Graco 312066z User Manual
Repair - Parts
312066Z
Electric, Heated, Plural Component Proportioner. For spraying polyurethane foam and
polyurea coatings. For professional use only.
Not approved for use in European explosive atmosphere locations.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
EN
See page 3 for model information, including
maximum working pressure and approvals.
Model E-XP1 Shown
TI10953a
9902471
Conforms to ANSI/UL
Std. 499 Certified to
CAN/CSA Std.
C22.2 No. 88
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Supplied Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Temperature Control Diagnostic Codes . . . . . . . . 8
E01: High fluid temperature . . . . . . . . . . . . . . . . 8
E02: High zone current . . . . . . . . . . . . . . . . . . . . 9
E03: No zone current . . . . . . . . . . . . . . . . . . . . 10
E04: Fluid Temperature Sensor (FTS) or
thermocouple disconnected . . . . . . . . . . . . 10
E05: Circuit board overheated . . . . . . . . . . . . . 10
E06: Communication cable unplugged . . . . . . . 10
Motor Control Diagnostic Codes . . . . . . . . . . . . . 11
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
E21: No component A transducer . . . . . . . . . . . 12
E22: No component B transducer . . . . . . . . . . . 12
E23: High fluid pressure . . . . . . . . . . . . . . . . . . 12
E24: Pressure Imbalance . . . . . . . . . . . . . . . . . 12
E25: High line voltage . . . . . . . . . . . . . . . . . . . . 14
E26: Low line voltage . . . . . . . . . . . . . . . . . . . . 14
E27: High Motor Temperature . . . . . . . . . . . . . 14
E28: High current in motor . . . . . . . . . . . . . . . . 14
E29: Brush Wear . . . . . . . . . . . . . . . . . . . . . . . . 14
E31: Motor Control Failure
(E-30 and E-XP2 only) . . . . . . . . . . . . . . . . 15
E32: Motor Control Overtemperature . . . . . . . . 16
Communication Diagnostic Codes . . . . . . . . . . . 16
E30: Momentary loss of communication . . . . . . 16
E99: Loss of communication . . . . . . . . . . . . . . . 16
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Reactor Electronics . . . . . . . . . . . . . . . . . . . . . . 18
Primary Heaters (A and B) . . . . . . . . . . . . . . . . 20
Hose Heat System . . . . . . . . . . . . . . . . . . . . . . 21
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Before Beginning Repair . . . . . . . . . . . . . . . . . . 23
Pressure Relief Procedure . . . . . . . . . . . . . . . . 23
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . 24
Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . 26
Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Capacitor Test . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Circuit Breaker Module . . . . . . . . . . . . . . . . . . . 32
Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Motor Control Board . . . . . . . . . . . . . . . . . . . . . 34
Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Electric Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Temperature Control Module . . . . . . . . . . . . . . . 37
Primary Heaters . . . . . . . . . . . . . . . . . . . . . . . . . 40
Heated Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Fluid Temperature Sensor (FTS) . . . . . . . . . . . . 44
Display Module . . . . . . . . . . . . . . . . . . . . . . . . . 46
Inlet Fluid Strainer Screen . . . . . . . . . . . . . . . . . 48
Pump Lubrication System . . . . . . . . . . . . . . . . . 48
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Reactor Assembly (Model E-XP1 Shown) . . . . . 50
Parts Used on All Models . . . . . . . . . . . . . . . . . 53
Parts that Vary by Model . . . . . . . . . . . . . . . . . . 54
Sub Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . 58
Proportioner Module . . . . . . . . . . . . . . . . . . . . . 58
Fluid Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.65 kW Single Zone Fluid Heater . . . . . . . . . . . 61
Reactor Frame . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Temperature Control . . . . . . . . . . . . . . . . . . . . . 64
Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Fluid Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Circuit Breaker Modules . . . . . . . . . . . . . . . . . . 67
248669 Conversion Kit . . . . . . . . . . . . . . . . . . . . . 71
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 74
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 74
2 312066Z
Models
E-20 SERIES
Models
Max Flow
Primary
Full Load Peak
Part, Series
259025, E 48 230V (1) 10,200 6,000 20 (9) 0.0104 (0.04) 2000 (14, 140)
259030, E 24 400V (3) 10,200 6,000 20 (9) 0.0104 (0.04) 2000 (14, 140)
259034, E 32 230V (3) 10,200 6,000 20 (9) 0.0104 (0.04) 2000 (14, 140)
Amps*
Voltage
(phase)
System
Watts†
Heater
Watts
Rate◆
lb/min
(kg/min)
Approximate
Output per Cycle
(A+B)
gal. (liter)
Maximum Fluid
Working Pressure
psi (MPa, bar)
E-30 SERIES
Max Flow
Primary
Part,
Series
259026, F 78 230V (1) 17,900 10,200 30 (13.5) 0.0272 (0.1034) 2000 (14, 140)
259031, F 34 400V (3) 17,900 10,200 30 (13.5) 0.0272 (0.1034) 2000 (14, 140)
259035, F 50 230V (3) 17,900 10,200 30 (13.5) 0.0272 (0.1034) 2000 (14, 140)
259057, F 100 230V (1) 23,000 15,300 30 (13.5) 0.0272 (0.1034) 2000 (14, 140)
259058, F 62 230V (3) 23,000 15,300 30 (13.5) 0.0272 (0.1034) 2000 (14, 140)
259059, F 35 400V (3) 23,000 15,300 30 (13.5) 0.0272 (0.1034) 2000 (14, 140)
Full Load Peak
Amps*
Voltage
(phase)
System
Watts†
Heater
Watts
Rate◆
lb/min
(kg/min)
Approximate
Output per Cycle
(A+B)
gal. (liter)
Maximum Fluid
Working Pressure
psi (MPa, bar)
E-XP1 SERIES
Approximate
Primary
Full Load Peak
Part, Series
259024, E 69 230V (1) 15,800 10,200 1.0 (3.8) 0.0104 (0.04) 2500 (17.2, 172)
259029, E 24 400V (3) 15,800 10,200 1.0 (3.8) 0.0104 (0.04) 2500 (17.2, 172)
259033, E 43 230V (3) 15,800 10,200 1.0 (3.8) 0.0104 (0.04) 2500 (17.2, 172)
Amps*
Voltage
(phase)
System
Watts†
Heater
Watts
Max Flow
Rate◆
gpm (lpm)
Output per Cycle
(A+B)
gal. (liter)
Maximum Fluid
Working Pressure
psi (MPa, bar)
E-XP2 SERIES
Approximate
Primary
Part,
Series
259028, F 100 230V (1) 23,000 15,300 2.0 (7.6) 0.0203 (0.0771) 3200 (22, 220)
259032, F 35 400V (3) 23,000 15,300 2.0 (7.6) 0.0203 (0.0771) 3200 (22, 220)
259036, F 62 230V (3) 23,000 15,300 2.0 (7.6) 0.0203 (0.0771) 3200 (22, 220)
Full Load Peak
Amps*
Voltage
(phase)
System
Watts†
Heater
Watts
Max Flow
Rate◆
gpm (lpm)
Output per Cycle
(A+B)
gal. (liter)
Maximum Fluid
Working Pressure
psi (MPa, bar)
* 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, based on maximum hose length for each unit:
• E-20 and E-XP1 series, 210 ft (64 m) maximum heated hose length, including whip hose.
• E-30 and E-XP2 series, 310 ft (94.5 m) maximum heated hose length, including whip hose.
◆
Maximum flow rate given for 60 Hz operation. For 50 Hz operation, maximum flow rate is 5/6 of 60 Hz maximum
flow.
312066Z 3
Supplied Manuals
Supplied Manuals
The following manuals are shipped with the Reactor™
Proportioner. Refer to these manuals for detailed equipment information.
Order Part 15M334 for a compact disk of Reactor manuals translated in several languages.
Manuals are also available at www.graco.com.
Reactor Electric Proportioner
Part Description
312065 Reactor Electric Proportioner,
Operation Manual (English)
Reactor Electrical Diagrams
Part Description
312067 Reactor Electric Proportioner,
Electrical Diagrams (English)
Displacement Pump
Part Description
309577 Electric Reactor Displacement Pump
Repair-Parts Manual (English)
Related Manuals
The following manuals are for accessories used with the
™
Reactor
Order Part 15M334 for a compact disk of Reactor manuals translated in several languages.
Reactor Data Reporting Kit
Part Description
309867 Instruction-Parts Manual (English)
Fusion Spray Gun
Part Description
309550 Instruction-Parts Manual (English)
Heated Hose
Part Description
309572 Instruction-Parts Manual (English)
Circulation and Return Tube Kit
Part Description
309852 Instruction-Parts Manual (English)
Rupture Disk Assembly Kit
Part Description
312416 Instruction-Parts Manual (English)
Electric Reactor Installation
.
Part Description
310815 Instruction Manual (English)
4 312066Z
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where
applicable.
WARNING
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power cord before servicing equipment.
• Use only grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on sprayer and extension cords.
• Do not expose to rain. Store indoors.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.
• Read MSDS’s to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
• Always wear impervious gloves when spraying or cleaning equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the
equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
• Hearing protection
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut,
but it is a serious injury that can result in amputation. Get immediate surgical treatment.
• Engage trigger lock when not spraying.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Do not spray without tip guard and trigger guard installed.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking,
or servicing equipment.
• Tighten all fluid connections before operating equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
312066Z 5
Warnings
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and
explosion:
• Use and clean equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths
(potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Ground equipment, personnel, object being sprayed, and conductive objects in work area. See Grounding
instructions.
• Use only Graco grounded hoses.
• Check gun resistance daily.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you
identify and correct the problem.
• Do not flush with gun electrostatics on. Do not turn on electrostatics until all solvent is removed from system.
• Keep a working fire extinguisher in the work area.
THERMAL EXPANSION HAZARD
Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure due to the thermal expansion. Over-pressurization can result in equipment rupture and serious injury.
• Open a valve to relieve the fluid expansion during heating.
• Replace hoses proactively at regular intervals based on your operating conditions.
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical reaction and
equipment rupture, and result in death, serious injury, and property damage.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• This equipment is for professional use only.
• Do not leave the work area while the equipment is energized or under pressure. Turn off all equipment and
follow Pressure Relief Procedure in this manual when the equipment is not in use.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component.
See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equip-
ment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS forms from distributor or retailer.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s
replacement parts only.
• Do not alter or modify equipment.
• 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.
6 312066Z
WARNING
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow
the Pressure Relief Procedure in this manual. Disconnect power or air supply.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns, do not
touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.
Warnings
312066Z 7
Temperature Control Diagnostic Codes
Temperature Control Diagnostic Codes
Temperature control diagnostic codes appear on temperature display.
These alarms turn off heat. E99 clears automatically
when communication is regained. Codes E03 through
E06 can be cleared by pressing . For other codes,
turn main power OFF then ON to
clear.
E01: High fluid temperature
Causes of E01 Errors
• Thermocouple A or B (310) senses a fluid temperature above 230°F (110°C).
Code Code Name Alarm
Zone
01 High fluid temperature Individual
02 High zone current Individual
03 No zone current with
hose heater on
04 FTS not connected Individual
05 Board overtemperature Individual
06 Communication cable
unplugged from module
99 Loss of communication ALL
For hose zone only, if FTS is disconnected at
startup, display will show hose current 0A.
Individual
Individual
Checks
Corrective
Action page
8
9
10
10
10
10
16
• Fluid temperature sensor (FTS) senses a fluid temperature above 230°F (110°C).
• Overtemperature switch A or B (308) senses a fluid
temperature above 230°F (110°C) and opens. At
190°F (87°C) the switch closes again.
• Thermocouple A or B (310) fails, is damaged, is not
touching the heater element (307), or has a poor
connection to the temperature control board.
• Overtemperature switch A or B (308) fails in the
open position.
• The temperature control board fails to turn off any
heat zone.
• Zone power wires or thermocouples are switched
from one zone to another.
• Failed heater element where thermocouple is
installed.
• Loose wire
• On 6.0 and 10.2 kW heater models only: Jumper
wire on J1 connector, between module (3) and display (4), is loose or incorrectly wired.
Troubleshooting this equipment requires access to
parts that may cause electric shock or other serious
injury if work is not performed properly. Have a qualified electrician perform all electrical troubleshooting.
Be sure to shut off all power to the equipment before
repairing.
Check which zone is displaying the E01 error.
1. Check that connector B is firmly plugged into temperature control board (see F
2. Clean and re-plug connections.
3. Check connections between the temperature control board and overtemperature switches A and B
(308), and between temperature control board and
thermocouples A and B (310) or FTS (21) [depending on which zone is displaying E01]. See Table 5,
page 37. Ensure that all wires are securely connected to connector B.
IG
. 5, page 37).
8 312066Z
Temperature Control Diagnostic Codes
4. Remove connector B from temperature control module, and check continuity of overtemperature
switches A and B, thermocouples A and B, or FTS
by measuring resistance across the pins on the plug
end; see T
Before doing the following checks, note which zone
(A, B, FTS, or all) has high fluid temperature.
Table 1: Sensor Connector Continuity Checks
Pins Description Reading
1 & 2 OT switch A nearly 0 ohms
3 & 4 OT switch B nearly 0 ohms
5 & 6 Thermocouple A 4-6 ohms
8 & 9 Thermocouple B 4-6 ohms
11 & 12 FTS approximately 35
10 & 12 FTS open
ABLE
1.
ohms per 50 ft (15.2
m) of hose, plus
approximately 10
ohms for FTS
E02: High zone current
1. Turn main power OFF .
2. Relieve pressure, page 23.
Disconnect whip hose.
3. Disconnect hose connector (D) at Reactor.
4. Using an ohmmeter, check between the two terminals of the connector (D). There should be no continuity.
5. Exchange zone module with another one. Turn
zone on and check for error. If error disappears,
replace faulty module.
For hose zone:
former Primary Check and Transformer Secondary
Check starting on page 45.
If error still occurs, perform Trans-
5. Verify fluid temperature, using an external temperature sensing device.
• If temperature
229°F [109°C] or above):
6. Check if thermocouples A and B are damaged, or
not contacting the heater element, page 42.
7. To test that temperature control module turns off
when equipment reaches temperature setpoint:
a. Set temperature setpoints far below displayed
temperature.
b. Turn zone on. If temperature rises steadily,
power board is failing.
c. Verify by swapping with another power module.
See Replacing Temperature Control Assem-
bly Modules, page 38.
d. If the swapped module does not fix the problem,
the power module is not the cause.
is
too high (sensor reading is
When there is a a high current error, the LED on
that zone’s module will turn red while the error is
displayed.
8. Verify continuity of heater elements with an ohmmeter, see page 40.
312066Z 9
Temperature Control Diagnostic Codes
E03: No zone current
1. Check for tripped circuit breaker inside electrical
cabinet or at power source for that zone. Replace
circuit breaker if it trips habitually.
2. Check for loose or broken connection at that zone.
3. Exchange zone module with another one. Turn
zone on and check for error (see page 38). If error
disappears, replace faulty module.
4. If E03 occurs for all zones, the contactor may not be
closing. Verify wiring from heater control to contactor coil.
a.
Hose zone
b. Perform Transformer Primary Check and
Transformer Secondary Check, starting on
page 45.
When a no current error occurs, the LED on the
specific zone’s module turns red when the error is
displayed.
: test hose continuity, page 43.
5. To verify heater control module is not causing the
problem, use a wire to short-circuit the two pins corresponding to the FTS (red and yellow for A or B
zone, red and purple for hose). The display will
show the control heater module temperature.
6. If an error occurred for the hose zone, temporarily
use the current control mode. Refer to Reactor
Operation manual 312062.
E05: Circuit board overheated
Each module has an on-board temperature sensor.
Heat is turned off if module temperature exceeds
185°F (85°C) within the heater module.
1. Check that fan above electrical cabinet is operating.
2. Check that electrical cabinet door is properly
installed.
3. Check for obstructions blocking cooling holes in bottom of electrical cabinet.
E04: Fluid Temperature Sensor (FTS) or thermocouple disconnected
1. Check temperature sensor connections to long
green connector (B) on temperature control module,
page 37. Unplug and re-plug sensor wires.
2. Test fluid temperature sensor continuity with ohmmeter, page 8.
3. If an error occurred for the hose zone, check FTS
connections at each section of hose.
4. If an error occurred for the hose zone, test FTS by
plugging directly into machine.
F
D
4. Clean heatsink fins behind heater control modules.
5. Ambient temperature may be too high. Allow Reactor to cool by moving to a cooler location.
E06: Communication cable unplugged
1. Unplug and re-plug cable that connects heater control module to heater module.
2. Replace communication cable if problem persists.
TI10964a
10 312066Z
Motor Control Diagnostic Codes
Motor Control Diagnostic Codes
Motor control diagnostic codes E21 through E29 appear
on pressure display.
There are two types of motor control codes: alarms and
warnings. Alarms take priority over warnings.
Alarms
Alarms turn off Reactor. Turn main power OFF
then ON to clear.
Alarms can also be cleared, except for code 23, by
pressing .
Warnings
Reactor will continue to run. Press to clear. A
warning will not recur for a predetermined amount of
time (varies for different warnings), or until main power
is turned OFF then ON .
Code Code Name Alarm (A) or
Warning (W)
21 No transducer (compo-
nent A)
22 No transducer (compo-
nent B)
23 High fluid pressure A
24 Pressure imbalance A/W (to
25 High line voltage A
26 Low line voltage A
27 High motor temperature A
28 High current A
29 Brush wear W
30 Momentary loss of
communication
31 Motor control failure A
32 Motor control
overtemperature
99 Loss of communication -
A
A
select, see
page 34)
-
A
Corrective
Action
page
16
16
16
16
18
18
18
29
19
16
15
16
16
312066Z 11
Motor Control Diagnostic Codes
E21: No component A transducer
1. Check transducer A connection at J3 on motor control board, page 34, and clean contacts.
2. Reverse A and B transducer connections. If error
moves to transducer B (E22), replace transducer A,
page 36. If error does not move, replace motor control board, page 34.
E22: No component B transducer
1. Check transducer B connection at J8 on motor control board, page 35, and clean contacts.
2. Reverse A and B transducer connections. If error
moves to transducer A (E21), replace transducer B,
page 36. If error does not move, replace motor control board, page 34.
E23: High fluid pressure
1. Relieve pressure. Verify low pressure with analog
b. Turn on the Reactor master power.
• If the error is gone, turn off the Reactor main
power, remove test transducer, and replace “A”
transducer.
• If the error persists, unplug the “test” transducer
from the “A” socket, and reinstall the “A” pressure transducer back into the “A” socket.
Repeat this test procedure on the “B” side.
4. If the error persists and no root cause is found
through the above testing, replace the motor control
board, page 34.
E24: Pressure Imbalance
If the pressure difference between components A
and B exceeds 500 psi (3.5 MPa, 35 bar), an E24
will occur. This default value is adjustable; see the
operation manual.
E24 can be an alarm or a warning, as desired. Set
DIP switch on motor control board ON for alarm,
OFF for warning. See page 34.
gauges. Turn main power OFF then ON
. If error persists, do checks below.
1. Check the jumpers and the wiring. Check jumper on
motor control board J10 for E20 and E-XP1, or J7
for E30 and E-XP2, pins 7-10, page 34.
2. Remove, clean and re-install the pressure transducer leads
If the jumpers and the wiring are in good working condition and you still have the error, then you will need to
replace the “A” and “B” pressure transducers.
3. To determine if it’s the “A” or the “B” transducer, you
will need a known good Reactor pressure transducer to use as a “test” transducer. The test is done
without removing the existing pressure transducers
from the fluid manifold.
a. Unplug the “A” transducer from the Motor con-
trol board socket (page 36) and replace with
“test” transducer.
Fast E24 Errors
Fast E24 errors occur:
• within 10 seconds of turning the pumps on, or
• as soon as you trigger the gun.
Causes of Fast E24 Errors
• one side of the gun is plugged.
• a pressure transducer has failed.
• damaged pump seals or check valve.
• no feed pressure or empty material drum
• plugged heater.
• plugged hose.
• plugged manifold.
• one PRESSURE RELIEF/SPRAY valve is leaking or
is set to PRESSURE RELIEF/CIRCULATION
12 312066Z
Motor Control Diagnostic Codes
Checks for Fast E24 Errors
If a fast E24 error occurs, first check the readings of
the analog gauges.
If gauge pressures are very close
1. Clear the error and run the unit.
2. Check plug J10 (E20/E-XP1) or J7 (E30/E-XP2) or
the jumpers 7 to 8, or 9 to 10 on the motor control
board.
3. Check pressure transducer performance:
The digital display on a Reactor always shows the
higher of the two pressures. As soon as the higher analog pressure drops below the lower analog pressure the
digital display will switch to the new highest reading.
Determine which transducer is performing poorly.
1. For testing purposes only, find the dip switches
labeled SW2 on the motor control board, page 35.
Set dips witch 3 to OFF. This will allow the Reactor
to run with a pressure imbalance alarm.
2. Run the unit to build up some pressure (1000 –
1200 psi). Shut down the unit, clear the alarm and
power back up. Do not depressurize the unit.
3. Check the analog gauges to see which pressure is
higher. Check if the display pressure matches, indicating that the motor control board “sees” that transducer. If not, the motor control board does not “see”
that transducer. Check the wire connections and or
replace the transducer.
4. With the pump zone off, use the pressure relief
valves to slowly relieve the “high” side pressure,
while watching the digital display and the analog
gauges. Once the higher analog gauge drops below
the lower analog pressure the motor control board
should start reading the “new” high side pressure
(because it is now the higher of the two). Continue
dropping the original “high” side pressure - the digital display should stop dropping. Repeat the process to check the other pressure transducer.
The last test determines if the pressure transducer has
failed or if the socket on the pressure control board has
gone bad.
1. Swap the transducer plug-ins on the motor control
board. (J3 and J8 for the E-20 and E-XP1. J3 and
J5 for the E30 and E-XP1).
2. Repeat above test.
3. If the problem stays with the same side as before,
then the pressure transducer is bad.
4. If the problem switches to the other transducer, then
the problem is in the motor control boards socket.
If the gauge readings are
1. Clear the error and balance the pressures using the
dump valves.
2. If you cannot get the pressures to balance:
• Check for pump failure.
• Check for adequate material.
• Using the feed pump to push fluid out through the
gun manifold, check for a plugged fluid path.
• Run the unit.
• Check and clean the gun inlet screens.
• Check and clean the mix chamber “A” and “B”
impingement ports a well as the center port. Note:
Some mix chambers have counter bored holes,
and require two drill sizes to clean impingement
ports completely.
“Slow” E24:
• When spraying, gradual pressure imbalance and
eventual E24.
Possible Causes:
• One side of the Gun is partially blocked.
• The “A” or the “B” pump on the Reactor has failed.
• The “A” or the “B” feed pump has failed.
• The “A” or the “B” feed pump pressure is set too
high.
• The “A” or the “B” inlet screen is plugged.
• The hose is not heating properly.
• Kinked supply hose.
• Bottom of the drum is damaged causing a blockage
to the inlet of the feed pump.
• The drum is not vented properly.
not
equal.
312066Z 13
Motor Control Diagnostic Codes
E25: High line voltage
Supply voltage too high. Check Reactor voltage requirements, page 73.
E26: Low line voltage
Supply voltage too low. Check Reactor voltage requirements, page 73.
E27: High Motor Temperature
1. Motor temperature too high. Reduce pressure, gun
tip size, or move Reactor to a cooler location. Allow
one hour for cooling.
2. Check fan operation.
3. Ensure there is no obstruction around the fan area
that would cause lack of airflow; ensure the
motor/fan shroud is installed.
4. Ensure the unit is being operated with the front
cover on.
5. Ensure the brush wear/over temp switch wire
assembly is plugged into J7 (E-20/E-XP1) or J6
(E-30/E-XP2) of the motor control board.
6. With the main power off, unplug the wire harness
from J7 (E-20/E-XP1) or J6 (E-30/E-XP2) on the
motor control board and install a jumper wire on
pins 1 and 2. Turn the main power back on.
E28: High current in motor
Check motor control board:
1. Turn the master power off.
2. Disconnect socket J4 (E-20/E-XP1) J1
(E-30/E-XP2) on the motor control board.
3. Turn the master power back on.
4. If the E28 error did not go away then there is a problem with the motor control board. Replace board,
page 34.
Check motor:
1. Check to see if the motor rotates freely.
2. Check to see if the brushes are damaged.
3. Check that the voltage going to the motor is good.
4. Check the three wire (yellow, yellow, orange) motor
connector to the motor board. A gentle tug on each
wire individually at the connector should identify the
loose wire. If a wire pulls out, bend the locking tab
on the crimp end, insert the wire until it seats and
repeat gentle tug.
5. If the above does not resolve the problem, replace
the motor, page 33.
E29: Brush Wear
If E27 is gone:
If the E27 error is gone and the motor is truly not overheated, then the problem can be in the motor/motor wire
harness assembly. Measure the resistance between the
two yellow wires that go to pins 1 and 2 of the motor
connector. If there is an open connection, the thermal
overload switch is open or there is a broken wire inside
the motor, or a broken wire in the motor harness.
If the E27 error code is still there, double check if pins 1
and 2 are jumpered properly. If jumpered properly, then
it would appear that the problem is with in the motor
control board.
14 312066Z
Prolonged operation of motor after a brush wear
warning may result in failure of motor and motor control board.
1. Check for normal brush wear, which causes the
brush sensor to come in contact with the motor
commutator. Replace the brushes, page 30.
2. Check spade plug. The spade plug inside the motor
housing may be twisted and contacting the commutator side of the brush sensor assembly, causing a
false alarm. Follow the orange wire coming from J7
(E-20/E-XP1), or J6 (E-30/E-XP2), up to the spade
connector on the motor. Using a flashlight, ensure
the spade plug assembly is not making contact with
the metal housing of the brush assembly.
CAUTION
3. Check wiring. The orange brush sensor wire coming
out of the brush may be routed online with the commutator wiring (thick red wire), causing a false
alarm. Reroute the orange wire coming out of the
brush, away from the commutator wiring.
4. Check motor control board.
• Remove the plug in J7 (E-20/E-XP1), or J6
(E-30/E-XP2). (This will cause an E27 alarm).
• To remove the E27 alarm, use a jumper wire on the
motor control board, across the two pins that the
two yellow wires plug into. Then turn the unit on.
Motor Control Diagnostic Codes
1. Turn main power OFF . Disconnect power
supply.
Wait 5 minutes for stored voltage to discharge (E-30
and E-XP2 models only).
2. Relieve pressure, page 23.
• The E27 as well as the E29 alarm should be gone. If
the E27 alarm is not gone double-check your
jumper.
• If the jumper is installed correctly and the E29 alarm
is still there, replace the motor control board, page
34.
E31: Motor Control Failure (E-30 and E-XP2 only)
The E31 error code represents a motor drive error. This
indicates that the 24G881 motor control board has malfunctioned and needs to be replaced. A motor control
board failure may also be indicated by the motor starting
up immediately upon the application of power to the sys-
tem, without pressing . This is an indication that
the output drivers of the motor control have shorted out
and are delivering full power to the motor at all times.
The cause of the failure may be one of the following conditions: motor failure, capacitor failure, shorted or frayed
wiring, or inadequate power supply. Perform the following procedure before replacing the motor control board.
3. Perform the following inspections.
a. Motor failure: Inspect the motor commutator by
removing the top brush (see Brush Removal,
page 30). Rotate the motor, inspecting the
whole commutator for burns, pocking, or shorts
between poles. Continue rotating the motor for a
complete pump cycle, up and down, to ensure
that there is no mechanical interference or
restriction in the pump lower or gear drive system.
b. Capacitor failure: Inspect and test the motor
start capacitor, following the Capacitor Test
instructions on page 32.
c. Shorted or frayed wiring: Inspect all wiring
connected to the motor control board and the
motor, for shorts or frayed insulation. Replace
any compromised wires with wire of the same
gauge, color. and temperature rating.
d. Inadequate power supply: Verify that the
power source is of the correct voltage and current rating for the system, and that all phases
are properly connected. Ensure that the power
does not dip or surge during operation.
Prior to shutting down the generator, ensure
that the motor has stopped and the main disconnect is opened. If the generator is stopped
during operation, even due to running out of
fuel, the drop in supply voltage may cause a
motor drive failure.
312066Z 15
Communication Diagnostic Codes
E32: Motor Control
1. Relieve pressure, page 23. Verify low pressure with
analog gauges.
Overtemperature
The E32 error code indicates a high temperature condition within the motor control board (701). This could be
caused by an abnormally high ambient temperature in
the work location, blockage of cooling vents in the cabinet, or the failure of the cooling fan inside the cabinet.
2. Turn main power OFF then ON .
If error still remains, identify cause of the overtemperature condition and remedy.
Communication Diagnostic Codes
E30: Momentary loss of communication
Communications between the display and the motor
control board or the temperature control board have
been momentarily lost. Normally, when communication
is lost, the corresponding display will show E99. The
corresponding control board will register E30 (The red
LED will flash 30 times). If communications are reconnected, the display can show the E30 for a short time
(no more than about two seconds). It should not be possible for E30 to be shown continuously, unless there is a
loose connection causing the display and the board to
continuously lose and regain communication.
E99: Loss of communication
Communications between the display and the motor
control board or the temperature control board has been
lost. When communication is lost, the corresponding
display will show E99.
1. Check all wiring between the display and the corresponding control board. Pay close attention to the
wire crimping on plug J13 for each board.
Check all wiring between the display and the corresponding control board.
Step 2 measures line voltage and should be done by a
qualified electrician. If work is not performed properly
it may cause electric shock or other serious injury.
2. Measure the incoming voltage to the board (it
should be ~ 230Vac).
3. If it was only receiving 1 leg of the 230Vac the board
may light up, and still not function properly. Correct
the incoming voltage problem.
16 312066Z
Troubleshooting
Troubleshooting
PROBLEM CAUSE SOLUTION
Reactor does not operate. No power. Plug in power cord.
Turn main power ON .
Turn circuit breakers ON, page 32.
Red stop button circuit open. Check button connections. See page
46 and electrical diagrams.
Motor does not operate. Loose connections. Check connections at motor control
board.
Circuit breaker tripped. Reset breaker (CB5), page 32.
Check 230Vac at output of breaker.
Worn brushes. Check both sides. Length must be
0.7 in. (17 mm) minimum. To replace,
page 30.
Broken or misaligned brush springs. Realign or replace, page 30.
Brushes or springs binding in brush
holder.
Shorted armature. Replace motor, page 33.
Check motor commutator for burn
spots or other damage.
Damaged motor control board. Replace board. See page 34.
Fan not working. Blown fuse. Replace, page 36.
Loose wire. Check.
Defective fan. Replace, page 36.
Pump output low. Obstructed fluid hose or gun; fluid
hose ID too small.
Worn piston valve or intake valve in
displacement pump.
Pressure setpoint too high. Reduce setpoint and output will
Fluid leak in pump packing nut area. Worn throat seals. Replace. See pump manual.
No pressure on one side. Fluid leaking from heater inlet rupture
disk (314).
Clean brush holder and align brush
leads for free movement.
Remove motor. Have motor shop
resurface commutator, if possible.
Open, clear; use hose with larger ID.
See pump manual.
increase.
Check if heater (2) and PRESSURE
RELIEF/SPRAY valve (SA or SB) are
plugged. Clear. Replace rupture disk
(314) with a new one; do not replace
with a pipe plug.
312066Z 17
Troubleshooting
Reactor Electronics
2. Turn main power OFF .
3. Allow equipment to cool.
Try the recommended solutions in the order given for
each problem, to avoid unnecessary repairs. Also,
Before performing any troubleshooting procedures:
1. Relieve pressure, page 23.
PROBLEM CAUSE SOLUTION
No power.
Both sides of display do not
illuminate.
Temperature display does not
illuminate.
Pressure display does not
illuminate.
Erratic display; display turns on and
off.
Hose display reads OA at startup. FTS disconnected or not installed. Verify proper installation of FTS (see
Low voltage. Ensure input voltage is within specifi-
Loose wire. Check connections, page 46.
Display disconnected. Check cable connections, page 46.
Display disconnected. Check cable connections, page 46.
Display cable damaged or corroded. Clean connections; replace cable if is
Defective circuit board. Swap display connection to motor
Display disconnected. Check cable connections, page 46.
Display cable damaged or corroded. Clean connections; replace cable if is
Defective circuit board. Swap display connection to motor
Low voltage. Ensure input voltage is within specifi-
Poor display connection. Check cable connections, page 46.
Display cable damaged or corroded. Clean connections; replace cable if is
Display cable not grounded. Ground cable, page 46.
Display extension cable too long. Must not exceed 100 ft (30.5 m)
determine that all circuit breakers, switches, and controls are properly set and wiring is correct before assuming there is a problem.
Plug in power cord.
Turn disconnect ON .
cations, page 46.
damaged.
control board with connection to
heater control board. If temperature
display illuminates, heater control
board is causing problem. Otherwise,
display cable or display is failing.
damaged.
control board with connection to
heater control board. If pressure display illuminates, motor control board
is causing problem. Otherwise, display cable or display is failing.
cations, page 46.
Replace damaged cable.
damaged.
Operation manual 312065), or adjust
FTS to desired current setting.
18 312066Z
PROBLEM CAUSE SOLUTION
Poor display connection. Check cable connections, page 46.
Replace damaged cable.
Display does not respond properly to
button pushes.
Display cable damaged or corroded. Clean connections; replace cable if is
damaged.
Ribbon cable on display circuit board
Connect cable (page 46) or replace.
disconnected or broken.
Broken display button. Replace, page 46.
Red stop button does not work. Broken button (fused contact). Replace, page 46.
Loose wire. Check connections, page 46.
Blown fuse. Verify with ohmmeter; replace if nec-
essary (page 46).
Fan not working.
Loose wire. Check fan wire.
Defective fan. Replace, page 46.
Troubleshooting
312066Z 19
Troubleshooting
Primary Heaters (A and B)
Before performing any troubleshooting procedures:
1. Relieve pressure, page 23.
PROBLEM CAUSE SOLUTION
Heat turned off.
Primary heater(s) does not heat.
Temperature control alarm. Check temperature display for diag-
2. Turn main power 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.
Press or zone
keys.
nostic code, page 8.
A
B
Control of primary heat is abnormal;
high temperature overshoots or E01
error occurs intermittently.
Signal failure from thermocouple. See E04: Fluid Temperature Sen-
sor (FTS) or thermocouple disconnected, page 10.
Dirty thermocouple connections. Examine connection of thermocou-
ples to long green plug on heater
control board. Unplug and re-plug
thermocouple wires, cleaning off any
debris. Unplug and re-plug long
green connector.
Thermocouple not contacting heater
element.
Failed heater element. See Primary Heaters, page 20.
Signal failure from thermocouple. See E04: Fluid Temperature Sen-
Thermocouple wired incorrectly. See E04: Fluid Temperature Sen-
Loosen ferrule nut (N), push in thermocouple (310) so tip (T) contacts
heater element (307). Holding themocouple tip (T) against heater element,
tighten ferrule nut (N) 1/4 turn past
tight. See page 42 for illustration.
sor (FTS) or thermocouple disconnected, page 10.
sor (FTS) or thermocouple disconnected, page 10. Power up zones
one at a time and verify that temperature for each zone rises.
20 312066Z
Troubleshooting
Hose Heat System
Before performing any troubleshooting procedures:
1. Relieve pressure, page 23.
2. Turn main power OFF .
PROBLEM CAUSE SOLUTION
Ambient temperature is too cold. Use auxiliary hose heat system.
Hose heats but heats slower
than usual or it does not reach
temperature.
FTS failed or not installed correctly. Check FTS, page 10.
Low supply voltage. Verify line voltage. Low line voltage signifi-
3. Allow equipment to cool.
Problems
Try the recommended solutions in the order given for
each problem, to avoid unnecessary repairs. Also,
determine that all circuit breakers, switches, and controls are properly set and wiring is correct before assuming there is a problem.
cantly reduces power available to hose
heat system, affecting longer hose
lengths.
Hose does not maintain temperature while spraying.
Hose temperature exceeds setpoint.
A and B setpoints too low. Increase A and B setpoints. Hose is
designed to maintain temperature, not to
increase it.
Ambient temperature is too cold. Increase A and B setpoints to increase
fluid temperature and keep it steady.
Flow too high. Use smaller mix chamber. Decrease pres-
sure.
Hose was not fully preheated. Wait for hose to heat to correct tempera-
ture before spraying.
Low supply voltage. Verify line voltage. Low line voltage signifi-
cantly reduces power available to hose
heat system, affecting longer hose
lengths.
A and/or B heaters are overheating
material.
Faulty thermocouple connections. Verify that all FTS connections are snug
Check primary heaters for either a thermocouple problem or a failed element
attached to thermocouple, page 10.
and that pins of connectors are clean.
Examine connection of thermocouples to
long green plug on heater control board.
Unplug and re-plug thermocouple wires,
cleaning off any debris. Unplug and
re-plug long green connector on heater
control board.
Missing/damaged insulation around
FTS, causing the hose heat to be ON
constantly.
312066Z 21
Ensure hose bundle has adequate insulation evenly covering the entire length and
connection joints.
Troubleshooting
PROBLEM CAUSE SOLUTION
Erratic hose temperature.
Faulty thermocouple connections. Verify that all FTS connections are snug
and that pins of connectors are clean.
Examine connection of thermocouples to
long green plug on heater control board.
Unplug and re-plug thermocouple wires,
cleaning off any debris. Unplug and
re-plug long green connector.
FTS not installed correctly. FTS should be installed close to end of
hose in same environment as gun. Verify
FTS installation, page 44.
Missing/damaged insulation around
FTS, causing the hose heat to be ON
constantly.
FTS failed or is not contacting
Ensure hose bundle has adequate insulation evenly covering the entire length and
connection joints.
Check FTS, page 44.
correctly.
FTS not installed correctly. FTS should be installed close to end of
Hose does not heat.
hose in same environment as gun. Verify
FTS installation, page 44.
Temperature control alarm. Check temperature display or diagnostic
code, page 44.
Hoses near Reactor are warm,
but hoses downstream are cold.
Shorted connection or failed hose
heating element.
With hose heat on and temperature setpoint above displayed hose zone temperature, verify voltage between
connectors at each section of hose.
Voltage should drop incrementally for
each section of hose further from Reactor.
Use safety precautions when hose heat is
turned on.
No hose heat. Loose hose electrical connections. Check connections. Repair as necessary.
Circuit breakers tripped. Reset breakers (CB1 or CB2), page 32.
Hose zone not turned on.
Press zone key.
A and B temperature setpoints too
Check. Increase if necessary.
low.
Failed temperature control board. Open cabinet. Check if board LED is
blinking. If not, check power wiring connections to ensure board has power. If
board has power and LED is not blinking,
replace board, page 37.
Low hose heat. A and B temperature setpoints too
low.
Increase A and B setpoints. Hose
designed to maintain temperature, not
increase temperature.
Hose temperature setpoint too low. Check. Increase if necessary to maintain
heat.
Flow too high. Use smaller mix chamber. Decrease pres-
sure.
Low current; FTS not installed. Install FTS, see operation manual.
Hose heat zone not turned on long
Allow hose to heat up, or preheat fluid.
enough.
Loose hose electrical connections. Check connections. Repair as necessary.
22 312066Z
Repair
Repair
Repairing this equipment requires access to parts
that may cause electric shock or other serious injury if
work is not performed properly. Have a qualified electrician connect power and ground to main power
switch terminals, see operation manual. Be sure to
shut off all power to the equipment before repairing.
Before Beginning Repair
1. Flush if necessary; see Flushing.
2. Park component A pump.
a. Press .
2. Engage gun piston safety lock.
ti2409a
3. Close gun fluid manifold valves A and B.
ti2421a
4. Shut off feed pumps and agitator, if used.
5. Turn PRESSURE RELIEF/SPRAY valves (SA, SB)
b. Trigger gun until pump A stops. After fluid pres-
sure drops below 700 psi (7.9 MPa, 79 bar),
motor will run until component A pump is at bottom of its stroke, then shut off.
c. Check ISO reservoir for component A pump. Fill
wet cup on component B pump. Refer to Reactor Operation manual 312065.
3. Turn main power OFF .
4. Relieve pressure.
Pressure Relief Procedure
to PRESSURE RELIEF/CIRCULATION .
Route fluid to waste containers or supply tanks.
Ensure gauges drop to 0.
SA
6. Disconnect gun air line and remove gun fluid manifold.
SB
ti10955a
1. Relieve pressure in gun and perform gun shutdown
procedure. See gun manual.
ti2554a
312066Z 23
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