.

Use a smaller mix chamber that is rated for the unit in use.

Flow too high for temperature setpoint, causing temperature overshoots when gun is de-triggered.

Bad RTD or bad

RTD placement against heater.

Flow too high for temperature setpoint, causing temperature overshoots when gun is de-triggered.

Swap A and B heater output cables and RTD cables and see if issue follows. If so, replace RTD.

Use a smaller mix chamber that is rated for the unit in use.

333024F 27

Troubleshooting

Error

T4DH

Location

Hose

Type

T4EA Heater A

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.

Disconnected or loose overtemperature switch cable/connection.

Overtemperature switch failed in the open position.

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 b e cleared when the heater temperature falls below 190°F (87°C).

If heater is not actually over temperature, check all wiring and connections between the TCM and the overtemperature switches.

Replace overtemperature switch.

28 333024F

Error

T4EB

Location

Heater B

Type

T4NM

T6DA

MCM

Heater A

Troubleshooting

Description

High Temperature

Switch B

High Temperature

Motor

Sensor Error A

Cause

Overtemperature switch sensed a fluid temperature above 230°F

(110°C).

Disconnected or loose overtemperature switch cable/connection.

Overtemperature switch failed in the open position.

Cooling fan is not operating properly.

Disconnected or loose motor temperature cable.

High ambient temperature.

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 b e cleared when the heater temperature falls below 190°F (87°C).

If heater is not actually over temperature, check all wiring and connections between the TCM and the overtemperature switches.

Replace overtemperature switch.

Check to see that the motor fan is moving. Measure voltage to fan. There should b e 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.

Verify wiring between the motor temperature sensor and the MCM.

Ensure ambient temperature is below

120°F(48°C) before using the system.

Bad electric motor. Replace electric motor.

Disconnected or loose RTD cable or connection.

Check all wiring and connection to RTD.

Bad RTD.

Switch the RTD with another and see if the error message follows the RTD.

Replace RTD if the error follows the RTD.

333024F 29

Troubleshooting

Error

T6DB

Location

Heater B

Type

T6DH

T6DT

Hose

TCM

Description

Sensor Error B

Sensor Error Hose

Sensor Error TCM

Cause

Disconnected or loose RTD cable or connection.

Bad RTD.

Solution

Check all wiring and connection to RTD.

Disconnected or shorted RTD cable in hose or bad FTS.

Switch the RTD with another and see if the error message follows the RTD.

Replace RTD if the error follows the RTD.

Expose each hose RTD connection to check and retighten any loose connector. Measure hose RTD cable and FTS continuity.

See

Repair Heated Hose, page 64

. Order RTD Test kit 24N365 for measurement.

Shorted RTD cable in hose or FTS.

Disconnect hose RTD and use manual hose mode to finish jobuntil repair can be completed.

Expose each hose RTD 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.

Shorted A or B

Heater RTD

Disconnect hose RTD and use manual hose mode to finish jobuntil repair can be completed.

If the error still occurs with the hose FTS unplugged, one of the heater RTDs is bad. Unplug the A or

B RTD from the TCM. If unplugging an RTD fixes the T6DT error, replace the

RTD.

30 333024F

Error

T8DA

Location

Heater A

Type

T8DB

T8DH

V1CM

Heater B

Hose

MCM

Troubleshooting

Description

No Temperature

Rise A

No Temperature

Rise B

No Temperature

Rise Hose

Low Voltage MCM

Cause

Bad RTD or bad

RTD placement against heater.

Bad heater rod or loose heater wire.

Started spraying before heater reached operating temperature.

Bad RTD or bad

RTD placement against heater.

Bad heater rod or loose heater wire.

Started spraying before heater reached operating temperature.

Started spraying before heater reached operating temperature.

Loose/bad connection or tripped circuit breaker.

Low incoming line voltage.

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 b e 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 b e 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.

Measure voltage at circuit breaker and ensure voltage is greater than 195 VAC.

333024F 31

Troubleshooting

Error

V1IT

Location

TCM

Type

V2IT

V2MA

V2MB

V2MH

V3IT

V3MA

TCM

TCM

TCM

TCM

TCM

TCM

Description

Low Voltage CAN

Low Voltage CAN

Low Voltage A

Low Voltage B

Low Voltage Hose

High Voltage CAN

High Voltage A

Cause

Bad 24 VDC power supply.

Bad 24 VDC power supply.

Loose connection or tripped circuit breaker.

Low incoming line voltage.

Loose connection or tripped circuit breaker.

Low incoming line voltage.

Loose connection or tripped circuit breaker.

Low incoming line voltage.

Bad 24 VDC power supply.

Incoming line voltage is too high.

Solution

Check voltage of power supply. Voltage should be 23-25 VDC. If out of tolerance, replace power supply.

Check voltage of power supply. Voltage should be 23-25 VDC. If out of tolerance, replace power supply.

Check wiring for loose connection or tripped circuit breaker.

Measure voltage at circuit breaker and ensure voltage is greater than 195 VAC.

Check wiring for loose connection or tripped circuit breaker.

Measure voltage at circuit breaker and ensure voltage is greater than 195 VAC.

Check wiring for loose connection or tripped circuit breaker.

Measure voltage at circuit breaker and ensure voltage is greater than 195 VAC.

Check voltage of power supply. Voltage should be 23-25 VDC. If out of tolerance, replace power supply.

Ensure incoming system power is wired properly.

Verify voltage at each circuit breaker is between 195 and

264 VAC.

32 333024F

Error Location

V3MB TCM

Type

V3MH

V4CM

V4IT

V4MA

V4MB

V4MH

TCM

MCM

TCM

TCM

TCM

TCM

Troubleshooting

Description

High Voltage B

High Voltage Hose

High Voltage MCM

High Voltage CAN

High Voltage A

High Voltage B

High Voltage Hose

Cause

Incoming line voltage is too high.

Incoming line voltage is too high.

Incoming line voltage is too high.

Bad 24 VDC power supply.

Incoming line voltage is too high.

Incoming line voltage is too high.

Incoming line voltage is too high.

Solution

Ensure incoming system power is wired properly.

Verify voltage at each circuit breaker is between 195 and

264 VAC.

Ensure incoming system power is wired properly.

Verify voltage at each circuit breaker is between 195 and

264 VAC.

Ensure incoming system power is wired properly.

Verify voltage at each circuit breaker is between 195 and

264 VAC.

Check voltage of power supply. Voltage should be 23-25 VDC. If out of tolerance, replace power supply.

Ensure incoming system power is wired properly.

Verify voltage at each circuit breaker is between 195 and

264 VAC.

Ensure incoming system power is wired properly.

Verify voltage at each circuit breaker is between 195 and

264 VAC.

Ensure incoming system power is wired properly.

Verify voltage at each circuit breaker is between 195 and

264 VAC.

333024F 33

Troubleshooting

Error Location

WBC0 MCM

Type

WMI0

WSUX

WXUD

WXUU

TCM

USB

ADM

ADM

Description

Software Version

Error

TCM Fan Error

Configuration Error

USB

Cause

Incorrect software version.

MCM does not have line voltage.

Fan inside TCM is not operating properly.

A valid configuration file can't be found for the USB.

USB Download Error Log download failed.

USB Upload Error Custom language file failed to upload.

Solution

Insert a system token into the ADM module and cycle the power. Wait until the upload is complete before removing the token.

If V1CM also exists, see troubleshooting for V1CM.

The software version cannot be read if the MCM does not have line voltage.

Check for debris in the TCM fan and clear with forced air if necessary.

Inset a system token into the ADM and cycle power.

Wait until the lights on the

USB port stop flashing before removing token.

Backup and reformat the

USB drive. Retry download.

Perform normal USB download and use the new disptext.txt file to upload the custom language.

34 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.

No power.

Cause

Failed 24 V power supply.

Failed surge protector.

Loose connections.

Tripped circuit breaker (CB02).

Electric motor runs erratically.

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

.

333024F 35

Troubleshooting

Problem

Cooling fans not working.

Pump output low.

Fluid leak in pump packing nut area.

No pressure on one side.

Loose wire.

Fan blade obstructed.

Defective fan.

Cause

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.

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.

Fluid leaking from heater inlet rupture disk (372).

Check if heater and PRESSURE

RELIEF/SPRAY valve (SA or SB) are plugged. Clear. Replace rupture disk (372) with a new one; do not replace with a pipe plug.

36 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.

Cause

Ambient temperature is too cold.

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.

Solution

Relocate hoses to a warmer area or recirculate heated fluid through the hose.

Hose was not fully preheated.

Low supply voltage.

Use smaller mix chamber.

Decrease pressure.

Wait for hose to heat to correct temperature before spraying.

Verify line voltage. Low line voltage significantly reduces power available to the hose heat system, affecting longer hose lengths.

333024F 37

Troubleshooting

Problem

Hose temperature exceeds setpoint.

Cause

A and/or B heaters are overheating material.

Faulty FTS connections.

Ambient temperature is too high.

Missing or damaged insulation around FTS, causing the hose heat to be ON constantly.

Solution

Check primary heaters for either a RTD problem or a failed element attached to RTD, see

Electrical Schematics, page 91 .

Verify that all FTS connections are snug and that pins of connectors are clean. Unplug and re-plug

RTD wires, cleaning off any debris.

Cover hoses or move to a location with a lower ambient temperature.

Make sure the hose b undle has adequate insulation evenly covering the entire length and connection joints.

38 333024F

Problem

Erratic hose temperature.

Hose does not heat.

Troubleshooting

Cause

Faulty FTS connections.

FTS not installed correctly.

Missing or damaged insulation around FTS, causing the hose heat to be ON constantly.

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 should be installed close to end of hose in same environment as gun. Verify FTS installation, see

Repair Fluid Temperature

Sensor (FTS), page 66 .

Make sure the hose b undle has adequate insulation evenly covering the entire length and connection joints.

FTS failed.

FTS not installed correctly.

Check FTS, see

Repair Fluid

Temperature Sensor (FTS), page

66 .

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.

A and B temperature setpoints too low.

Turn on hose heat zone.

Check. Increase if necessary.

333024F 39

Troubleshooting

Problem

Hoses near Reactor are warm, but hoses downstream are cold.

Low hose heat.

Cause

Shorted connection or failed hose heating element.

A and B temperature setpoints too low.

Solution

With power off, check the hose resistance with and without the whip hose attached. With the whip hose attached, the reading should b e less than 3 ohm. Without the whip hose attached, the reading should b e OL (open loop).

See

Check Hose Heat Power

Connectors, page 64

.

Increase A and B setpoints. Hose designed to maintain temperature, not increase temperature.

Hose temperature setpoint too low.

Flow too high.

Check. Increase if necessary to maintain heat.

Use smaller mix chamber.

Decrease pressure.

Install FTS, see operation manual.

Low current; FTS not installed.

Hose heat zone not turned on long enough to reach setpoint.

Allow hose to heat up, or preheat 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

Primary Heater(s) does not heat.

Cause

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.

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

.

333024F 41

Troubleshooting

Graco InSite

Problem

No module status LEDs are illuminated.

Has not identified GPS location

(green module status LED flashing).

Has not established cellular connection (orange module status

LED flashing).

Cause

No power to cellular module.

Still identifying location.

Unable to identify location. In a location where GPS lock cannot occur. Buildings and warehouses often prevent GPS locks.

Still establishing cellular connection.

Unable to establish cellular connection.

Cannot view data for my unit(s) on website.

Graco InSite unit has not been activated.

Temperature data not displayed on website.

Hose zone temperature data not displayed on website.

Pressure data not displayed on website.

Reactor temperature measurement is not working.

The RTD or thermocouple is not correctly installed on the hose or is broken.

Reactor pressure measurement is not working.

Solution

Turn Reactor ON.

Ensure unit is properly installed.

Verify 24V at output of the power supply.

Make sure the M8, 4–pin to M12,

8–pin cable is installed between cellular module and power supply.

Wait a few minutes for the unit to identify the location.

Move system to a location with a clear view of the sky.

Use extension cable 16X521 and move cellular module to a location with a clear view of the sky.

Wait a few minutes for the unit to establish the connection.

Move system to a location with cellular service to establish cellular connection.

Use extension cable 16X521 and move cellular module to a location with a clear view of the sky.

Activate unit. See Registering and Activating the Graco InSite section.

See System troubleshooting section.

See RTD or Thermocouple repair section.

See System troubleshooting section.

42 333024F

Pressure Relief Procedure

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

4. Route fluid to waste containers or supply tanks.

Turn PRESSURE RELIEF/SPRAY valves (SA,

SB) to PRESSURE RELIEF/CIRCULATION

. Ensure gauges drop to 0.

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.

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.

5. Engage gun piston safety lock.

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 stop the pumps.

5. Press to deactivate the system.

6. Turn off the air compressor, air dryer, and breathing air.

7. Turn main power switch OFF.

2. Turn off all heat zones.

3. Relieve pressure. See

Pressure Relief Procedure, page 43

.

To prevent electric shock do not remove any shrouds or open the electrical enclosure door.

44 333024F

8. Close all fluid supply valves.

Shutdown

9. Engage gun piston safety lock then close fluid inlet valves A and B.

Fusion Probler

333024F 45

Flushing

Flushing

To flush feed hoses, pumps, and heaters separately from heated hoses, set PRESSURE

RELIEF/SPRAY valves (SA, SB) to PRESSURE

RELIEF/CIRCULATION lines (N).

. Flush through bleed

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.

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 .

46 333024F

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 .

Flush Inlet Strainer Screen

Repair

1. Close the fluid inlet valve on the y-strainer inlet and shut off the appropriate feed pump. This prevents material from being pumped while cleaning the screen.

2. Place a container under the strainer base to catch drain off when removing the strainer plug (C).

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.

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.

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.

Figure 1

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.

4. When the reservoir is flushed clean, fill with fresh lubricant.

5. Thread the reservoir onto the cap assembly and place it in the b racket.

6. The lubrication system is ready for operation. No priming is required.

Pump Lubrication System

Figure 2

48 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

See manual 309577 for pump repair instructions.

1. Press to stop the pumps.

2. Turn off heat zones.

3. Flush pump.

4. Press to park the pumps in the down position.

5. Press to deactivate the system.

6. Turn main power switch off.

8. Route fluid to waste containers or supply tanks.

Turn PRESSURE RELIEF/SPRAY valves (SA,

SB) to PRESSURE RELIEF/CIRCULATION

. Ensure gauges drop to 0.

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 A

Figure 3

1

2

3

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.

Pump B

Figure 4

1

2

3

Flat side faces up.

Lubricate threads with ISO oil or grease.

Pump top threads must be nearly flush with bearing face (N).

Install Pump

Note

Steps 1–5 apply to pump B. To reconnect pump A, proceed to step 6.

1. Ensure locknut (G) is screwed on pump with flat side up. Screw pump into bearing housing

(M) until pin holes align. Push pin (F) in. Pull retaining wire clip (E) down. See

Fig. 4

for view and assembly notes.

2. Continue screwing pump into housing until fluid outlet (D) is aligned with steel tube and top threads are +/- 1/16 in. (2 mm) of bearing face

(N).

3. Tighten locknut (G) by hitting firmly with a non-sparking hammer.

4. Reconnect fluid inlet (C) and outlet (D).

5. Go to step 13.

Note

Steps 6–12 apply to pump A only.

6. Ensure star-shaped locknut (G) is screwed on pump with flat side up. Carefully twist and extend displacement rod 2 in. (51 mm) above wet-cup.

50 333024F

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.

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 b etween two b arb s.

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

1. Press to stop the pumps.

2. Turn off heat zones.

3. Flush pump.

4. Press to park the pumps in the down position.

5. Press to deactivate the system.

6. Turn main power switch off.

333024F 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).

Figure 6

52 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

If bearing housing (103), connecting rod

(105), or pump (106) were removed, reassemble rod in housing and install pump, see

Install Pump, page 50

.

5. Route cycle counter switch cable (121) around the motor fan and reattach to housing (102) with screws (122).

6. Install bearing housing (103), screws (113), and washers (114). Pumps must be in phase (both at same position in stroke).

7. Install cover (60) and screws (21).

8. Install motor shield (11) and screws (21).

Figure 7

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.

2. Remove drive housing and pump assemblies.

See

Repair Drive Housing, page 51

.

3. Disconnect electric motor (101) power cable from port #15 on the MCM. Remove connector by loosening four terminal screws.

4. Remove motor shroud (11). Rest the motor shroud assembly behind the motor without straining the fan power cable.

5. Disconnect over temperature cable from port

#2 on MCM. Cut tie wraps around harness to remove cable.

6. Remove four screws (25) holding motor (101) to bracket. Lift motor off unit.

Installation

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 the motor.

3. Install drive housing and pump assemblies, see

Installation, page 53 .

4. Route motor (101) power cord from motor through conduit and connect to port #15 on

MCM. Route over temperature cable up from motor and connect to port #2 on MCM. Insert cables in conduit and use tie wraps to secure the conduit together.

5. Connect motor shroud assembly to motor (101).

6. Install drive housing covers and motor cover.

7. Return to service.

54 333024F

Repair Circuit Breaker Module

Repair

new circuit breaker. Insert wires and tighten down all screws.

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 tabout 1/4 in. (6mm) and pull circuit breaker away from the din rail. Install

Ref.

CB01

CB02

CB03

CB04

CB05

Figure 8

Circuit Breakers

Size

50 A

Circuit Breakers

Component

Heated Hose

20 A Motor Control Module

(MCM)

40 A

40 A

ISO Heater

RES Heater

40 A Hose Heat Transformer

333024F 55

Repair

Replace Fluid Inlet Sensor

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

.

5. Replace sensor (602).

Replace Pressure Transducers

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

Figure 12

333024F

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).

Repair

4. Disconnect fan and transformer connections from terminal blocks. Connections are on left side lab eled: 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.

59

Repair

Repair Primary Heater

Replace Heater Element

1. Press to stop the pumps.

2. Turn off heat zones.

8. Wait for heater to cool.

9. Remove four bolts (23) and shroud (10).

3. Flush pump.

4. Press to park the pumps in the down position.

The park operation is complete when green dot goes out. Verify the park operation is complete before moving to next step.

5. Press to deactivate the system.

6. Turn main power switch off.

7. Relieve pressure. See

Pressure Relief Procedure, page 43

.

10. Remove screw (20) and lower din rail cover (48).

11. Disconnect heater wires: a. A Side: Disconnect A side heater wires, transformer, and transformer fan wires from lower din rail (33).

b. B Side: Disconnect B side heater wires and remove lower din rail (33) from B side heater

(5).

12. Test heater wires with ohmmeter.

System Total

Heater

Wattage

10,200

Element Ohms

2,550 E-30 (10 kw)

E-XP2,

E-30 (15 kw)

15,300 2,550

18–21 per element

18–21 per element

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.

60 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. Perform

Shutdown, page 44 .

2. Wait for heaters to cool.

3. Remove heater cover (10).

4. Disconnect overtemperature switches (209) from cable (46). Test across spade terminals with ohmmeter.

a. If the resistance is not approximately 0 ohms, the overtemperature switch needs to be replaced. Go to step 5.

b. If the resistance is approximately 0 ohms, inspect cable (46) to ensure it is not cut or open. Reconnect the overtemperature switch (209) and cable (46). Disconnect cable from TCM. Test from pin 1 to 3 and

1 to 4. If resistance is not approximately 0, and switches are 0. Replace cable in place of original cable.

5. If switch fails test, remove screws. Discard failed switch. Apply a thin layer of thermal compound

110009, install new switch in same location on housing (201), and secure with screws (213).

Reconnect cables.

62 333024F

Repair

Replace RTD

1. Perform

Shutdown, page 44 .

2. Wait for heater to cool.

3. Remove heater cover (10).

4. Cut cable ties around the woven wrap with the

RTD cable (212).

5. Disconnect RTD cable(212) from TCM (453).

6. Loosen ferrule nut (N). Remove RTD (212) from heater housing (201), then remove RTD housing

(H). Do not remove the adapter (206) unless necessary. If adapter must be removed, ensure that mixer (210) is out of the way when replacing the adapter.

7. Remove RTD cable (212) from woven wrap.

8. Replace RTD (212).

a. Apply PTFE tape and thread sealant to male pipe threads and tighten RTD housing (H) into adapter (206).

b. Push in RTD (212) so tip contacts heater element (208).

c. Holding RTD (212) against heater element, tighten ferrule nut (N) 3/4 turn past finger-tight.

9. Route wires (S) as before through woven wrap and reconnect RTD cable (212) to the TCM.

10. Replace heater shroud (10).

11. Follow startup instructions in the operation manual. Turn on A and B heat simultaneously to test. Temperatures should rise at same rate. If one is low, loosen ferrule nut (N) and tighten RTD housing (H) to ensure RTD tip contacts element

(212) when ferrule nut (N) is retightened.

Figure 14

333024F 63

Repair

Repair Heated Hose

Refer to the heated hose manual 309572 for hose replacement parts.

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).

3. For Series A only: Disconnect hose connector

(D) at Reactor.

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 andFTS

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

3 to 4

1 to 4

2 to any

Result approximately 1090 ohms approximately 1090 ohms

0.2 - 0.4 ohms 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.

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

3 to 4 / b lue to b lack

Result

3 to 1 / brown to blue approximately 1090 ohms approximately 1090 ohms

1 to 4 / b rown to b lack 0.2 - 0.4 ohms

2 to any / N/A infinity (open)

333024F 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.

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.

66 333024F

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

Repair

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 b e 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.

333024F 67

Figure 20

68

Repair

Replace Transformer

1. Perform

Shutdown, page 44 .

2. Remove four bolts (23) and shroud (10).

3. Remove lower dinrail cover (48).

4. Disconnect fan and transformer connections from terminal blocks. Connections are on left side labeled: V+, V-, 1, 2, 3, and 4.

5. Remove four nuts (27) holding metal transformer cover (8) to frame. Carefully remove cover while sliding wires through hole in cover.

6. Remove nuts (27) and transformer (17).

7. Install transformer (17) in reverse order.

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 tabon 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.

4. Install new surge protector (505) in reverse order.

Note

Wire on both the circuit breaker and power supply are interchangeable.

Figure 23

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

.

Replace Temperature Control Module

(TCM)

1. Perform

Shutdown, page 44

.

2. Open electrical enclosure door (61).

3. Disconnect all connectors from the TCM (453).

4. Remove four nuts (461) and TCM (453).

5. Install new TCM module (453). Reassemble parts in reverse order.

Figure 24 Replace MCM

Software Update Procedure

NOTICE

Repair kit GCA modules are shipped pre-programmed and software loading is not necessary. If software version upgrade is necessary, follow the procedure in the manual provided.

Figure 25 Replace TCM

70 333024F

Parts

Proportioners

Parts

333024F 71

Parts

72

1

2

3

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

3

4

5

6

7

8

9+

10

11

12

13

14

15

16

17

18

19

20

Ref

1

2

Parts

Part Description

- - -

- - -

FRAME

ENCLOSURE, electrical; see

Electrical Enclosure, page 84

246995 BOTTLE, assembly, complete

16X531 BRACKET, tsl, bottle

24U843 HEATER, 10kw, 2 zone, RTD; see

Fluid Heater, page 80

24U842 HEATER, 7.5kw,

1 zone, RTD; see

Fluid Heater, page 80

24U704 MANIFOLD, fluid; see

Fluid Manifold, page 82

16W654 INSULATOR, foam, heater

24R684 COVER, transformer

261821 CONNECTOR, wire,

6awg

24U841 COVER, heater

16W765 COVER, motor

16W764 COVER, heater, rear

24U837 TUBE, b-side, inlet

24U838 TUBE, b-side, inlet, 10kw

24U839 TUBE, b-side, outlet

24U840 TUBE, b-side, outlet,

10kw

24U834 TUBE, a-side, inlet

24U833 TUBE, a-side, inlet

24U836 TUBE, a-side, outlet

24U835 TUBE, a-side, outlet

15K742 TRANSFORMER,

4090va, 230/90

15B456 GASKET, manifold

125643 FITTING, elbow, 3/8 npt x #8 jic

119865 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

1

1

2

1

1

1

1

1

1

1

1

1

1

1

2

9

1

1

2

1

4

1

1

1

1

1

1

1

1

1

1

1

2

9

1

1

2

1

4

1

1

1

1

1

1

1

1

1

1

1

2

9

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

2

9

1

1

2

1

4

1

1

1

1

1

1

1

1

1

1

1

2

9

1

1

2

1

4

1

1

1

1

1

1

1

2

9

1

1

1

1

333024F 73

Parts

Ref

23

24

25

21

22

29

30

31

32

26

27

28

33

33a

39

40

41

42 ★

43 ★

33b

33c

33d

34

35

36

37

38

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, rub b er

16X095 CONNECTOR, power, male, 4 pin

125871 TIE, cab le, 7.5 in.

24K207 KIT, fts, rtd, single hose

Quantity

272010 272011 272012 272110 272111 272112

12 12 12 12 12 12

8

11

6

4

2

8

2

4

2

1

2

1

1

1

1

1

1

5

4

2

4

4

4

1

25

1

8

13

6

4

2

8

2

4

2

1

2

1

1

1

1

1

1

6

4

2

4

4

4

1

25

1

8

13

6

4

2

8

2

4

2

1

2

1

1

1

1

1

1

6

4

2

4

4

4

1

25

1

8

11

6

4

2

8

2

4

2

1

2

1

1

1

1

1

1

5

4

2

4

4

4

1

25

1

8

13

6

4

2

8

2

4

2

1

2

1

1

1

1

1

1

6

4

2

4

4

4

1

25

1

8

13

6

4

2

8

2

1

2

4

2

1

1

4

4

1

25

1

1

1

1

1

6

4

2

4

74 333024F

Parts

Ref Part Description

47

48

49

50

44

45

46

51

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

52  16X118 MODULE, cellular, gps, temp

53  24T050 CABLE, m8 4p f to m12

8p m 1.5m

54  16W130 CABLE, m12 5p, fem male, 2.0m

55

56

24U845 TUBE, pressure relief

191892 FITTING, elbow, street,

90 deg; 1/8 npt

57 116746 FITTING, barbed, plated;

1/8–27 npt x 1/4 in. hose

I.D.

58 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

4 4 4 4 4 4

1

1

2

1

1

1

1

2

2

2

1

1

1

2

1

1

1

1

2

2

2

1

1

1

2

1

1

1

1

2

2

2

1

1

1

2

1

1

1

1

1

1

2

2

2

2

1

1

1

2

1

1

1

1

1

1

2

2

2

2

1

1

1

1

1

1

1

1

1

1

2

2

2

2

1

333024F 75

Parts

59 ★

60

61

62

63

64 ★

65 ★

67 ★

68

70

Ref

71

85

88

89

83 ★

84 ★

74

75

72

73

79+ ★

81

82

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 b ottle

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 inhib itor

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

1 1 1 1 1 1

2

1

2

1

1

1

1

1

4

10

1

1

1

1

1

2

1

1

1

2

1

2

2

1

2

1

1

1

1

1

4

10

1

1

1

1

1

2

1

1

1

2

1

2

2

1

2

1

1

1

1

1

4

10

1

1

1

1

1

2

1

1

1

2

1

2

2

1

2

1

1

1

1

1

4

10

1

1

1

1

1

2

1

1

1

2

1

2

2

1

2

1

1

1

1

1

4

10

1

1

1

1

1

2

1

1

1

2

1

2

2

1

2

1

1

1

1

1

4

10

1

1

1

1

1

2

1

1

1

2

1

2

76 333024F

Parts

Ref Part Description

90

91

92

93

94

95

96

97

98*

16W213 LABEL, b randing, 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

99* 17C258 ENCLOSURE, cover

100* ▲ 189930 LABEL, caution

101* ▲ 172953 LABEL, ground

102*

103*

17D955 BRACKET, mounting

113161 SCREW, flange, hex hd

▲ Replacement Warning labels, signs, tags, and cards are available at no cost.

★ Not shown.

 Parts included in Graco Insite Kit 24T280.

Quantity

272010 272011 272012 272110 272111 272112

2 2 2 2 2 2

4

1

4

1

4

1

4

1

4

1

4

1

2

1

1

1

1

1

1

1

2

2

1

1

1

1

1

1

1

2

2

1

1

1

1

1

1

1

2

2

1

1

1

1

1

1

1

1

1

2

2

1

1

1

1

1

1

1

1

1

2

 See

Electrical Schematics, page 91 .

+ Part applies to Series A only.

* Part applies to Series B only.

2

1

1

1

1

1

1

1

1

1

2

333024F 77

Parts

Proportioner Module

24V150, Module for E-30

24V151, Module for E-XP2

78

1

2

5

6

3

4

7

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.

Apply grease to all gear teeth proportionally, motor pinion and drive housing.

Torque to 20–30 ft-lbs (27–40.6 N•m).

Crankshaft must be in line with crankshaft at other end of motor.

Torque to 70–80 ft-lbs (95–108 N•m).

Flat side faces up.

333024F

Parts

Ref

101

102

103

104

105 

106

107

108

110

111

112

Part

24U050

- - -

257355

245927

287290

241279

245971

245972

114699

114672

183169

183210

15C753

113

114

115

114666

106115

116

246831

246832

193031

193394

118 

120

121

122

116192

116618

24P728

127301

125 187437

126 ▲ 192840

Description

MOTOR, brushless, double ended, 2 HP

HOUSING, drive, Mark VII

HOUSING, bearing

HOUSING, bearing

KIT, repair, gear

KIT, rod, connecting

PUMP, displacement B

PUMP, displacement B

WASHER, thrust; copper colored

WASHER, thrust; steel colored

SPRING, retaining

PIN, str, hdls

SCREW, machine, hex wash hd; 1.25 in. x

5/16–18

SCREW, cap, socket head; 2.25 x 3/8–16

WASHER, lock (hi-collar)

PUMP, displacement, A

PUMP, displacement, A

NUT, retaining

NUT, retaining

WASHER, thrust (1595)

MAGNET

SWITCH, reed, M8 4-pin

SCREW, hexhead, thread cut, 4-40 x 0.375

LABEL, torque

LABEL, warning

▲ Replacement Warning labels, signs, tags, and cards are available at no cost.

★ See pump repair manual 309577 for repair kits.

 Spring(110) included in ConnectingRod Kit

241279.

24V150

E-30

1

2

2

2

2

1

2

4

2

2

10

8

8

1

2

2

1

1

2

2

2

24V151

E-XP2

1

2

2

2

2

1

2

4

2

2

10

8

8

1

2

2

1

1

2

2

2

Gear Repair Kit includes washers (107) and

(108).

Drive HousingRepair Kit includes housing(1), screws (5), and washer (1) to replace one end.

333024F 79

Parts

Fluid Heater

24U843 — 10kW, 2–zone

24U842 — 7.5 kW, 1–zone

80

3

4

1

2

5

6

7

Torque to 120 ft-lbs (163 N•m).

Torque to 23 ft-lbs (31 N•m).

Torque to 40 ft-lbs (54 N•m).

Apply thermal paste.

Apply pipe sealant and PTFE tape to all non-swiveling threads and threads without o-rings.

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

Ref

201

202

203

204

205

206

207

208

209

210

211*

212*

213

214

*

Part Description

15J090 HEATER, machined, 1 zone

15K825 HEATER, machined, dual zone

124132 O-RING

15H305 FITTING, plug, hollow, hex, 1-3/16 sae

121309 FITTING, adapter, sae-orb x jic

15H304 FITTING, plug 9/16 sae

15H306 ADAPTER, 9/16 x 1/8

120336 O-RING, packing

16A110 HEATER, immersion, 2550W, 230V

15B137 SWITCH, over temperature

15B135 MIXER, immersion heater

- - -

FITTING, compression

- - -

SENSOR, RTD

124131 SCREW, machine, pnhd; 5/16 in. x #6–32

15M178 HOUSING, rupture disc

Included in 24L973 Heater RTD Repair Kit.

2

2

4

2

2

4

1

2

2

24U843 24U842

1

1

4

2

4

4

3

5

2

3

1

2

3

1

1

3

1

1

1

Parts

333024F 81

Parts

Fluid Manifold

24U844

82

1

2

3

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

407

408

411

412

Ref Part Description

401 255228 MANIFOLD, fluid

402 ★ 247824 KIT, valve, cartridge, drain

402a ★ 158674 O-RING, BUNA-N

402b ★ 247779 SEAL, seat, valve

403

404

405

406

102814 GAUGE, press, fluid

162453 FITTING, 1/4 NPSM X 1/4

NPT

15M669 SENSOR, pressure, fluid outlet

247788 HANDLE, red

247789 HANDLE, blue

112309 NUT, hex, jam

117556 NIPPLE, #8 JIC x 1/2 NPT

121312 FITTING, elbow, 3/4 SAE x 1/2 JIC

Qty

1

2

2

2

1

1

2

1

1

2

1

1

Ref

413

414

Part Description

100840 FITTING, elbow, street

111457 O-RING, PTFE

Qty

2

2

415 ▲ 189285 LABEL, caution

416 150829 SPRING, compression

419 117557 NIPPLE, #10 JIC x 1/2

NPT

▲ Replacement Warninglabels, signs, tags, and cards are available at no cost.

★ Included in the followingcomplete 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.

1

1

2

333024F 83

Parts

Electrical Enclosure

84 333024F

Parts

Electrical Enclosure

Ref

451

453

454

455

457

458

459

460

461

462

463

464

466

Part Description

24U087 ENCLOSURE

24U855 MODULE, TCM

24U848 FAN, cooling, 80 mm,

24VDC

24R736 SWITCH, disconnect, door mounted

117666 TERMINAL, ground

120859 NUT, strain relief, M40 thread

120858 BUSHING, strain relief,

M40 thread

123967 KNOB, operator disconnect

115942 NUT, hex, flange head

103181 WASHER, lock external

124131 SCREW, machine, pan head; 5/16 in. x #6–32

194337 WIRE, grounding, door

113505 NUT, keps, hex head

Qty

▲ Replacement Warning labels, signs, tags, and cards are available at no cost.

See

Electrical Schematics, page 91

.

1

1

1

1

5

2

1

1

1

1

2

1

6

Ref

468

469

470

Part Description

111218 CAP, tube, square

114269 GROMMET, rubber

127282 GROMMET, rubber

471 127278 NUT, keps, hex

472

473

474

475

476

16W925 GASKET, enclosure, foam

16W926 GASKET, enclosure, foam

24R735 CABLE, CAN power, M12 female, pigtail

127068 CABLE, CAN, female/female 1.0 meter

24U850 MODULE, breaker

477 127290 CABLE, 4-pin, male/female, 1.3 meter, molded (hose RTD)

478

16X050 LABEL, safety; enclosure

479 ▲

16X049 LABEL, safety; multi

Qty

2

1

2

4

2

2

1

2

1

1

1

1

333024F 85

Parts

System DIN Rail and Harness Module Kit

24U850, System DIN Rail and Harness Module Kit

See

Electrical Schematics, page 91 .

86

1

2

3

Torque to 6–8 in.-lbs (0.7–1 N●m)

Torque to 28–33 in.-lbs (3–3.8 N●m)

Torque to 23–26 in.-lbs (2.6–3 N●m)

333024F

Parts

Ref

501

502

503

Part

16U529

16V515

16U522

Description

HARNESS, breaker module

HARNESS, hose out

MODULE, din rail, term blk, power sup; see

System Circuit Breaker

Module, page 88

Qty

1

1

1

Ref

504

505

Heater and Transformer Terminal Block Module

24U849

Part

16U526

16U530

Description

MODULE, din rail, circuit breakers; see

Power Supply and

Terminal Block Module, page 88

MODULE, sys surge protector

Qty

1

1

Ref

511

512

513

514

Part

24T315

126811

126383

126382

Description

RAIL, DIN; 35 mm x 7.5

mm x 7 in.

BLOCK, clamp, end

COVER, end

BLOCK, terminal

Qty

1

2

1

2

Ref

515

516

517

Part

120570

24R758

24R759

Description

BLOCK, terminal

BLOCK, terminal,

UT-2.5, red

BLOCK, terminal,

UT-2.5, black

Qty

6

1

1

333024F 87

Parts

System Circuit Breaker Module

16U526

Ref

521

522

523

Part

514014

120838

17A319

Description

RAIL, DIN; 35 mm x

7.5 mm x 8.625 in.

TERMINAL, end stop

CIRCUIT, breaker, 1 pole, 50A, C Curve

Qty

1

2

1

Power Supply and Terminal Block Module

16U522

Ref

524

525

Part

17A314

17A317

Description

CIRCUIT, breaker, 2P,

20A, UL489

CIRCUIT, breaker, 2P,

40A, UL489

Qty

1

3

Ref

531

532

533

Part

514014

Description

RAIL, DIN; 35 mm x 7.5

mm x 8.625 in.

TERMINAL, end stop 120838

24R722 BLOCK, terminal PE, quad, ABB

Qty

1

3

1

Ref

534

535

536

Part

24R723

126453

24R724

Description

BLOCK, terminal, quad

M4, ABB

POWER SUPPLY, 24V

BLOCK, terminal, UT35

Qty

2

1

6

88 333024F

Fluid Inlet Kits

24U320, Standard

24U321, Elite

Parts

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

602

603 

604

160327

118459

247503

FITTING, union adapter, 90°

FITTING, union, swivel, 3/4 in.

MANIFOLD, strainer, inlet

605

606 ★

24U852 THERMOMETER, dial

24U853

- - -

GAUGE, press, fluid

FILTER, replacement

607 ★  C20203 PACKING, o-ring, 1.17, fluoroelastomer

608  16V879 CAP, filter

609 

610

613

614

614

615

555808

15D757

109077

C20487

624545

24U851

PLUG, 1/4mp w/ hex hd

HOUSING, thermometer, viscon hp

VALVE, ball 3/4 npt

FITTING, nipple, hex

FITTING, tee 3/4m run x 1/4f branc

TRANSDUCER, pressure, temperature (includes foam)

* Optional 80 mesh filter 255082 (2 pack)

★ Included in 24V020 Inlet Filter and Seal Kit, 20 mesh (2 pack).

 Included in 247503 Manifold Repair Kit.

2

1

2

2

2

2

2

Quantity

24U320 24U321

2 2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

90 333024F

Electrical Schematics

Reactor 2 E-30

Reactor 2 E-XP2

To TCM

24U831

24U832

Electrical Schematics

16X118

333024F 91

Electrical Schematics

PS-L

PS-N

CB-B

CB-A ti22680b

92 333024F

1

2

Locate near TCM.

Heated hose wire termination enclosure (series

B only).

24U855

1

16V515

TO HTD HOSE

ELEC ENCL

GND STUD

2

Electrical Schematics

16U526 ti22678b

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

--

Part Description

15C852 E-30 Pump Repair Kit

15C851 E-XP2 Pump Repair Kit

246963 E-XP2 Wet Cup Repair Kit

246964 E-30 Wet Cup Repair Kit

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

Part of Assembly

Pump

Pump

Pump

Pump

Y-Strainer

Fluid Manifold

Fluid Manifold

Fluid Manifold

Heater

24K207 Hose FTS

24N450 RTD Cable (50 ft. replacement)

24N365 RTD Cable Test Kit (To assist measureing

RTDs and RTD cable resistances)

Hose

Hose

Hose

94 333024F

E-30

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)

1500

(103)

AR5252

(02)

AR6060

(03) PRESSURE psi (bar)

1000

(69)

AR7070

(04)

500

(34)

0 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)

333024F 95

Performance Charts

Proportioners For Coatings

Table 1 Fusion Air Purge, Round Pattern

3500

(241)

3000

(207)

2500

(172)

AR2020

(000)

PRESSURE psi (bar)

2000

(138)

1500

(103)

1000

(69)

500

(34) 0

AR2929

(00)

AR4242

(01)

Table 2 Fusion Air Purge, Flat Pattern

0.5

(1.9)

1.0

(3.8)

FLOW gal./min (l/min)

E-XP2

1.5

(5.7)

PRESSURE psi (bar)

3500

(241, 24.1)

3000

(207, 20.7)

2500

(174, 17.4)

2000

(138, 13.8)

1500

(103, 10.3)

1000

(69, 6.9)

500

(35, 3.5)

0

AF2020

(FTXX24 TIP)

AF2929

(FTXX38 TIP)

AF4242

(FTXX38 TIP)

AF5252

(FTXX48 TIP)

0.5

(1.9)

1.0

(3.8)

FLOW gal./min (l/min)

1.5

(5.7)

E-XP2

2.0

(7.6)

2.0

(7.6)

96 333024F

Performance Charts

Table 3 Fusion Mechanical Purge, Round Pattern

PRESSURE psi (bar)

3500

(241, 24.1)

3000

(207, 20.7)

2500

(174, 17.4)

2000

(138, 13.8)

XR2323

(RTM040)

E-XP2

XR2929

(RTM040)

MR3535

(RTM040)

1500

(103, 10.3)

1000

(69, 6.9)

XR3535

(RTM055)

XR4747

(RTM055)

500

(35, 3.5)

0 0.5

(1.9)

1

(3.8)

FLOW gal./min (l/min)

Table 4 Fusion Mechanical Purge, Flat Pattern

MR4747

(RTM055)

1.5

(5.7)

2.0

(7.6)

PRESSURE psi (bar)

3500

(241, 24.1)

3000

(207, 20.7)

2500

(174, 17.4)

2000

(138, 13.8)

1500

(103, 10.3)

1000

(69, 6.9)

500

(35, 3.5)

0

XF1313

(FTM424)

MF1818

(FTM424)

XF1818

(FTM424)

XF2323

(FTM424)

MF2929

(FTM424)

XF2929

(FTM424)

MF3535

(FTM638)

XF3535

(FTM638)

0.2

(0.7)

0.4

(1.5)

0.6

(2.3)

0.8

(3.0)

1

(3.8)

MF4747

(FTM638)

MF5757

(FTM638)

XF5757

(FTM638)

1.2

(4.5)

FLOW gal./min (l/min)

1.4

(5.3)

E-XP2

1.6

(6.0)

1.8

(6.8)

2.0

(7.6)

333024F 97

Technical Speci fi cations

Technical Specifications

Reactor 2 E-30 and E-XP2 Proportioning System

U.S.

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

Output per Cycle

ISO and RES

E-30

E-XP2

Operating Ambient Temperature Range

Temperature

Line Voltage Requirement

Nominal 200–240 VAC, 1 Phase,

50/60 Hz

Nominal 200–240 VAC, 3 phase,

DELTA, 50/60 Hz

Nominal 350–415 VAC, 3 phase,

WYE, 50/60 Hz

Heater Power

(at 230 VAC rated voltage)

E-30 10 kW

E-30, 15 kW

E-XP2 15 kW

2000 psi

3500 psi

190°F

190°F

30 lb/min

2 gpm

150°F

150°F

300 psi

300 psi

310 ft

0.0272 gal.

0.0203 gal.

20° to 120°F

195–265 VAC

195–265 VAC

340–455 VAC

10,200 Watts

15,300 Watts

15,300 Watts

Metric

14 MPa, 140 bar

24.1 MPa, 241 bar

88°C

88°C

13.5 kg/min

7.6 lpm

66°C

66°C

2.1 MPa, 21 bar

2.1 MPa, 21 bar

94 m

0.1034 liter

0.0771 liter

-7° to 49°C

98 333024F

Technical Speci fi cations

Sound Pressure

Sound Pressure measured per ISO-9614–2.

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)

Sound Power

E-30

Measured from 3.1 ft (1 m), at

1000 psi (7 MPa, 70 bar), 3 gpm

(11.4 lpm)

E-XP2

Measured from 3.1 ft (1 m), at

3000 psi (21 MPa, 207 bar), 1 gpm

(3.8 lpm)

Fluid Inlets

Component A ISO) and

Component B (RES)

Fluid Outlets

Component A (ISO)

Component B (RES)

Fluid Circulation Ports

Size

Maximum Pressure

Dimensions

Width

Height

Depth

Weight

E-30, 10 kW

E-30, 15 kW

E-30, 10 kW Elite

E-30, 15 kW Elite

E-XP2

E-XP Elite

Wetted Parts

Material

250 psi

26.3 in.

63 in.

15 in.

87.3 dBA

79.6 dBA

93.7 dBA

86.6 dBA

3/4 NPT(f) with 3/4 NPSM(f) union

#8 (1/2 in.) JIC, with #5 (5/16 in.) JIC adapter

#10 (5/8 in.) JIC, with #6 (3/8 in.) JIC adapter

1/4 NPSM(m)

1.75 MPa, 17.5 bar

668 mm

1600 mm

381 mm

315 lb143 kg

350 lb159 kg

320 lb145 kg

355 lb161 kg

345 lb156 kg

350 lb159 kg

Aluminum, stainless steel, zinc plated carbon steel, brass, carbide, chrome, chemically resistant o-rings, PTFE, ultra-high molecular weight polyethylene

333024F 99

Notes

Notes

100 333024F

Graco Extended Warranty for Reactor ® 2

Components

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 with Graco’s written recommendations.

Graco Part Number Description

Electric Motor

Warranty Period

36 Months or 3 Million Cycles

24U831

24U832

24U855

24U854

All other Reactor 2parts

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

12Months 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 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.

free of charge any defective parts. The equipment will be returned to the original purchaser transportation made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

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.

their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

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 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

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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