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

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

Repair, Parts

E E -XP2

Electric, polyurea coatings.

or hazardous

Important

Read all warnings and instructions in this manual before using the equipment. Save these instrustions.

333024U

EN

PROVEN QUALITY. LEADING TECHNOLOGY.

WWLL DD

Warnings ......................................................... 3

Important Isocyanate Information .................... 7

Models............................................................. 9

Approvals ...................................................... 11

Accessories.................................................... 11

Supplied Manuals........................................... 12

Related Manuals ............................................ 12

Troubleshooting ............................................ 13

Troubleshoot Errors ................................ 13

Pressure Relief Procedure............................... 46

Shutdown ...................................................... 47

Flushing ........................................................ 49

Repair............................................................ 50

Before Beginning Repair .......................... 50

Flush Inlet Strainer Screen ....................... 50

Change Pump Lubricant........................... 51

Clean Flow Meter ..................................... 52

Clean E-XP2 Flow Meter........................... 53

Remove Pump ......................................... 54

Install Pump ............................................ 56

Repair Drive Housing............................... 56

Repair Electric Motor ............................... 59

Repair Circuit Breaker Module.................. 60

Replace Fluid Inlet Sensor ........................ 61

Replace Flow Meter.................................. 61

Replace Pressure Transducers ................. 62

Replace Fans ........................................... 63

Repair Primary Heater.............................. 65

Repair Heated Hose ................................. 69

Repair Fluid Temperature Sensor

(FTS) ........................................... 72

Calibration Procedure .............................. 73

Transformer Primary Check ..................... 74

Transformer Secondary Check ................. 75

Replace Transformer ............................... 76

Replace Power Supply .............................. 76

Replace Surge Protector........................... 76

Replace Motor Control Module

(MCM) ......................................... 77

Replace Temperature Control Module

(TCM).......................................... 77

Replace Advanced Display Module

(ADM) ......................................... 78

Software Update Procedure...................... 78

Update ADM Software.............................. 79

Parts .............................................................. 80

Electrical Schematics.................................... 105

Reactor 2 Repair Spare Parts

Reference........................................ 108

Performance Charts ..................................... 109

Technical Specifications ............................... 112

Notes ......................................................... 114

Graco Extended Warranty for Reactor® 2

Components ................................... 115

2 333024U

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.

This equipment can be powered by more than 240 V. Contact with this voltage will cause death or serious injury.

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

• This equipment must be grounded. Connect only to grounded power source.

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

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

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

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.

333024U 3

4

Warnings

High-pressure fluid from dispensing device, 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

• Engage trigger lock when not spraying.

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

• Do not put your hand over the fluid outlet.

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

checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

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

Paint or solvent flowing through the equipment can cause static sparking. 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 sparking).

• 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.

• Use only grounded hoses.

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

Stop equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

333024U

333024U

Warnings

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.

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.

• Do not use chlorine bleach.

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

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

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

of construction. Consult the solvent manufacturer for information and recommendations about compatibility.

5

6

Warnings

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

• Use fluids and solvents that are compatible with equipment wetted parts. See manufacturer’s warnings. For complete information about your material, request

Safety Data Sheets (SDSs) from distributor or retailer.

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

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 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.

• Equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure

Equipment surfaces and fluid that is heated can become very hot during operation.

To avoid severe burns:

• Do not touch hot fluid or equipment.

333024U

Important Isocyanate Information

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

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:

333024U 7

8

Important Isocyanate Information

Self -Ignition

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.

Some materials may become self-igniting if applied too thick. Read material manufacturer’s warnings and SDS.

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

Never component B wetted parts.

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

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 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: crystallization varies depending on the blend of

ISO, the humidity, and the temperature.

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.

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.

333024U

Models

2 EE and EE 30

All elite systems include fluid inlet sensors, ratio monitoring, and Xtreme-Wrap 50 ft (15 m) heated hose. For part numbers, see

Accessories, page 11

.

EE EE -

272010

Maximum Fluid

Pressure

Approximate Output

Cycle

Flow

(kg/min)

2000 (14, 140)

0.0272 (0.1034)

System Load

◊ (Watts)

Configurable Voltage

Phase

200

–240

VAC

Current * 78

30 (13.5)

17,900

200

–240

VAC

3Ø∆

50

350

–415

VAC

3ØY

34

272011

2000 (14, 140)

0.0272 (0.1034)

30 (13.5)

23,000

272110

2000 (14, 140)

0.0272 (0.1034)

30 (13.5)

17,900

200

–240

VAC

100

200

–240

VAC

3Ø∆

62

350

–415

VAC

3ØY

35

200

–240

VAC

78

200

–240

VAC

3Ø∆

50

350

–415

VAC

3ØY

34

272111

2000 (14, 140)

0.0272 (0.1034)

30 (13.5)

23,000

200

–240

VAC

200

–240

VAC

3Ø∆

100 62

350

–415

VAC

3ØY

35

(Gun Part No.)

(Gun Part No.)

(Gun Part No.)

Heated Hose

50 ft (15

24K240 (scuff guard)

24Y240 (Xtreme-Wrap)

AP2010

(246102)

CS2010

(CS02RD)

AH2010

(246102)

CH2010

(CS02RD)

AP2011

(246102)

CS2011

(CS02RD)

AH2011

(246102)

CH2011

(CS02RD)

AP2110

(246102)

CS2110

(CS02RD)

AH2110

(246102)

CH2110

(CS02RD)

AP2111

(246102)

CS2111

(CS02RD)

AH2111

(246102)

CH2111

(CS02RD)

P22010

(GCP2R2)

PH2010

(GCP2R2)

P22011

(GCP2R2)

PH2011

(GCP2R2)

P22110

(GCP2R2)

PH2110

(GCP2R2)

P22111

(GCP2R2)

PH2111

(GCP2R2)

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

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 ratio monitoring and fluid inlet sensors.

Low line input voltage will reduce power available and heaters will not perform at full capacity.

Ø Phase

∆ DELTA

Y WYE

333024U 9

Models

2 EE and EE XP2

All elite systems include fluid inlet sensors and Xtreme-Wrap 50 ft (15 m) heated hose. For part numbers, see

Accessories, page 11 .

Maximum Fluid

Pressure

Approximate Output

Cycle

Flow Rategpm/min

(l/min)

◊ (Watts)

Configurable Voltage

Phase

200–240

VAC 1Ø

100

272012

3500 (24.1, 241)

0.0203 (0.0771)

2 (7.6)

23,000

200–240

VAC 3Ø∆

62

350–415

VAC 3ØY

35

200–240

VAC 1Ø

100

272112

3500 (24.1, 241)

0.0203 (0.0771)

2 (7.6)

23,000

200–240

VAC 3Ø∆

62

350–415

VAC 3ØY

35

(Gun Part No.)

(Gun Part No.)

Heated Hose

50

Heated

10 ft

AP2012

(246100)

P22012

(GCP2R1)

24K241

(scuff guard)

246055

AP2112

(246100)

P22112

(GCP2R1)

24Y241

(Xtreme-Wrap)

246055

*

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

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

• E–30 and E–XP2 series: 310 ft (94.5

m) maximum heated hose length, including whip hose.

See

Approvals, page 11

.

Packages include gun, heated hose, and whip hose. Elite packages also include fluid inlet sensors.

Low line input voltage will reduce power available and heaters will not perform at full capacity.

Ø Phase

∆ DELTA

Y WYE

10 333024U

Approvals

Intertek approvals apply to proportioners without hoses.

Conforms to ANSI/UL Std. 499

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

Kit Number Description

24U315

24U314

Air Manifold Kit (4 outlets)

16X521

24N449

24K207

Wheel and Handle Kit

Graco InSite Extension cable,

24.6 ft (7.5 m)

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

Fluid Temperature Sensor (FTS) with RTD

24U174

24K337

15V551

Remote Display Module Kit

Light Tower Kit

15M483

24M174

121006

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)

24N365

24N748

979200

RTD Test Cables (to aid resistance measurements)

Ratio Monitoring Kit

979201

979202

Integrated PowerStation, Tier 4

Final, no air

Integrated PowerStation, Tier 4

Final, 20 cfm

Integrated PowerStation, Tier 4

Final, 35 cfm

333024U 11

Supplied Manuals

The following manuals are shipped with the

Reactor 2. Refer to these manuals for detailed equipment information.

333023

333091

333092

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

The following manuals are for accessories used with the Reactor. Manuals are available at www.graco.com.

333023 Reactor 2 E-30 and E-XP2 Operation

309577 Electric Reactor Displacement

Pump, Repair-Parts

309572 Heated Hose, Instructions-Parts

309852 Circulation and Return Tube Kit,

Instructions-Parts

309815 Feed Pump Kits, Instructions-Parts

309827 Feed Pump Air Supply Kit,

Instructions-Parts

309550 Fusion ™ AP Gun

312666 Fusion ™ CS Gun

313213 Probler ® P2 Gun

3A1906 Light Tower Kit, Instructions-Parts

3A1907 Remote Display Module Kit,

Instructions-Parts

332735 Air Manifold Kit, Instructions-Parts

332736 Handle and Wheel Kit,

Instructions-Parts

3A6738 Ratio Monitor Kit, Instructions

3A6335 Integrated PowerStation,

Instructions

12 333024U

Troubleshooting

DANGER

SEVERE

This equipment can be powered by more than

240V. Connect with this voltage will cause death or serious injury.

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

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

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:

1. Press the soft key for help with the active error.

To avoid injury due to unexpected machine operation initiated by a remote controller, disconnect the cellular module from the system prior to troubleshooting. Refer to your

Reactor app kit manual for instructions.

There are three types of errors that can occur.

Errors are indicated on the display as well as by the light tower (optional).

or to return to the previously displayed screen.

2. The QR code screen will be displayed. Scan the QR code with your smartphone to be sent directly to online troubleshooting for the active error code. Or, manually navigate to help.graco.com and search for the active error.

333024U

3. If no internet connection is available, see

Error Codes, page 13

for causes and solutions for each error code.

13

Troubleshooting

See help.graco.com for more detail on troubleshooting errors.

error code occurred, see the Errors screen to view the last 200 errors, including date, time, and description.

Error Location Type

05CH ADM /

TCM

A1NM MCM

Hose re-calibration recommended

Low Motor

Current

Hose Resistance

Mode is selected and TCM has been replaced without re-calibration.

Hose Resistance

Mode is selected and ADM has been moved to a new system without re-calibration.

Fluid not in system.

Re-calibrate the hose. Follow the

Calibration Procedure, page 73

.

Re-calibrate the hose. Follow the

Calibration Procedure, page 73

.

System cannot build pressure.

Loose/broken connection.

No fluid in the pump can cause a low motor current error. Verify:

• Fluid is in pumps.

• Inlet valves are open.

An outlet restriction does not exist.

Verify relief valves are in SPRAY position.

Verify:

• Power connector is tightly connected at MCM port #15.

Confirm wiring is not pulling connector out of proper position.

• Cable insulation or wire is not cut or frayed.

• Wires are tightly torqued in power connector terminals. Test by pulling on individual wires in power connector.

• Cable not damaged at strain relief on motor case.

14 333024U

Troubleshooting

Error Location Type

A4DA

A4DB

A4DH

A4NM

Heater A

Heater B

Hose

MCM

High Current

A

High Current

B

High Current

Hose

High Motor

Current

Bad motor.

Disconnect motor power connector at MCM port #15. Measure resistances at motor power connector.

Must read 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 and previous step ("Loose/broken power connection or motor cable") was verified, then motor may need replacement.

Check wiring for touching wires.

Short circuit in heater wiring.

Bad Heater.

Confirm resistance of heater.

Heater resistance should be 18–21

Ω for each heater element, 9–12 Ω combined for 10 kW systems, and

6-8 Ω for 15 kW systems. If out of tolerance, replace heater element.

Check wiring for touching wires.

Short circuit in heater wiring.

Bad Heater.

Supply voltage and/or frequency fluctuation may be affecting hose current control.

Generator may be undersized for combination of Reactor and other supporting equipment.

Software bug.

Short circuit of motor wiring.

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.

Measure voltage and frequency at system disconnect switch and confirm they are stable.

Use continuous-run compressor with head-unloader.

Turn off unnecessary loads connected to generator.

A bug identified in software can cause nuisance triggering of this error, especially when running at high pressure and low flow rates. Upgrade system to the latest system software.

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

333024U 15

Troubleshooting

Error Location Type

A7DA

A7DB

A7DH

A8DA

A8DB

A8DH

Heater A

Heater B

Hose

Heater A

Heater B

Hose

Unexpected

Current A

Unexpected

Current B

Unexpected

Current Hose

No Current A

No Current B

No Current

Hose

Motor will not rotate.

Damaged gear train.

Chemical pump is stuck.

Shorted TCM

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.

Shorted TCM

Shorted TCM

Tripped circuit breaker.

Loose/broken connection.

Tripped circuit breaker.

Loose/broken connection.

Tripped circuit breaker.

Loose/broken connection.

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.

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.

16 333024U

Troubleshooting

Error Location Type

CACM MCM MCM Communication

Error

Cross threaded

CAN cable.

No 24 VDC supply to module.

Module does not have software.

Loose or broken

CAN cable.

Dial set to wrong position.

Software mismatch between modules.

CAN cables carry 24 V dc power and communication between modules.

A cross threaded CAN cable connector may cause problems with communication and/or power to modules. Carefully check for cross threaded CAN connections on the MCM and on other modules.

Green light on each module should be lit.

If green light is not lit, check to make sure each CAN cable connection is not cross threaded and is tight.

Verify the power supply is outputting 24 V dc. If not, check power supply wiring. If wiring is okay, replace the power supply.

Insert a software upgrade token into the ADM and cycle the power. Make certain to wait until the upload is complete before removing the token. For more information on loading software, refer to module programming manual 3A1244.

Check the CAN cables running between GCA modules. Check for cross threading and tighten if needed.

If the problem still persists, grasp the cable near the connector, move it around, and watch the flashing yellow light on the GCA modules. If the yellow light stops flashing, replace the

CAN cable.

Ensure the MCM dial is set to the correct position (E-30: dial position = 2, E-XP2: dial position

= 3).

Installing a new module in the system, or swapping in a module from another system, may cause a software mismatch.

Update software in all modules by following the procedure in your system's manual.

Make certain to wait until the upload is complete before removing the token. For more information on loading software, refer to module programming manual 3A1244.

333024U 17

Troubleshooting

Error Location Type

CACT TCM TCM Communication

Error

Cross threaded

CAN cable.

Software mismatch between modules.

No 24 VDC supply to module.

Module does not have software.

Loose or broken

CAN cable.

CAN cables carry 24 V dc power and communication between modules.

A cross threaded CAN cable connector may cause problems with communication and/or power to modules. Carefully check for cross threaded CAN connections on the TCM and on other modules.

Installing a new module in the system, or swapping in a module from another system, may cause a software mismatch.

Update software in all modules by following the procedure in your system's manual.

Make certain to wait until the upload is complete before removing the token. For more information on loading software, refer to module programming manual 3A1244.

Green light on each module should be lit.

If green light is not lit, check to make sure each CAN cable connection is not cross threaded and is tight.

Verify the power supply is outputting 24 V dc. If not, check power supply wiring. If wiring is okay, replace the power supply.

Insert a software upgrade token into the ADM and cycle the power. Make certain to wait until the upload is complete before removing the token. For more information on loading software, refer to module programming manual 3A1244.

Check the CAN cables running between GCA modules. Check for cross threading and tighten if needed.

If the problem still persists, grasp the cable near the connector, move it around, and watch the flashing yellow light on the GCA modules. If the yellow light stops flashing, replace the

CAN cable.

18 333024U

Troubleshooting

Error Location Type

DADX MCM

DE0X

EVCH

EAUX

EVUX

MCM

ADM

ADM

ADM

Pump

Runaway

Cycle Switch

Error

Manual

Hose Mode

Enabled

USB Busy

Flow rate is too large.

Switch disconnect or cable damaged.

The switch is faulty.

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, Port 12.

Missing or out of place cycle switch magnet.

Manual hose mode has been enabled in System

Setup screen.

USB drive has been inserted into the ADM.

USB disabled USB download/uploads are disabled.

Measure resistance between pin 3 and 4, Normally switch is open, and resistance is very high (open circuit). With cycle switch magnet near switch (contacts closed), normal resistance is less than 1 ohm.

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

Install a functioning fluid temperature sensor (FTS) on the hose. Manual hose mode will automatically turn off.

Do not remove USB drive until download/upload is complete.

Enable USB download/uploads on the Advanced Setup screen before inserting a USB drive.

333024U 19

Troubleshooting

Error Location Type

F9DX MCM

F9FA

F9FB

H2MA

H2MB

H2MH

H3MA

H3MB

H3MH

ADM

ADM

Heater A

Heater B

Hose

Heater A

Heater B

Hose

High Pressure/Flow

Cutback

Machine is operating above pressure/flow rating.

Motor or motor control temperature is too high.

Flow Cutback

Low Inlet

Pressure

(A-side)

Flow Cutback

Low Inlet

Pressure

(B-side)

Low

Frequency A

Low

Frequency B

Low

Frequency

Hose

High

Frequency A

High

Frequency B

High

Frequency

Hose

A-side (ISO) inlet pressure is too low.

A-side (ISO) inlet flow is too low.

B-side (RES) inlet pressure is too low.

B-side (RES) inlet flow is too low.

Line frequency is below 45 Hz

Line frequency is below 45 Hz

Line frequency is below 45 Hz

Line frequency is above 65 Hz

Line frequency is above 65 Hz

Line frequency is above 65 Hz

Mix chamber is too large for set pressure.

Set pressure is too high for given mix chamber.

Reference the pressure/flow performance chart in the operation manual and decrease the mix chamber size or set pressure accordingly.

Applies to Advanced Display

Module (ADM) software 16N725

(all versions) and 17A157 (version

1.01.001 only):

• For these specific software releases, the causes for the codes F9DX, T3NM and T3CM were combined and all triggered the code F9DX. ADM software more recent than 17A517

1.01.001 splits these three codes apart.

• For all causes/solutions, see

T3NM and/or T3CM.

Increase the A-side (ISO) feed pump pressure.

Install a larger A-side (ISO) feed pump.

Increase the B-side (RES) feed pump pressure.

Install a larger B-side (RES) feed pump.

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.

20 333024U

Troubleshooting

Error Location Type

K8NM MCM

L1AX

L1BX

MMUX

ADM

ADM

USB

Locked Rotor

Motor

Low Chemical

Level A

Low Chemical

Level B

Software bug.

Chemical pump is stuck.

Damaged gear train.

A bug exists in older motor control software that may falsely trigger this error code when there is neither a locked rotor, nor mechanical issues or damage to the proportioner motor. Upgrade software to system version

2.01.001 (Motor Control Module

2.01.001) or greater.

Repair or replace chemical pump.

Motor will not rotate.

Low material level.

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

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

Refill material and update drum level on ADM Maintenance screen.

Low material level.

Alarm can be disabled on the

System Setup screen.

Refill material and update drum level on ADM Maintenance screen.

Maintenance

Due - USB

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

Alarm can be disabled on the

System Setup screen.

Insert a USB drive into the ADM and download all logs.

333024U 21

Troubleshooting

Error Location Type

P0AX MCM

P0BX

P1FA

P1FB

MCM

MCM

MCM

Pressure

Imbalance A

High

Pressure

Imbalance B

High

Low Inlet

Pressure A

Low Inlet

Pressure B

Pressure difference between A and

B material is greater than the defined value.

Pressure imbalance is defined too low.

Out of material.

Feed system defective.

Fluid leaking from heater inlet rupture disk.

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 feed pump and hoses for blockage. Check that feed pumps have correct air pressure.

Check if heater and PRESSURE

RELIEF/SPRAY valve are plugged.

Clear. Replace rupture disk. Do not replace with a pipe plug.

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.

Feed system defective.

Fluid leaking from heater inlet rupture disk.

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 feed pump and hoses for blockage. Check that feed pumps have correct air pressure.

Check if heater and PRESSURE

RELIEF/SPRAY valve are plugged.

Clear. Replace rupture disk. Do not replace with a pipe plug.

Ensure that inlet pressure to the pump is sufficient.

Inlet pressure lower than defined value.

Value defined too high.

Inlet pressure lower than defined value.

Value defined too high.

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.

22 333024U

Troubleshooting

Error Location Type

P2FA MCM

P2FB

P4AX

P4BX

P4FA

MCM

MCM

MCM

ADM

Low Inlet

Pressure A

Low Inlet

Pressure B

High Pressure

A

High Pressure

B

High Inlet

Pressure

(A-side)

Inlet pressure lower than defined value.

Value defined too high.

Inlet pressure lower than defined value.

Value defined too high.

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.

The A-side (ISO) pump inlet ball or seat is damaged.

The A-side

(ISO) material is expanding between the material drum and the proportioner.

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.

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 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.

Replace the A-side (ISO) pump inlet ball and seat.

To avoid thermal expansion, condition the A-side (ISO) material drum to the same ambient temperature as the proportioner.

333024U 23

Troubleshooting

Error Location Type

P4FB ADM

P6AX

P6BX

P6FA

MCM

MCM

MCM

High Inlet

Pressure

(B-side)

Pressure

Sensor Error

A

Pressure

Sensor Error

B

Pressure

Sensor Error

Inlet A

The B-side (RES) pump inlet ball or seat is damaged.

The B-side

(RES) material is expanding between the material drum and the proportioner.

Loose/bad connection.

Replace the B-side (RES) pump inlet ball and seat.

To avoid thermal expansion, condition the B-side (RES) material drum to the same ambient temperature as the proportioner.

Bad sensor.

Loose/bad connection.

Bad sensor.

Inlet sensors not installed.

Loose/bad connection.

Bad sensor.

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.

24 333024U

Troubleshooting

Error Location Type

P6FB MCM

P7AX

P7BX

MCM

MCM

Pressure

Sensor Error

Inlet B

Pressure

Imbalance A

High

Pressure

Imbalance B

High

Inlet sensors not installed.

Loose/bad connection.

Bad sensor.

Out of material.

Feed system defective.

Fluid leaking from heater inlet rupture disk.

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.

Feed system defective.

Fluid leaking from heater inlet rupture disk.

Pressure difference between A and

B material is greater than the defined value.

Pressure imbalance is defined too low.

Ensure that the pressure imbalance value, on the System Setup screen, is at an acceptable maximum pressure to prevent unnecessary alarms and abort dispenses.

Fill tanks with material

Check feed pump and hoses for blockage. Check that feed pumps have correct air pressure.

Check if heater and PRESSURE

RELIEF/SPRAY valve are plugged.

Clear. Replace rupture disk. Do not replace with a pipe plug.

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 feed pump and hoses for blockage. Check that feed pumps have correct air pressure.

Check if heater and PRESSURE

RELIEF/SPRAY valve are plugged.

Clear. Replace rupture disk. Do not replace with a pipe plug.

333024U 25

Troubleshooting

Error Location Type

R1D0 ADM

R4D0

R9AX

R9BX

ADM

ADM

ADM

Low

Ratio/Low

Flow (A-side)

High

Ratio/Low

Flow (B-side)

No Pulses,

A-side Flow

Meter

No Pulses,

B-side Flow

Meter

Fluid leak between the

B-side pump and the meter.

Damaged

B-side (RES) recirculation valve.

Damaged B-side

(RES) flow meter.

The B-side material drum is empty.

Cavitation on the B-side (RES) pump.

Damaged A-side

(ISO) flow meter.

No flow of A-side component (ISO).

Damaged B-side

(RES) flow meter.

No flow of B-side component (RES).

Damaged A-side

(ISO) pump.

Fluid leak between the

A-side pump and the meter.

Damaged A-side

(ISO) recirculation valve.

Damaged A-side

(ISO) flow meter.

The A-side material drum is empty.

Cavitation on the A-side (ISO) pump.

Damaged B-side

(RES) pump.

Inspect the A-side (ISO) pump for damage. If necessary, replace the pump.

Inspect the fluid lines for leaking

A-side chemical (ISO).

Replace the A-side (ISO) recirculation valve.

Replace the A-side (ISO) flow meter.

Replace the A-side (ISO) material drum.

Increase the A-side (ISO) feed pump pressure.

Inspect the B-side (RES) pump for damage. If necessary, replace the pump.

Inspect the fluid lines for leaking

B-side chemical (RES).

Replace the B-side (RES) recirculation valve.

Replace the B-side (RES) flow meter.

Replace the B-side (RES) material drum.

Increase the B-side (RES) feed pump pressure.

Replace the A-side (ISO) flow meter.

Verify that the A-side (ISO) inlet valves are open.

Replace the B-side (RES) flow meter.

Verify that the B-side (RES) inlet valves are open.

26 333024U

Troubleshooting

Error Location Type

T2DA Heater A

T2DB

T2DH

Heater B

Hose

Low

Temperature

A

Low

Temperature

B

Low

Temperature

Hose

Flow is too high at current setpoint.

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

If recirculating, decrease flow or decrease temperature setpoint.

Reconnect or install jumper.

Loose or missing jumper on the heater terminal blocks

Bad RTD or bad

RTD placement against heater.

Loose heater wires or connector.

Bad heater element.

Flow is too high at current setpoint.

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

Check for loose heater element wires or loose green connector at

TCM.

Confirm resistance of heater.

Heater resistance should be 18-21

Ω for each heater element, 9-12

Ω combined for 10 kW systems,

6-8 Ω for 15 kW systems, and 4-6

Ω for 20 kW systems. If out of tolerance, replace heater element.

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

If recirculating, decrease flow or decrease temperature setpoint.

Reconnect or install jumper.

Loose or missing jumper on the heater terminal blocks

Bad RTD or bad

RTD placement heater.

Loose heater wires or connector.

Bad heater element.

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

Flow is too high at current setpoint.

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

Check for loose heater element wires or loose green connector at

TCM.

Confirm resistance of heater.

Heater resistance should be 18-21

Ω for each heater element, 9-12

Ω combined for 10 kW systems,

6-8 Ω for 15 kW systems, and 4-6

Ω for 20 kW systems. If out of tolerance, replace heater element.

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

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

333024U 27

Troubleshooting

Error Location Type

T2FA MCM

T2FB

T3CH

T3CT

T3CM

MCM

Hose

TCM

MCM

Low

Temperature

Inlet A

Low

Temperature

Inlet B

Hose Cutback

TCM Cutback

MCM

Temperature

Cutback

Inlet fluid temperature is below the defined level.

Inlet fluid temperature is below the defined level.

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 control temperature is too high.

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.

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.

Ensure ambient temperature is below 120° F (48° C).

Verify that all fans are working.

28 333024U

Troubleshooting

Error Location Type

T3NM MCM

T4CM

T4CT

MCM

TCM

Motor

Temperature

Cutback

High

Temperature

MCM

High

Temperature

TCM

Cooling fan on back of motor not operating properly.

Ambient temperature is too high.

Machine is operating above pressure/flow rating.

High ambient temperature.

Enclosure fan not operating.

High ambient temperature.

Enclosure fan not operating.

Module fan not operating.

• Ensure fan is always running when machine is powered on.

• Ensure fan is blowing air toward the motor (inward).

• Ensure fan is clean and moves freely. Remove any obstructions in front of fan grill.

• Ensure no hot air (from other heat sources) is being directed toward the fan.

Ensure system ambient temperature is below 120° F

(48° C).

Mix chamber is too large for set pressure.

Set pressure is too high for given mix chamber.

NOTE: to preserve motor life. If the motor gets too hot this advisory automatically reduces the pressure setpoint to allow the motor to cool. To avoid this advisory, run the system at a lower duty cycle or with a smaller mix chamber.

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.

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.

333024U 29

Troubleshooting

Error Location Type

T4DA Heater A

T4DB Heater B

High

Temperature

A

High

Temperature

B

Bad RTD or bad

RTD placement against heater.

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.

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.

30 333024U

Troubleshooting

Error Location Type

T4DH Hose

T4DH Hose

High

Temperature

Hose

High

Temperature

Hose

Fluid is overheated in portions of hose exposed to an excessive heat source, like hot direct sunlight. When spraying begins, overheated fluid passes over the

FTS, triggering this alarm.

Trigger point is

27° F (15° C) over hose temperature setting.

Coiled hose creates excessive heat in a portion of the hose.

When spraying begins, the overheated fluid passes over the

FTS.

Fluid hose insulation missing from over FTS, leading to erratic hose temperature control.

Shade exposed hose from hot sun or expose FTS to same environment when at rest.

Uncoil entire hose before heating.

Multiple sections of hose piled or wrapped creates self-heating and leads to this problem.

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.

Hose temperature is measured in the A-side (red) fluid hose approximately 18 in. (0.5 m) back toward the proportioner from the

FTS fittings.

Confirm that insulation is intact over, at minimum, the last 6 ft

(2 m) of the A-side hose. If not, replace missing insulation over the individual hoses. (Wrapping replacement insulation over the whole hose bundle is not sufficient for proper hose temperature control.)

Replacement insulation is available from Graco or a hardware store.

Increase hose setpoint so it is closer to A and B setpoints.

333024U 31

Troubleshooting

Error Location Type

T4EA

T4EB

Heater A

Heater B

High

Temperature

Switch A

High

Temperature

Switch B

Cold ambient temperature is causing hose to heat.

Overtemperature switch sensed a fluid temperature above 230° F

(110° C).

Cold ambient temperature is chilling the FTS and causing hose heat to stay on longer than needed. Insulate the FTS area of the hose so that it heats at the same rate as the rest of the hose.

Heater was delivered too much power, causing the overtemperature switch to open.

RTD is not reading properly. After the heater cools down, replace

RTD. Switch closes and the error can be cleared when the heater temperature falls below 190° F (87°

C).

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

Disconnected or loose overtemperature switch cable/connection.

Overtemperature switch failed in the open position.

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.

Replace overtemperature switch.

Heater was delivered too much power, causing the overtemperature switch to open.

RTD is not reading properly. After the heater cools down, replace

RTD. Switch closes and the error can be cleared when the heater temperature falls below 190° F (87°

C).

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

Replace overtemperature switch.

32 333024U

Troubleshooting

Error Location Type

T4NM MCM High

Temperature

Motor

High ambient temperature.

Cooling fan is not operating properly.

Disconnected or loose motor temperature cable.

Failed motor temperature sensor.

Ensure ambient temperature is below 120° F (49° C) before using the system.

• Check to see that the motor fan is moving. Measure voltage to the fan. There should be 24

VDC. If no voltage is measured, check the fan wiring.

• If the fan has voltage but is not moving, replace the fan.

• If necessary, use an air hose to blow out around the fan housing and remove any built-up debris.

Verify wiring between the motor temperature sensor and the module.

Measure resistance between pins

1 and 3 on motor temperature cable connector. Readings vary depending on temperature, but at room temperature (72° F /

22° C), the resistance should be approximately 1500 to 2500 ohms. An open circuit reading indicates a possible wire break.

Replace the motor.

T6DA Heater A

T6DB Heater B

Sensor Error

A

Sensor Error

B

Disconnected or loose RTD cable or connection.

Bad RTD.

Check all wiring and connection to

RTD.

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

Check all wiring and connection to

RTD.

Disconnected or loose RTD cable or connection.

Bad RTD.

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

333024U 33

Troubleshooting

Error Location Type

T6DH Hose

T6DT TCM

Sensor Error

Hose

Disconnected or shorted RTD cable in hose or bad FTS.

Sensor Error

TCM

Shorted RTD cable in hose or FTS.

Shorted A or B

Heater 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 69 .

Order RTD Test kit 24N365 for measurement.

Disconnect the hose RTD and use Hose Manual Mode or Hose

Resistance Mode to continue the job until repair can be completed.

Hose Resistance Mode requires a saved calibration factor. Refer to your proportioner operation manual to enable Hose Control

Modes.

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 69 .

Order RTD Test kit 24N365 for measurement.

Disconnect the hose RTD and use Hose Manual Mode or Hose

Resistance Mode to continue the job until repair can be completed.

Hose Resistance Mode requires a saved calibration factor. Refer to your proportioner operation manual to enable Hose Control

Modes.

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.

34 333024U

Troubleshooting

Error Location Type

T6NM MCM Sensor Error

Motor

Disconnected or loose motor temperature cable.

Failed motor temperature sensor.

Verify wiring between the motor temperature sensor and the module.

Measure resistance between pins

1 and 3 on motor temperature cable connector. Readings vary depending on temperature, but at room temperature (72° F /

22° C), the resistance should be approximately 1500 to 2500 ohms. An open circuit reading indicates a possible wire break.

Replace motor.

T8DA Heater A

T8DB Heater B

333024U

No

Temperature

Rise A

Bad RTD or bad

RTD placement against heater.

Loose heater wires or connector.

Bad heater element.

No

Temperature

Rise B

Started spraying before heater reached operating temperature.

Bad RTD or bad

RTD placement against heater.

Loose heater wires or connector.

Bad heater element.

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

Check for loose heater element wires or loose green connector at

TCM.

Confirm resistance of heater.

Heater resistance should be 18-21

Ω for each heater element, 9-12

Ω combined for 10 kW systems,

6-8 Ω for 15 kW systems, and 4-6

Ω for 20 kW systems. If out of tolerance, replace heater element.

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.

Check for loose heater element wires or loose green connector at

TCM.

Confirm resistance of heater.

Heater resistance should be 18-21

Ω for each heater element, 9-12

Ω combined for 10 kW systems,

6-8 Ω for 15 kW systems, and 4-6

Ω for 20 kW systems. If out of tolerance, replace heater element.

35

Troubleshooting

Error Location Type

T8DH

V1CM

V1IT

V2IT

V2MA

Hose

MCM

TCM

TCM

TCM

No

Temperature

Rise Hose

Low Voltage

MCM

Low Voltage

CAN

Low Voltage

CAN

Low Voltage

A

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.

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.

Mis-adjusted

24 VDC power supply.

Measure voltage at circuit breaker and ensure voltage is greater than

195 VAC.

Measure voltage of power supply.

Voltage should be 23-25 VDC.

If out of tolerance, adjust output voltage to approximately 24 VDC.

Reference schematics in repair manual. Trace all CAN cables and check all connections.

Short circuit or intermittent connection in wiring.

Bad 24 VDC power supply.

Mis-adjusted

24 VDC power supply.

If voltage can not be adjusted back into tolerance range, replace power supply.

Measure voltage of power supply.

Voltage should be 23-25 VDC.

If out of tolerance, adjust output voltage to approximately 24 VDC.

Reference schematics in repair manual. Trace all CAN cables and check all connections.

Short circuit or intermittent connection in wiring.

Bad 24 VDC power supply.

Loose connection or tripped circuit breaker.

Low incoming line voltage.

If voltage can not be adjusted back into tolerance range, 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.

36 333024U

Troubleshooting

Error Location Type

V2MB TCM

V2MH

V3IT

V3MA

V3MB

V3MH

V4CM

V4IT

TCM

TCM

TCM

TCM

TCM

MCM

TCM

Low Voltage

B

Low Voltage

Hose

High Voltage

CAN

High Voltage

A

High Voltage

B

High Voltage

Hose

High Voltage

MCM

High Voltage

CAN

Loose connection or tripped circuit breaker.

Low incoming line voltage.

Loose connection or tripped circuit breaker.

Low incoming line voltage.

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.

Bad 24 VDC power supply.

Incoming line voltage is too high.

Generator is set to a high-leg delta configuration.

Incoming line voltage is too high.

Generator is set to a high-leg delta configuration.

Incoming line voltage is too high.

Incoming line voltage is too high.

Bad 24 VDC power supply.

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.

If the generator is wired in a high-leg delta configuration and is consistently causing this error, change generator configuration to

208 VAC wye (star). Contact Graco

Technical Assistance.

Ensure incoming system power is wired properly. Verify voltage at each circuit breaker is between

195 and 264 VAC.

If the generator is wired in a high-leg delta configuration and is consistently causing this error, change generator configuration to

208 VAC wye (star). Contact Graco

Technical Assistance.

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.

333024U 37

Troubleshooting

Error Location Type

V4MA TCM

V4MB

V4MH

WBC0

WMC0

WMI0

WSUX

WXUD

WXUU

Z1DH

TCM

TCM

MCM

TCM

TCM

USB

ADM

ADM

Hose

High Voltage

A

High Voltage

B

High Voltage

Hose

Software

Version Error

Software

Update

Required

TCM Fan

Error

Configuration Error USB

USB

Download

Error

USB Upload

Error

Incoming line voltage is too high.

Incoming line voltage is too high.

Incoming line voltage is too high.

Incorrect software version.

MCM does not have line voltage.

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.

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.

Update the ADM with software version 4.01.001 or newer. See

Update ADM Software, page 79 .

TCM software must be updated to use Hose

Resistance Mode.

Fan inside TCM is not operating properly.

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

Log download failed.

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.

Low

Resistance

Hose Wire

Custom language file failed to upload.

Hose section removed or replaced without re-calibration.

Hose wire temperature is too low.

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

Re-calibrate the hose. Follow the

Calibration Procedure, page 73

.

Ensure hose wire temperature is above –4 ° F (-20 ° C).

38 333024U

Troubleshooting

Error Location Type

Z4DH Hose

Z6DH Hose

High

Resistance

Hose Wire

Sensor Error

Hose Wire

Hose section added or replaced without re-calibration.

Hose wire temperature is too high.

TCM is unable to sense hose wire resistance

Re-calibrate the hose. Follow the

Calibration Procedure, page 73

.

Ensure hose wire temperature is below 221 ° F (105 ° C).

• Ensure at least 50 ft (15.2 m) of heated hose is connected to the system.

• If the error cannot be cleared or the error regenerates consistently, replace the TCM.

333024U 39

Troubleshooting

Before performing any troubleshooting procedures:

1. Relieve Pressure. See

Pressure Relief Procedure, page 46

.

2. Turn main power switch OFF.

3. Allow equipment to cool.

Reactor ADM does not turn on.

Electric motor does not operate.

Electric motor runs erratically.

Cooling fans not working.

Pump output low.

No power.

Failed 24 V power supply.

Failed surge protector.

Loose connections.

Fan blade obstructed.

Defective fan.

Obstructed fluid hose or gun; fluid hose ID too small.

Worn piston valve or intake valve in displacement pump.

Pressure setpoint too high.

Turn main power switch ON.

Replace power supply.

Replace surge protector.

Check MCM connection 13.

Tripped circuit breaker (CB02).

Reset breaker, see

Repair Circuit Breaker Module, page 60 . Check 240VAC at

output of breaker.

Shorted windings.

Replace motor, see

Repair Electric Motor, page 59 .

Software bug.

Failed motor bearing.

Update to the latest software version. See

Update ADM Software, page 79

.

Replace motor, see

Repair Electric Motor, page 59 .

Loose wire.

Check. See

Electrical

Schematics, page 105

.

Remove obstruction.

Replace.

See

Replace Motor Fan, page 63

.

Open, clear; use hose with larger ID.

See pump manual.

Worn throat seals.

Reduce setpoint and output will increase.

Replace. See pump manual.

Fluid leak in pump packing nut area.

No pressure on one side.

Fluid leaking from heater inlet rupture disk (372).

Check if heater and PRESSURE

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

40 333024U

Troubleshooting

Before performing any troubleshooting procedures:

1. Relieve Pressure. See

Pressure Relief Procedure, page 46

.

2. Turn main power switch OFF.

3. Allow equipment to cool.

Hose heats but heats slower than usual or it does not reach temperature.

Hose does not maintain temperature while spraying.

Ambient temperature is too cold.

FTS failed or not installed correctly.

Low supply voltage.

If Hose Resistance Mode is enabled, the calibration factor may be inaccurate.

A and B setpoints too low.

Ambient temperature is too cold.

Flow too high.

Hose was not fully preheated.

Low supply voltage.

If Hose Resistance Mode is enabled, the calibration factor may be inaccurate.

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

Check FTS, see

Check RTD

Cables and FTS, page 70

.

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

Re-calibrate the hose.

Follow the

Calibration Procedure, page 73

.

Increase A and B setpoints.

Hose is designed to maintain temperature, not to increase it.

Increase A and B setpoints to increase fluid temperature and keep it steady.

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.

Re-calibrate the hose.

Follow the

Calibration Procedure, page 73

.

333024U 41

Troubleshooting

Hose temperature exceeds setpoint.

Erratic hose temperature.

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.

If Hose Resistance Mode is enabled, the calibration factor may be inaccurate.

Faulty FTS connections.

FTS not installed correctly.

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

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

Electrical Schematics, page

105

.

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 bundle has adequate insulation evenly covering the entire length and connection joints.

Re-calibrate the hose.

Follow the

Calibration Procedure, page 73

.

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 72 .

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

42 333024U

Troubleshooting

Hose does not heat.

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

Low hose heat.

FTS failed.

FTS not installed correctly.

Loose hose electrical connections.

Circuit breakers tripped.

Check FTS, see

Repair Fluid

Temperature Sensor (FTS), page 72 .

FTS should be installed close to end of hose in same environment as gun.

Verify FTS installation, see

Repair Fluid Temperature

Sensor (FTS), page 72 .

Check connections. Repair as necessary.

Reset breakers (CB01 ), see

Repair Circuit Breaker Module, page 60 .

Turn on hose heat zone.

Check. Increase if necessary.

Hose zone not turned on.

A and B temperature setpoints too low.

Shorted connection or failed hose heating element.

A and B temperature setpoints too low.

Hose temperature setpoint too low.

With power off, check the hose resistance with and without the whip hose attached. With the whip hose attached, the reading should be less than

3 ohm. Without the whip hose attached, the reading should be OL (open loop). See

Check Hose Wires, page 69 .

Increase A and B setpoints.

Hose designed to maintain temperature, not increase temperature.

Check. Increase if necessary to maintain heat.

Flow too high.

Use smaller mix chamber.

Decrease pressure.

Low current; FTS not installed.

Install FTS, see operation manual.

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

Loose hose electrical connections.

Allow hose to heat up, or preheat fluid.

Check connections. Repair as necessary.

Ambient temperature is to low Relocate hoses to a warmer area or increase A and B setpoints.

If Hose Resistance Mode is enabled, the calibration factor may be inaccurate.

Re-calibrate the hose.

Follow the

Calibration Procedure, page 73

.

333024U 43

Troubleshooting

Before performing any troubleshooting procedures:

1. Relieve Pressure. See

Pressure Relief Procedure, page 46

.

2. Turn main power switch OFF.

3. Allow equipment to cool.

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.

Primary Heater(s) does not heat.

Control of primary heat is abnormal; high temperature overshoots (T4DA, T4DB) occurs intermittently.

Heat turned off.

Temperature control alarm.

Signal failure from RTD.

Dirty RTD connections.

RTD not contacting heater element.

Failed heater element.

Signal failure from RTD.

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 65 .

See (T6DA, T6DB),

Error Codes

.

44 333024U

Troubleshooting

Before performing any troubleshooting procedures:

1. Relieve Pressure. See

Pressure Relief Procedure, page 46

.

2. Turn main power switch OFF.

3. Allow equipment to cool.

Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs.

The material ratio is significantly offset from 1

: 1.

The ADM displays low inlet pressure alarms, but the inlet pressure reading appears correct..

The material flow and ratio are not displayed on the ADM.

The flow meter repeatedly disables itself.

The k-factor entered in the

ADM is incorrect.

Cavitation is reducing the pump performance.

Update the k-factor. See

Replace Flow Meter, page 61 .

Increase the feed pump pressure.

Install a larger feed pump.

Air is trapped in the system, between the feed pumps and the heated hose.

While spraying, the inlet pressure drops below 30 psi.

Clean the y-strainer filter.

Install a smaller mix chamber in the spray gun.

Condition the material in the drums to the ambient temperature of the proportioner.

Re-route the feed hoses to a lower height.

Purge air from the system.

Refer to your ratio monitor manual for instructions.

Place the heated hose on flat ground. Spray material into a waste container until all air has left the system.

Increase the feed pump pressure.

Install a larger feed pump.

The flow meter is disabled.

Install a smaller mix chamber in the spray gun.

Enable the flow meter on

System Screen 1.

The inlet sensors are disabled.

Enable the inlet sensors. Inlet sensors must be enabled for the flow meter to function.

333024U 45

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

4. Close gun fluid inlet valves A and B.

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. Press to stop the pumps.

2. Turn off all heat zones.

5. Shut off feed pumps and agitator, if used.

6. 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. Engage gun piston safety lock.

3. Relieve pressure in gun and perform gun shutdown procedure. See your gun manual.

8. Disconnect the gun air line and remove the gun fluid manifold.

46 333024U

Shutdown

5. Press to deactivate the system.

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.

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

2. Turn off all heat zones.

7. Turn main power switch OFF.

3. Relieve pressure.

See

Pressure Relief Procedure, page 46 .

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.

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

333024U 47

Shutdown

8. Close all fluid supply valves.

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

9. Set PRESSURE RELIEF/SPRAY valves to SPRAY to seal out moisture from the drain line.

48 333024U

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, page 7

.

333024U 49

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.

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 49 .

2. See

Shutdown, page 47

.

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.

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.

50 333024U

Repair

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 46

.

2. Lift the lubricant reservoir (R) out of the bracket and remove the container from the cap. Holding the cap over a suitable container, remove the check valve and allow the lubricant to drain. Reattach the check valve to the inlet hose.

3. Drain the reservoir and flush it with clean lubricant.

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

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

6. Manually prime the ISO pump. Plug the small vent hole (H) between the tube grommets while squeezing the bottle to force the lubricant up the feed tube. Repeat until the fluid level reaches the ISO pump to force the air out.

7. Verify that the ISO pump is operating correctly by feeling the pulsation in the return tube during normal proportioner pump operation.

8. Ensure the vent hole stays open.

333024U 51

Repair

1. Perform

Shutdown, page 47 .

2.

Perform

Pressure Relief Procedure, page 46 .

3. Disconnect the flow meter cable.

4. Disconnect the heated hose from the flow meter. Remove the flow meter.

5. Remove four screws (VS) and remove the top cover (PL).

9. Reinstall the gears.

a. Place the gear with the magnets (MG) on the left pin of the housing.

6. Remove eight screws (MS) and remove the metal cap (SD).

7. Remove gears (GS) from the housing (HG).

8. Clean the gears and the fluid section of the housing with compatible solvent.

must be installed on the left side or the meter will not function. Install the gears as shown.

b. Position the gears perpendicular (90°) to each other and install the rounded bottom (RB) of the gear into the housing.

stay engaged and rotate together once installed. Reinstall the gears if they do not stay engaged or rotate together.

10. Reinstall the flow meter. Reconnect the heated hose and flow meter cable.

52 333024U

Repair

Clean EE -XP2

1. Perform

Shutdown, page 47 .

2.

Perform

Pressure Relief Procedure, page 46 .

3. Disconnect the flow meter cable.

4. Disconnect the heated hose from the flow meter. Remove the flow meter.

5. Remove four screws (A) and remove the top cover (B).

$$

9. Reinstall the gears.

a. Place the gear with the magnets (G) on the left pin of the housing.

&&

&&

''

((

))

WWLL DD

6. Remove eight screws (C) and remove the metal cap (D).

7. Remove gears (E) from the housing (F).

8. Clean the gears and the fluid section of the housing with compatible solvent.

WWLL DD must be installed on the left side or the meter will not function. Install the gears as shown.

b. Position the gears perpendicular (90°) to each other and install the rounded bottom (H) of the gear into the housing.

stay engaged and rotate together once installed. Reinstall the gears if they do not stay engaged or rotate together.

10. Reinstall the flow meter. Reconnect the heated hose and flow meter cable.

55 %%

** 66 90

°

++ **

WW LL DD

333024U 53

Repair

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.

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 Displacement Pump manual for pump repair instructions.

1. Press to stop the pumps.

2. Turn off heat zones.

3. Flush pump.

4. Press position.

to park the pumps in the down

5. Press to deactivate the system.

6. Turn main power switch off.

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.

7. Shut off both feed pumps. Close all fluid supply valves.

54 333024U

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.

Repair

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 A

Figure 1

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.

Pump B

Figure 2

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).

333024U 55

Repair

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.

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.

11. Apply thin film of TSL to barbed fittings.

Using two hands, support tubes (T) while pushing straight onto barbed fittings. Secure each tube with a wire tie between two barbs.

Note

Do not let tubes kink or buckle.

12. Reconnect fluid inlet (C).

13. Purge air and prime the system. See Reactor operation manual.

1. Press to stop the pumps.

2. Turn off heat zones.

3. Flush pump.

4. Press position.

to park the pumps in the down

5. Press to deactivate the system.

6. Turn main power switch off.

Figure 3

56 333024U

Repair

7.

Perform

Pressure Relief Procedure, page 46 .

8. Remove the system frame from the floor and

L-brackets.

13. Disconnect pump inlet and outlet lines.

Remove screws (113), washers (115), and bearing housing (103).

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 54

.

11. Remove cover (60) and screws (21).

12. Remove cycle counter (121) from housing by removing screw (122).

Figure 4

333024U 57

Repair

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 56

.

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 5

58 333024U

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.

Repair

6. Remove four screws (25) holding motor

(101) to bracket. Lift motor off unit.

2. Remove drive housing and pump assemblies.

See

Repair Drive Housing, page 56

.

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.

1. Place motor on unit. Thread motor cables into conduit as before. See

Electrical Schematics, page 105

.

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 58

.

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.

333024U 59

Repair

1. See

Before Beginning Repair, page 50

.

2. Using an ohmmeter, check for continuity across circuit breaker (top to bottom). If no continuity, trip breaker, reset, and retest.

If still no continuity, replace breaker as follows: a. Refer to

Electrical Schematics, page 105

, and circuit breaker table.

b. Follow Shutdown instructions. See

Shutdown, page 47

.

c. Refer to circuit breaker identification table and electrical diagrams in Reactor repair manual.

d. Loosen two screws connecting wires and bus bar to circuit breaker that will be replaced. Disconnect wires.

e. Pull locking tab out 1/4 in. (6mm) and pull circuit breaker away from the din rail. Install new circuit breaker. Insert wires and tighten down all screws.

CB01

CB02

CB03

CB04

CB05

50 A

20 A

40 A

40 A

40 A

Heated Hose

Motor Control Module

(MCM)

ISO Heater

RES Heater

Hose Heat Transformer

60 333024U

Repair

1. Perform

Shutdown, page 47 .

2. Disconnect inlet sensor cable from the fluid inlet assembly. Inspect cable for damage and replace if necessary. See

Electrical Schematics, page 105

.

1. Perform

Shutdown, page 47 .

2.

Perform

Pressure Relief Procedure, page 46 .

3. Disconnect the flow meter cable.

4. Disconnect the hose. Remove the flow meter.

5. Install the new flow meter and reconnect the hose.

Figure 6 Fluid Inlet Sensor

3. 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 105 .

To prevent damage to cable, route and secure cable in wire bundle with wire ties.

4. Replace sensor (602).

Figure 7 Flow Meter

6. Connect the flow meter cable.

7. Enter the k-factor on the System Screen 2 in

2 operation manual.

333024U 61

Repair

1. Perform

Shutdown, page 47 .

2.

Perform

Pressure Relief Procedure, page 46 .

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.

62 333024U

Repair

Shutdown system to avoid electric shock. To avoid burns, do not perform maintenance on the fan until the system has reached ambient temperature.

1. Perform

Shutdown, page 47

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.

1. Perform

Shutdown, page 47 .

2. Open cabinet door and disconnect fan cables from terminal blocks. See

Electrical Schematics, page 105

.

3. Remove four screws (21) from motor cover (11). If necessary, fold frame

(1) to remove motor cover (10). See

Repair Drive Housing, page 56 , 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 9

Figure 8

333024U 63

Figure 10

64

Repair

1. Perform

Shutdown, page 47 .

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

3. Remove bolt (20) on top of the heater junction box (48).

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

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

6. Remove four screws (23), washers (29), and fan (32).

7. Install fan in reverse order.

333024U

7. Relieve pressure.

See

Pressure Relief Procedure, page 46 .

Repair

8. Wait for heater to cool.

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

1. Press to stop the pumps.

2. Turn off heat zones.

3. Flush pump.

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

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.

Element Ohms

E-30 (10 kw)

E-XP2,

E-30 (15 kw)

Heater

Wattage

10,200

15,300

2,550

2,550

18–21 per element

18–21 per element

333024U

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.

65

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 65 .

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).

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 11

66 333024U

1. Perform

Shutdown, page 47 .

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.

is ohms, the overtemperature switch needs to be replaced. Go to step 5.

is 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.

Repair

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.

333024U 67

Repair

1. Perform

Shutdown, page 47 .

2. Wait for heater to cool.

3. Remove heater cover (10).

4. Cut cable ties around the woven wrap with the RTD cable (212).

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

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

RTD housing (H). Do not remove the adapter

(206) unless necessary. If adapter must be removed, ensure that mixer (210) is out of the way when replacing the adapter.

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

8. Replace RTD (212).

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

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

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

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

TCM.

10. Replace heater shroud (10).

11. Follow startup instructions in the operation manual. Turn on A and B heat simultaneously to test. Temperatures should rise at same rate. If one is low, loosen ferrule nut (N) and tighten RTD housing (H) to ensure RTD tip contacts element (212) when ferrule nut (N) is retightened.

Figure 12

68 333024U

Repair

Refer to your heated hose manual for replacement hose parts.

1. Perform

Shutdown, page 47

NOTE: Whip hose must be connected.

2. Remove the cover.

3. For series A only: Disconnect hose connector

(D) at Reactor.

4. Disconnect system wires from terminal block.

5. Use and ohmeter to check between the hose wires. There should be continuity.

6. If the hose fails the test, retest at each length of hose from the system out to the gun, including whip hose, until the failure is isolated.

7. Reconnect wires and install the cover.

Figure 13

333024U 69

Repair

1. Perform

Shutdown, page 47 .

2. Disconnect RTD cable (C) at Reactor.

3. Test with an ohmmeter between pins of cable connector C.

Note

Do not touch outer ring with test probe.

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.

3 to 1 See

RTD Resistance vs.

Temperature, page 71

.

3 to 4 See

RTD Resistance vs.

Temperature, page 71

.

1 to 4 0.2 - 0.4 ohms at the FTS (each 50 ft cable adds 2.5 ohms)

2 to any infinity (open)

4. Retest at each length of hose, including whip hose, until failure is located.

5. If the FTS is not reading properly at the end of the hose, connect FTS directly to RTD cable (C) at the manifold.

Heated Hose

Figure 14

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

3 to 1 / brown to blue

3 to 4 / blue to black

1 to 4 / brown to black

2 to any

/ N/A

See

RTD Resistance vs.

Temperature, page 71 .

See

RTD Resistance vs.

Temperature, page 71 .

0.2 - 0.4 ohms at the FTS (each

50 ft cable adds 2.5 ohms) infinity (open)

70 333024U

333024U

1117

1155

1194

1232

1271

1309

1347

1385

843

882

922

961

1000

1039

1078

-40 (-40)

-30 (-22)

-20 (-4)

-10 (14)

0 (32)

10 (50)

20 (68)

30 (86)

40 (104)

50 (122)

60 (140)

70 (158)

80 (176)

90 (194)

100 (212)

Repair

71

Repair

The Fluid Temperature Sensor (FTS) is supplied with the system. Install FTS between main hose and whip hose. See your heated hose manual for instructions.

Figure 15

1. Perform

Shutdown, page 47 .

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 70 .

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.

72 333024U

Repair

3. Wait while the system measures the hose resistance.

To prevent damage to the heated hose, a hose calibration is required if any of the following conditions are true:

• The hose has never been calibrated before.

• A section of hose has been replaced.

• A section of hose has been added.

• A section of hose has been removed.

the same ambient temperature to get the most accurate calibration.

1. Enter Setup Mode and navigate to System screen 3, then press the Calibrate soft key

.

NOTE: calibration procedure, the system will wait up to five minutes to allow the wire temperature to equalize.

2. Press the Continue soft key to acknowledge the reminder to have the hose at ambient conditions.

32 °F (0 °C) during calibration.

333024U 73

Repair

4. Accept or cancel the hose calibration.

NOTE: displayed if the system was able to measure the hose wire resistance.

See

Electrical Schematics, page 105 .

1. Check wires and transformer: a. See

Shutdown, page 47 .

b. Shut off CB05.

c. Use an ohmmeter to test for continuity between terminals 2 and 4 of CB05. If there is no continuity, check transformer.

2. Check transformer: a. See

Shutdown, page 47 .

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.

74 333024U

Repair

See

Electrical Schematics, page 105 .

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 indicator on the circuit breaker GREEN. Use an ohmmeter to test for continuity between two transformer wires in terminal blocks TB17 and TB18; there should be continuity.

c. Close the circuit breaker CB01.

Figure 16 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.

333024U 75

Repair

4. Install new power supply (535) in reverse order.

1. Perform

Shutdown, page 47 .

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

3. Remove lower dinrail cover (48).

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

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

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

7. Install transformer (17) in reverse order.

Figure 18 24 VDC Power Supply

1. Loosen connections on terminals 1 and 3 on

CB13. See

Electrical Schematics, page 105 .

2. Loosen connections on input to power supply (805) on N and L connections. See

Electrical Schematics, page 105

.

3. Remove two screws (612), washers (611), and surge protector (705) from enclosure.

4. Install new surge protector (705) in reverse order.

NOTE: power supply are interchangeable.

Figure 17

1. Perform

Shutdown, page 47 .

2. Disconnect input and output cables from both sides of the power supply. See

Electrical Schematics, page 105

.

3. Insert a flat head screw driver in the mounting tab on the bottom of the power supply to remove from the din rail.

76

Figure 19 Surge Protector

333024U

Repair

1. Perform

Shutdown, page 47 .

2. Disconnect connectors from MCM (63).

Disconnect two power cables. See

Electrical Schematics, page 105

.

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 105

.

1. Perform

Shutdown, page 47 .

2. Open electrical enclosure door (61).

3. Disconnect all connectors from the TCM

(453).

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

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

6. Update software by inserting an upgrade token into the ADM and cycling system power. Wait until the update is complete before removing the token and restarting the system.

Figure 20 Replace MCM

Figure 21 Replace TCM

333024U 77

Repair

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.

4. Update software by inserting an upgrade token into ADM and cycling system power.

Wait until the update is complete before removing the token and restarting the system.

Repair kit GCA modules are shipped pre-programmed and with upgrade token

(part number 17E206). If software version upgrade is necessary, follow the procedure in the manual provided.

Figure 22

78 333024U

Repair

NOTE: may see the following screens:

Software is checking which modules will take the available updates.

1. Turn the main power switch OFF.

Status of the update with approximate time until completion.

2. Open the top and bottom door latches to the electric cabinet.

3. Open the electrical cabinet. Use a Phillips screwdriver to loosen the four ADM mounting screws on the inside of the cabinet door.

4. Lift the ADM up and pull it away from the

Reactor to unseat the mounting screws. For easy reassembly, leave the loosened screws attached to the ADM.

5. Remove the token access panel on the back of the ADM.

6. Insert and press the software upgrade token firmly into the slot.

the token.

7. Close the electrical cabinet.

8. Turn the main power switch ON.

Updates are compete. Icon indicates update success/failure. See the following table.

Update successful

Update unsuccessful

Update complete, no changes necessary

Modules were updated or did not require an update; however, one or more modules need to be updated manually with a token.

A status is shown while software is updating to indicate progress. To prevent corrupting the software load, do not remove the token until the status screen disappears.

9. Press screen.

to continue to the operation

10. Turn the main power switch OFF.

11. Remove the software update token.

12. Replace the token access panel.

13. Open the electrical cabinet, remount the

ADM, and fully tighten the four mounting screws.

14. Close the lock and the cabinet door with the door latches.

333024U 79

Parts

80 333024U

Parts

1

2

3

Apply anaerobic polyacrylate pipe sealant to all non-swiveling pipe threads.

Apply grease to tube fitting threads. Torque to 43 ft-lb (58 N•m).

Safety labels are from label sheet (68).

333024U 81

Parts

1

2

10

11

12

Ref Part

3

4

5

6

7

8

9+

13

14

15

- - FRAME

- - -

ENCLOSURE, electrical; see

Electrical

Enclosure, page 98

246995 BOTTLE, assembly, complete

16X531

24U843

24U842

24U704

BRACKET, tsl, bottle

HEATER, 10kw, 2 zone, RTD; see

Fluid Heater, page

90

HEATER, 7.5kw,

1 zone, RTD; see

Fluid Heater, page

90

MANIFOLD, fluid; see

Fluid Manifold, page 96

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,

15 kW

24U838 TUBE, b-side, inlet,

10kw

24U839 TUBE, b-side, outlet, 15 kW

24U840 TUBE, b-side, outlet, 10kw

24U834

24U833

TUBE, a-side, inlet,

10 kW

TUBE, a-side, inlet,

15 kW

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

2

1

4

1

1

1

1

1

1

1

1

1

1

2

1

4

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

2

1

4

1

1

1

1

1

1

1

1

1

1

2

1

4

1

1

1

1

1

1

1

1

82 333024U

Parts

Ref Part

16

17

18

19

20

21

22

23

24

25

29

30

31

32

33

26

27

28

33a

24U836

24U835

15K742

15B456

125643

119865

118444

117683

113796

112731

111800

111218

110996

104859

103181

100020

115836

24U847

24R685

24U849

TUBE, a-side, outlet, 10 kW

TUBE, a-side, outlet, 15 kW

TRANSFORMER,

4090va, 230/90

GASKET, manifold

FITTING, elbow,

3/8 npt x #8 jic

SCREW, mch, hex serrated; 3/8 in. x

1/4–20

SCREW, mch, slot hex wash hd; 1/2 in. x #10–24

SCREW, mch, phil pan hd; 1.5 in. x

#6–32

SCREW, flanged, hex hd; 3/4 in. x

1/4–20

NUT, hex, flanged

SCREW, cap, hex hd; 7/32 in. x

5/16–18

CAP, tube, square

NUT, hex, flange head

SCREW, tapping pnhd; 5/16 in. x

#10–16

WASHER, lock ext

WASHER, lock

GUARD, finger

FAN, cooling,

120mm, 24vdc

ENCLOSURE, lower, dinrail; includes

33a-33d

KIT, module, din rail, heater; see

Heater and Transformer

Terminal Block

Module, page 101

272010 272011 272012 272110 272111 272112

1 1

1

1

2

9

12

8

11

6

4

2

8

2

4

2

1

2

1

1

1

1

1

2

9

12

8

13

6

4

2

8

2

4

2

1

2

1

1

1

1

1

2

9

12

8

13

6

4

2

8

2

4

2

1

2

1

1

1

1

2

9

12

8

11

6

4

2

8

2

4

2

1

2

1

1

1

1

1

2

9

12

8

13

6

4

2

8

2

4

2

1

2

1

1

1

1

1

2

9

12

8

13

6

4

2

8

2

4

2

1

2

1

1

333024U 83

Parts

Ref Part

33b 16W667

33c

- - -

39

40

41

33d 113505

34

35

36

37

38

151395

120685

114269

125625

127277

127278

127282

16X095

42◊ 125871

43◊ 24K207

44◊ 24R725

47

48

49

50

45◊ 106569

46‡ 24T242

24P970

104765

16V268

15Y118

24V150

24V151

INSULATOR, FOAM

COVER, bottom, dinrail

NUT, keps, hex hd

WASHER, flat

GROMMET

GROMMET, rubber

TIE, cable, fir tree

BOLT, carriage,

1/2-13 x 3.5 l

NUT, keps, hex

GROMMET, rubber

CONNECTOR, power, male, 4 pin

TIE, cable, 7.5 in.

KIT, fts, rtd, single hose

BRIDGE, plug-in jumper, ut35

TAPE, electrical

CABLE, over-temp,

10 kW Reactor

CABLE, over-temp,

15 kW Reactor

PLUG, pipe headless

COVER, top, dinrail

LABEL, made in the

USA

PROPORTIONER, module, E-30; see

Proportioner

Module, page 88

PROPORTIONER, module, E-XP2; see

Proportioner

Module, page 88

272010 272011 272012 272110 272111 272112

1 1 1 1 1 1

1 1 1 1 1 1

1

4

2

1

5

4

4

4

1

25

1

4

1

1

2

1

1

1

1

4

2

1

6

4

4

4

1

25

1

4

1

1

2

1

1

1

1

4

2

1

6

4

4

4

1

25

1

4

1

1

2

1

1

1

1

4

2

1

5

4

4

4

1

25

1

4

1

1

2

1

1

1

1

4

2

1

6

4

4

4

1

25

1

4

1

1

2

1

1

1

4

4

1

25

1

4

1

1

1

1

1

1

2

1

1

4

6

4

84 333024U

Parts

Ref Part

51 24U321

56

24U320 KIT, assembly, pair, std, reactor; see

Fluid Inlet Kits, page 103

53‡ 24T050 CABLE, m8 4p f to m12 8p m 1.5m

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

55 24U845 TUBE, pressure relief

191892 FITTING, elbow, street, 90 deg; 1/8 npt

57

KIT, asm, pair, elite, reactor; see

Fluid Inlet Kits, page 103

58

116746 FITTING, barbed, plated; 1/8–27 npt x 1/4 in. hose I.D.

16W218 LABEL, branding, e-30

16W321 LABEL, branding, e-30, elite

16W215 LABEL, branding, e-xp2

16W322 LABEL, branding, e-xp2, elite

59◊ 16U530 MODULE, system surge protector

(spare)

60

61

287292 COVER, drive, plastic

16W766 COVER, control, box

62

63

16W596 LATCH, door

24U832 MODULE, MCM

24U831

64◊ 206995

65◊ 206994

MODULE, MCM

FLUID, tsl, 1 qt.

FLUID, tsl 8 oz bottle

67◊ 114225 TRIM, edge protection; 1.6

ft (0.48 m)

272010 272011 272012 272110 272111 272112

1 1 1

1

2

2

2

1

1

2

1

2

1

1

1

1

1

2

2

2

1

1

2

1

2

1

1

1

1

1

2

2

2

1

1

2

1

2

1

1

1

1

1

2

2

2

2

1

1

2

1

2

1

1

1

1

1

2

2

2

2

1

1

2

1

2

1

1

1

1

1

2

2

2

2

1

1

2

1

2

1

1

1

1

333024U 85

Parts

Ref Part

68

70

71

72

73

74

75

16X250

127296

16X129

117502

117677

299521

299520

LABEL, identification

SCREW, mchn, pnh, w/ext tooth wash;

M4 x 0.7

SCREW, mach, phillips, tooth wash; 5/16 x 8–32

FITTING, reducer

#5 x #8 (JIC)

FITTING, reducer

#6 x #10 (JIC)

CAP, 1/2-20 jic cap-aluminum

CAP, 9/16-18 JIC cap-aluminum

79+

81

261843 FLUID, oxide inhibitor

82

83◊

16V806

15V551

24K409

84◊

85

88

89

24K411

127276

BAR, 55 gal chem.

measure. B side

BOLT, carriage,

1/2-13 x 2.5 l

MODULE, ADM 24U854

16W967 FITTING, swivel,

3/4 npt x 1 npsm

118459 FITTING, union, swivel, 3/4 in.

90

91

16W213 LABEL, branding, reactor

115942 NUT, hex, flange head

92‡ 15D906

BRACKET, wall, mount

SHIELD, membrane, ADM

(10 pack)

BAR, 55 gal chem.

measure; A side

93◊

94

127368

127377

SUPPRESSOR, round snap ferrite

.260

SLEEVE, split, wire,

1.50 ID

TIE, cable, 6 in.

272010 272011 272012 272110 272111 272112

1 1 1 1 1 1

4

10

1

1

1

1

1

2

1

1

1

2

1

2

2

4

1

2

4

10

1

1

1

1

1

2

1

1

1

2

1

2

2

4

1

2

4

10

1

1

1

1

1

2

1

1

1

2

1

2

2

4

1

2

4

10

1

1

1

1

1

2

1

1

1

2

1

2

2

4

1

2

1

4

10

1

1

1

1

1

2

1

1

1

2

1

2

2

4

1

2

1

4

10

1

1

1

1

1

2

1

1

1

2

1

2

2

4

1

2

1

86 333024U

Parts

Ref Part

95

96◊

16X154

333091

LABEL, InSite

MANUAL, quick guide, startup

97◊ 333092 MANUAL, quick guide, shutdown

98* 24W204 ENCLOSURE, terminal block

ENCLOSURE, cover

LABEL, caution

99* 25A234

100

*▲

189930

172953 101

*▲

102

*

17D955

103

*

113161

104

- - -

105

- - -

106 17R703

LABEL, ground

BRACKET, mounting

SCREW, flange, hex hd

METER, flow, ISO

METER, flow, RES

CABLE, GCA,

M12–5P, m/f, 0.3

m

107 17Y983

108 25E540

CABLE, GCA,

M12–5P, m/f, 2.0

m

CONNECTOR, splitter

272010 272011 272012 272110 272111 272112

1 1 1

1 1 1 1 1 1

1

1

1

1

1

1

2

1

1

1

1

1

1

2

1

1

1

1

1

1

2

1

1

1

1

1

1

2

1

1

1

2

1

1

1

1

1

1

1

2

1

1

1

2

1

1

1

1

1

1

1

2

+

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

Not shown.

See

Electrical Schematics, page 105 .

Part applies to Series A only.

*

Part applies to Series B only.

Part includes four screws (Ref. 21).

Part included in kit 25N930 for E-30. Parts included n kit 25P388 for E-XP2.

333024U 87

Parts

for EE for EE -XP2

88

1

2

3

6

7

4

5

Torque to 190–210 in-lb (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-lb (27–40.6 N•m).

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

Torque to 70–80 ft-lb (95–108 N•m).

Flat side faces up.

333024U

Parts

Ref

101

102*

103

104‡

105†

106◊

107‡

108‡

110†

111

112*

113

114

115◊

116

118*

120

121

122

125

126 ▲

Part

24U050

17W869

257355

245927

287290

241279

245971

245972

114699

114672

183169

183210

15C753

114666

106115

246831

246832

193031

193394

116192

116618

24P728

127301

187437

192840

Description

MOTOR, brushless, double ended, 2 hp

KIT, drive housing

HOUSING, bearing

HOUSING, bearing

KIT, repair, gear

KIT, rod, connecting

PUMP, displacement, B-side

PUMP, displacement, B-side

WASHER, thrust, steel colored

WASHER, thrust, copper 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-side

PUMP, displacement, A-side

NUT, retaining

NUT, retaining

WASHER, thrust (1595)

MAGNET

SWITCH, reed, M8 4-pin

SCREW, hex head, thread cut, 4-40 x 0.375

LABEL, torque

LABEL, warning

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

See pump repair manual 309577 for repair kits.

Spring (110) included in Connecting Rod

Kit 241279.

Gear Repair Kit includes washers (107) and

(108).

*

24V150

E-30

1

2

1

2

2

2

2

2

1

1

8

8

4

2

1

2

2

10

2

2

2

2

2

2

2

1

1

24V151

E-XP2

1

2

2

8

8

1

2

2

2

4

10

2

2

1

2

Drive Housing Repair Kit includes housing

(1), screws (5), and washer (1) to replace one end.

Part included in A-side Pump Repair Kits

25E300 (for E-30) and 25E302 (for E-XP2).

Part included in B-side Pump Repair Kits

25E301 (for E-30) and 25E303 (for E-XP2).

333024U 89

Parts

90

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).

333024U

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

247520 HOUSING, rupture disc

Part included in 24L973 Heater RTD

Repair Kit.

2

2

4

2

2

2

4

1

24U843 24U842

1

1

4

4

4

2

2

3

5

2

3

1

1

2

3

1

1

1

3

1

Parts

333024U 91

Parts

1

2

Torque to 90–100 in-lb (11 N•m).

Torque to 15–25 in-lb (2 N•m).

WWLL EE

92 333024U

701

703

- - -

25C298

HOUSING, 3/4" orb, w/ pins, sub-assembly

GEAR, magnets, sd/matrix

704 15V690PKG GEAR, oval, metering element

705 17Y063PKG GASKET, meter

706 131971PKG O-RING, 031, fx75

707 17Y062PKG CAP, meter

708 108787 SCREW, cap, sch

709 110163PKG SCREW, thd forming, pnh

710 25E134PKG BOARD, assembly, ratio monitor

711 - - -

COVER, meter

712 131172

716

SCREW, mach, torx pan hd

25E486PKG FITTING, swivel, JIC-08, 3/4-16 orb, A-side, ISO

717

25E474PKG FITTING, swivel, JIC, 10 x 3/4-16 orb, B-side, RES

117677 FITTING, reducer #6 x #10 (JIC), B-side, RES

718

719

720

721

117502

- - -

- - -

070268

17Y236

FITTING, reducer #5 x #8 (JIC), A-side, ISO

LABEL, blank

LABEL, branding, G-2000

LUBRICANT, grease

722

17Y235

070408

FITTING, adapter, sae-orb x JIC, A-side, ISO

ADAPTER, str thread, B-side, RES

SEALANT, pipe, sst

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

Parts

1

8

1

1

1

1

1

2

1

1

4

1

1

1

1

1

1

1

1

1

1

333024U 93

Parts

EE XP2

1

2

Torque to 396–420 in-lb (44–47 N•m).

Torque to 15–25 in-lb (2–3 N•m).

WWLL DD

94 333024U

801 18A877

802 25C298

803 15V690

804 166623

HOUSING, high pressure meter

GEAR, magnets, sd/matrix

GEAR, oval, metering element

PACKING, o-ring

805 192387

806 109114

807

809

810 18A879

811

18A878

808 25E134

110163

PIN, dowel

SCREW, cap, sch

CAP, high pressure meter

BOARD, assy reactor ratio monitor

SCREW, thd forming, pnh

COVER, high pressure meter

25E486PKG FITTING, swivel, JIC-08, 3/4–16 orb

812

813

25E474PKG FITTING ,swivel, JIC, 10X3/4-16 orb

117502 FITTING, reducer, #5 x #8 (JIC)

117677

113360

814 070268

FITTING, reducer, #6 X #10 (JIC)

LABEL, blank

LUBRICANT, grease

815 17Y236

17Y235

816 18A979

817 112310

818 120853

FITTING, 45 deg elbow, 3/4 x 3/4

FITTING, 45 deg elbow, 3/4 X 7/8

LABEL, branding, G-3500

SCREW, cap, sch

PIN, dowel

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

Parts

1

1

1

1

1

1

2

1

1

1

1

1

4

2

8

1

1

2

1

1

1

333024U 95

Parts

96

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.

333024U

Parts

401† 255228 MANIFOLD, fluid

402◊ 247824 KIT, valve, cartridge, drain

402a◊ 158674 O-RING, BUNA-N

402b◊ 247779 SEAL, seat, valve

403 102814 GAUGE, press, fluid

404

405

406

407

162453 FITTING, 1/4 NPSM X

1/4 NPT

15M669 SENSOR, pressure, fluid outlet

247788 HANDLE, red

247789 HANDLE, blue

408

411‡

412

112309 NUT, hex, jam

17Y236 FITTING, 3/4 ORB x #8

JIC

117556 FITTING, 1/2 NPT x #8

JIC

121312 FITTING, elbow, 3/4

SAE x 1/2 JIC

100840 FITTING, elbow, street 413

414 111457 O-RING, PTFE

415▲ 189285 LABEL, caution

416 150829 SPRING, compression

1

1

2

1

1

1

2

2

1

1

1

2

2

2

2

1

2

419‡ 17Y235 FITTING, 3/4 ORB x

#10 JIC

117557 FITTING, 1/2 NPT x

#10 JIC

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

1

1

Part included in the following complete valve kits:

ISO Valve Kit (left/red) handle 255149.

Resin Valve Kit (right/blue handle)

255150.

Valve Set Kit (both handles and grease gun) 255148.

Part includes replacement ORB fittings

(part 411 and 419).

To order a replacement part, verify the type of fitting used with your fluid manifold (1/2 NPT or 3/4 ORB fitting).

333024U 97

Parts

98 333024U

Parts

Ref Part Description

451 24U087 ENCLOSURE

453

454

24U855 MODULE, TCM

455

457

24U848 FAN, cooling, 80 mm,

24VDC

24R736 SWITCH, disconnect, door mounted

117666 TERMINAL, ground

458

459

460

461

462

463

255048 NUT, strain relief, M40 thread

255047 BUSHING, strain relief,

M40 thread

123967 KNOB, operator disconnect

115942 NUT, hex, flange head

103181 WASHER, lock external

464

466

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

194337 WIRE, grounding, door

113505 NUT, keps, hex head

Qty

1

1

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

NOTE:

Electrical Schematics, page 105

.

1

1

1

1

1

1

5

2

2

1

6

Ref

468

469

470

Part Description

111218 CAP, tube, square

114269 GROMMET, rubber

127282 GROMMET, rubber

471

472

127278 NUT, keps, hex

16W925 GASKET, enclosure, foam

473

474

475

16W926 GASKET, enclosure, foam

24R735 CABLE, CAN power, M12 female, pigtail

127068 CABLE, CAN, female/female 1.0 meter

24U850 MODULE, breaker 476

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

478 ▲ 16X050 LABEL, safety; enclosure

479 ▲ 16X049 LABEL, safety; multi

Qty

4

2

2

2

1

2

1

2

1

1

1

1

333024U 99

Parts

See

Electrical Schematics, page 105 .

1

2

3

Torque to 6–8 in.-lb (0.7–1 N●m)

Torque to 28–33 in.-lb (3–3.8 N●m)

Torque to 23–26 in.-lb (2.6–3 N●m)

100 333024U

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 102

Qty

1

1

1

Ref

504

505

Part

16U526

16U530

Description

MODULE, din rail, circuit breakers; see

Power Supply and

Terminal Block Module, page 102

MODULE, sys surge protector

Qty

1

1

Ref

511

512

513

514

515

516

517

Part

24T315

126811

126383

126382

120570

24R758

24R759

Description

RAIL, DIN; 35 mm x 7.5

mm x 7 in.

BLOCK, clamp, end

COVER, end

BLOCK, terminal

BLOCK, terminal

BLOCK, terminal,

UT-2.5, red

BLOCK, terminal,

UT-2.5, black

Qty

1

1

2

6

2

1

1

Ref

518*

*

Part

120573

Description

BRIDGE, jumper

Qty

Jumpers are used to select the wattage of the electric heaters used in your proportioning system. When the

Integrated PowerStation accessory is installed, the jumpers are removed.

2

333024U 101

Parts

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

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

120838

24R722

Description

RAIL, DIN; 35 mm x 7.5

mm x 8.625 in.

TERMINAL, end stop

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

102 333024U

Parts

55 HH DD FF WWRR UU (( OOLLWWHH

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.

55 HH DD FF WWRR UU (( OOLLWWHH

WWLL DD

333024U 103

Parts

601

602

160327 FITTING, union adapter, 90°

118459 FITTING, union, swivel, 3/4 in.

603‡ 247503 MANIFOLD, strainer, inlet

604 24U852 THERMOMETER, dial

605

606†

24U853 GAUGE, press, fluid

- - FILTER, replacement

607†‡ 128061 PACKING, o-ring

608‡ 16V879 CAP, filter

609‡ 555808 PLUG, 1/4mp w/ hex hd

610

613

614

615

616

617

618

15D757

109077 VALVE, ball 3/4 npt

C20487 FITTING, nipple, hex

24U851 TRANSDUCER, pressure, temperature (includes foam)

158586

158383 FITTING, union adapter

624545

HOUSING, thermometer, Viscon HP

FITTING, bushing

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

*

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.

1

2

2

2

2

2

2

24U320 25N920

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

104 333024U

To TCM

Rea c tor 2 E-30

Rea c tor 2 E-XP2

24U831

24U832

333024U

ti40831a

Electrical Schematics

105

Electrical Schematics

PS-L

PS-N

CB-B

CB-A ti22680b

106 333024U

24U855

1

16V515

TO HTD HOSE

ELEC ENCL

GND STUD

2

Electrical Schematics

16U526 ti35626a

1

2

Locate near TCM.

Heated hose wire termination enclosure

(series B only).

333024U

ti35627a

107

Reactor 2 Repair Spare Parts Reference

403

405

211,

212

--

--

--

106,

115

106,

115

106,

115

106,

115

606,

607

402

15C852

15C851

246963

246964

24V020

247824

102814

15M669

24L973

24K207

24N450

24N365

E-30 Pump Repair Kit

E-XP2 Pump Repair Kit

Pump

Pump

E-XP2 Wet Cup Repair Kit

E-30 Wet Cup Repair Kit

Pump

Pump

Y-Strainer Filter and Gasket Kit

(pack of two each)

Drain Valve Cartridge

Fluid Pressure Gauge

Pressure Sensor

RTD Repair Kit

Y-Strainer

Fluid Manifold

Fluid Manifold

Fluid Manifold

Heater

Hose FTS

RTD Cable (50 ft. replacement)

RTD Cable Test Kit (To assist measuring

RTDs and RTD cable resistances)

Hose

Hose

Hose

108 333024U

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.

To prevent system damage, do not pressurize the system above the line for the gun tip size being used.

2000

(138)

AR4242

(01)

1500

(103)

PRESSURE psi (bar)

1000

(69)

AR5252

(02)

AR6060

(03)

AR7070

(04)

E-30

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)

333024U 109

Performance Charts

PRESSURE psi (bar)

3500

(241)

3000

(207)

2500

(172)

2000

(138)

1500

(103)

1000

(69)

500

(34)

0

AR2020

(000)

AR2929

(00)

E-XP2

AR4242

(01)

0.5

(1.9)

1.0

(3.8)

FLOW gal./min (l/min)

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

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)

110 333024U

Performance Charts

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

E-XP2

XR2323

(RTM040)

XR2929

(RTM040)

MR3535

(RTM040)

XR3535

(RTM055)

XR4747

(RTM055)

MR4747

(RTM055)

0.5

(1.9)

1

(3.8)

FLOW gal./min (l/min)

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)

MF4747

(FTM638)

MF5757

(FTM638)

XF5757

(FTM638)

0.6

(2.3)

0.8

(3.0)

1

(3.8)

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) based on typical operating conditions. Periods of continuous spraying or very high ambient temperatures reduce the performance envelope.

333024U 111

Technical Specifications

2 EE and EE -XP2

E-30

E-XP2

E-30

E-XP2

E-30

E-XP2

Length

E-30

E-XP2

Temperature

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

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

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

14 MPa, 140 bar

24.1 MPa, 241 bar

88°C

88°C

13.5 kg/min

7.6 lpm

94 m

0.1034 liter

0.0771 liter

-7° to 49°C

112 333024U

Technical Specifications

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)

87.3 dBA

79.6 dBA

93.7 dBA 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)

Component A ISO) and

Component B (RES)

Component A (ISO)

Component B (RES)

86.6 dBA

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

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

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

Size

Maximum Pressure 250 psi

1/4 NPSM(m)

1.75 MPa, 17.5 bar

26.3 in.

63 in.

15 in.

668 mm

1600 mm

381 mm

Width

Height

Depth

E-30, 10 kW

E-30, 15 kW

E-30, 10 kW Elite

E-30, 15 kW Elite

E-XP2

E-XP Elite

Material

315 lb

350 lb

320 lb

355 lb

345 lb

350 lb

143 kg

159 kg

145 kg

161 kg

156 kg

159 kg

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

333024U 113

Notes

114 333024U

for Reactor

®

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

24U050

24U051

24U831

24U832

24U855

24U854

All other Reactor 2 parts

Electric Motor

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

36 Months or 3 Million Cycles

12 Months

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified,

Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS

INCLUDING

FOR

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above.

The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty hereunder must be brought within the latter of two (2) years of the date of sale, or one (1) year the warranty period expires.

GRACO

AND

MATERIALS manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

For the latest information about Graco products, visit www.graco.com.

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 www.graco.com

Revision U, December 2022

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