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.

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

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

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 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

Checks

Corrective

Action page

• 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.

. 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

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.

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.

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.

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 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 -

select, see page 34)

Corrective

Action

page

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

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 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.

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

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

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

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.

6. Disconnect gun air line and remove gun fluid manifold.

ti10955a

1. Relieve pressure in gun and perform gun shutdown procedure. See gun manual.

ti2554a

312066Z 23

Repair

Flushing

Flush equipment only in a well-ventilated area. Do not spray flammable fluids. Do not turn on heaters while flushing with flammable solvents.

• 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 fluid components are compatible with common solvents. Use only moisture-free solvents.

• To flush feed hoses, pumps, and heaters separately from heated hoses, set PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE

See manual 309577 for pump repair instructions.

1. Shut off , , and heat zones.

2. Flush pump.

3. If pumps are not parked, press . Trigger gun

until pumps stop.

4. Turn main power off . Disconnect power supply.

5. Shut off both feed pumps. Close both fluid inlet ball valves (B).

RELIEF/CIRCULATION . Flush through bleed lines (N).

TI10954a

• 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 dry or filled with a moisture-free plasticizer or oil. Do not use water.

Pump Removal

ti4147a

6. Turn both PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF. Route fluid to waste containers or supply tanks. Ensure gauges drop to

TI10956a

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.

24 312066Z

Repair

Use drop cloth or rags to protect Reactor and surrounding areas from spills.

Steps 7-9 apply to pump A. To disconnect pump B, go to steps 10 and 11.

7. Disconnect fittings at fluid inlet (C) and outlet (D, out of view). Also disconnect steel outlet tube from heater inlet.

8. Disconnect tubes (T). Remove tube fittings (U) from wet-cup.

9. Loosen locknut (G) by hitting firmly with a non-sparking hammer. Unscrew pump far enough to separate and push up finger guard (P), to expose rod retaining pin. Push retaining wire clip up. Push pin out. Continue unscrewing pump.

Steps 10 and 11 apply to pump B.

10. Disconnect fluid inlet (C) and outlet (D). Also disconnect steel outlet tube from heater inlet.

11. Push retaining wire clip (E) up. Push pin (F) out. Loosen locknut (G) by hitting firmly with a non-sparking hammer. Unscrew pump.

TI3765a-1

TI3765a-2

312066Z 25

Repair

Pump Installation

Steps 1-5 supply 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.

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.

Flat side faces up.

Lubricate threads with ISO oil or grease.

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

TI3765a-1

26 312066Z

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). Place finger guard (P) over rod when it is accessible through window of bearing housing. When pin holes align, insert pin. Pull retaining wire clip down.

Finger guard is not used on Model E-30.

8. Seat finger guard (P) on wet-cup. Continue threading pump into bearing housing (M) until top threads are +/- 1/16 in. (2 mm) of bearing face (N). Ensure

Repair

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.

Do not let tubes kink or buckle.

Secure each tube with a wire tie between two barbs.

12. Reconnect fluid inlet (C).

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

Flat side faces up.

Lubricate threads with ISO oil or grease.

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

Finger guard (P) not used on Model E-30.

TI3765a-2

312066Z 27

Repair

Drive Housing

Removal

1. Turn main power OFF . Disconnect power supply.

2. Relieve pressure, page 23.

3. Remove screws (38) and motor shield (9), page 50.

4. Remove screws (209) and front cover (217).

Examine bearing housing (203) and connecting rod (205). If these parts need replacing, first remove the pump (206), page 28.

5. Disconnect pump inlet and outlet lines. Remove screws (213), washers (215), and bearing housing (203).

CAUTION

Do not drop gear cluster (204) when removing drive housing (202). Gear cluster may stay engaged in motor front end bell (R) or drive housing.

Installation

1. Apply grease liberally to washers (207, 208, 218), all gears, and inside drive housing (202).

2. Install one bronze washer (208) in drive housing, then install steel washers (207, 218) as shown.

3. Install second bronze washer (208) on gear cluster (204) and insert gear cluster in drive housing.

Drive housing crankshaft (S) must be in line with crankshaft at other end of motor.

4. Push drive housing (202) onto motor (201). Install screws (212, 219) and washers (214).

If bearing housing (203), connecting rod (205), or pump (206) were removed, reassemble rod in housing and install pump, page 26.

5. Install bearing housing (203), screws (213), and washers (215). Pumps must be in phase (both at same position in stroke).

6. Install front cover (217) and screws (209).

6. Remove screws (212, 219) and washers (214) and pull drive housing (202) off motor (201).

The A side drive housing includes cycle counter switch (221). If replacing this housing, remove pins (P) and switch. Reinstall pins and switch on new drive housing. Switch wires connect to J10 pins 5 and 6 on motor control board, page 34.

221

TI3250

7. Install motor shield (9) and screws (38).

28 312066Z

214

Repair

214

219

201

202

209

217

203

213

206B

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

205

215

212

218

206A

204

207208

208

TI3152

312066Z 29

Repair

Motor Brushes

Brush Removal

Replace brushes worn to less than 1/2 in. (13 mm). Brushes wear differently on each side of motor; check both sides. Brush Repair Kit 234037 is available.

1. Turn main power OFF . Disconnect power supply.

Wait 5 min for stored voltage to discharge (E-30 and E-XP2 models only).

2. Relieve pressure, page 23.

5. Loosen terminal screw (R). Pull away brush lead (L), being careful motor lead terminal (T) remains in place. Remove and discard brush (B).

RLT

6. Inspect commutator for excessive pitting, burning, or gouging. Black color on commutator is normal. Have commutator resurfaced by qualified motor repair shop if brushes wear too quickly.

7. Repeat for other side.

01227-4

3. Remove motor cover, screw, and washers. Remove inspection covers, screws, and gaskets from each end of motor.

4. Push in spring clip (C) to release hooks (H) from brush holder. Pull out clip and spring (S).

One brush has a wire on top for brush wear signal. Note which side of motor it is on. Unplug at spade connector provided.

01227-2

30 312066Z

Repair

Brush Installation

CAUTION

When installing brushes, follow steps carefully. Improper installation damages parts beyond use.

Install brush with wires on same side of motor as before. Plug spade terminal into connector.

1. Install new brush (B) so lead (L) is in long slot (D) of holder.

01227-5

4. Install spring clip (C) and push in until hooks (H) catch slots in housing. Incorrect installation may jam clip.

01227-2

01227-6

2. Slide terminal (L) under terminal screw (R). Make sure motor lead terminal (T) is still connected at screw. Tighten screw.

01227-4

3. Install spring (S) so it will uncoil onto brush (B), as shown. Spring will be damaged if installed backwards.

Note direction of spring coil.

Do not touch brushes, leads, springs, or brush holders while equipment is plugged in, to reduce the risk of electric shock and serious injury.

CAUTION

Do not run pumps dry for more than 30 sec while checking brushes, to avoid damaging pumps.

5. Reinstall brush inspection covers, gaskets, and screws. Reinstall motor cover, screws, washers, and drive housing/pump assemblies.

6. Test brushes with both pump pins (F) disconnected, page 30.

Select J 1 (jog mode). Press motor to start

motor. Slowly increase jog setting to J 6. Inspect brush and commutator contact area for excessive arcing. Arcs should not “trail” or circle around commutator surface.

Run motor for 20-30 min at J 6 to seat brushes.

312066Z 31

01227

Repair

Capacitor Test

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 23.

3. Locate the large, blue capacitor in the upper right corner of the lower cabinet.

4. With a DC voltmeter, measure the voltage across the capacitor terminals to verify that the voltage has discharged to below 10 volts.

5. With an insulated handle screw driver, short across the two contacts on the end of the capacitor to complete discharging it. Hold for two seconds.

NOTE: A small spark may issue from the contact point.

6. Inspect the capacitor for irregularities such as cracks, leakage, burn marks, or irregular shape.

7. Set an Ohmmeter to a range of at least 1K connect the meter leads to the capacitor with the red lead to the positive (+) terminal and the black lead to the negative (-) terminal.

8. Observe the meter reading. It should start near 0

and climb up to 10K battery charges the capacitor. This indicates a good capacitor.

9. A reading of 0 bad capacitor. In this case, replace the capacitor. with the exact replacement part, item 76 on pages 55 and 56.

, 20KΩ, etc., as the meter

(shorted) or O.L (open) indicates a

and

Circuit Breaker Module

1. Turn main power OFF . Disconnect power supply. Turn circuit breakers on to test.

2. Relieve pressure, page 23.

3. 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 diagrams and to T

connect wires and remove bad breaker.

b. Install new breaker and reconnect wires.

Table 2: Circuit Breakers, see FIG. 1

Ref. Size Component

909 50A Hose/Transformer

911 40A Transformer

912A 25A, 40A* Heater A

912B 25A, 40A* Heater B

913 20A Motor/Pumps

* Depending on model.

Secondary Side

Primary

ABLE

2. Dis-

NOTE: To reference cables and connectors, see the electrical diagrams and the parts drawings on pages 67-68.

FIG. 1. Circuit Breaker Module

32 312066Z

909

911

912A

912B

913

ti9884a

Repair

Electric Motor

Removal

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 23.

3. Remove drive housing/pump assemblies, page 28.

4. Disconnect motor cables as follows:

a. Refer to electrical diagrams. Motor control

board is on right side inside cabinet, see page

34.

Installation

1. Place motor on unit. Thread motor cables into cabinet and into bundles as before. See electrical diagrams.

2. Fasten motor with screws.

3. Plug 3-pin connector J7 to board.

4. Plug motor power harness to connector J4 on board.

5. Install drive housing/pump assemblies, page 28.

6. Return to service.

b. Unplug motor power harness from connector J4

on board. See F

c. Unplug 3-pin connector J7 from board.

d. Thread cables through top of cabinet to free

motor.

Motor is heavy. Two people may be required to lift.

5. Remove screws holding motor to bracket. Lift motor off unit.

. 2, page 35.

CAUTION

312066Z 33

Repair

Motor Control Board

Motor control board has one red LED (D11). Power must be on to check. See F tion is:

• Startup: 1 blink for 60 Hz, 2 blinks for 50 Hz.

• Motor running: LED on.

• Motor not running: LED off.

• Diagnostic code (motor not running): LED blinks diagnostic code, pauses, then repeats (for example, E21=21 blinks, pause, 21 blinks).

CAUTION

Before handling board, put on a static conductive wrist strap to protect against static discharge which can damage board. Follow instructions provided with wrist strap.

1. Turn main power OFF . Disconnect power

supply.

. 2 for location. Func-

8. Set DIP switch (SW2) on new board. See T for factory settings. See F

. 2 for location on board.

ABLE

Table 3: DIP Switch (SW2) Settings

DIP

Switch Switch Position

Switch 1 not used Switch 2 ON for E-20 and

E-30 models

Switch 3 ON to enable pres-

sure imbalance

warning

OFF for E-XP1 and

E-XP2

OFF to enable

pressure imbalance

alarm

Switch 4 not used

9. Install new board in reverse order. Apply thermal heatsink compound to mating surfaces of board and heatsink.

Order Part 110009 Thermal Compound.

Table 4: Motor Control Board Connectors

Wait 5 minutes for stored voltage to discharge (E-30 and E-XP2 models only).

2. Relieve pressure, page 23.

3. Refer to electrical diagrams. Motor control board is on right side inside cabinet.

4. Put on static conductive wrist strap.

5. Disconnect all cables and connectors from board.

6. Remove nuts (40) and take entire motor control assembly to workbench.

7. Remove screws and take board off heatsink.

Model

E-20

and

E-XP1

J1 N, L n/a Main motor power

J8 J3 n/a Transducer B

J4 J1 n/a Motor output

J7 J6 1, 2 Motor thermal overload signal

J3 J5 n/a Transducer A

J10 J7 1-4 Not used

J12 J12 n/a Data reporting

J13 J13 n/a To display board

Model

E-30

and

E-XP2 Pin Description

3 Brush wear signal

5, 6 Cycle switch signal

7-10 Jumper 15C866 (available in

repair kit 246961)

34 312066Z

24G879 Motor Control, for E-20 and E-XP1

DIP Switch (SW2) Settings

Model E-20

ON (UP)

TI3178b-3

Repair

J3 (A)

J8 (B)

Model E-XP1

ON (UP)

TI3178b-4

24G881 Motor Control, for E-30 and E-XP2

DIP Switch (SW2) Settings

Model E-30

J13

J10

J12

D11

J12

SW2

TI3153A-1

SW2

J13

J5 (A)

ON (Down)

Model E-XP2

TI3178b-2

J3 (B)

ON (Down)

Apply 110009 thermal heatsink compound to mating surfaces.

TI3178b-1

TI2576A-1

FIG. 2. Motor Control Board

312066Z 35

Repair

Transducers

1. Turn main power OFF . Disconnect power

supply.

4. Disconnect transducer cables at board; see F

. 2, page 35. Reverse A and B connections and check if diagnostic code follows; see E21: No component A transducer, page 12.

5. If transducer fails test, thread cable through top of cabinet. Note path as cable must be replaced in same way.

2. Relieve pressure, page 23.

3. Refer to electrical diagrams. Motor control board is on right side inside cabinet.

806 (A Side)

801

6. Install o-ring (820) on new transducer (806), F

. 3.

7. Install transducer in manifold. Mark end of cable with tape (red=transducer A, blue=transducer B).

8. Route cable into cabinet and thread into bundle as before.

9. Connect transducer cable at board; see F

. 2, page

35.

806 (B Side)

820

TI10957a

FIG. 3. Transducers

Electric Fan

4. Refer to electrical diagrams. Disconnect fan wires from fuses (F).

5. Remove fan.

1. Turn main power OFF . Disconnect power

supply.

6. Install fan in reverse order.

2. Relieve pressure, page 23.

3. Check fuses (F) at left of breaker module, F Replace if blown. If good, continue with step 4.

. 4.

ti9884a-1

FIG. 4. Fan Fuses

36 312066Z

Temperature Control Module

Repair

Table 5: Temperature Control Module Connections

Connector Description

DATA (A) Data reporting

HOSE T/C P; FTS (purple)

12 11 HOSE T/C R; FTS (red) 10 HOSE T/C S; FTS (silver

(unshielded bare wire))

9 HEATER T/C B, Y;

Thermocouple (yellow)

SENSOR (B)

8 HEATER T/C B, R;

Thermocouple (red) 7 Not used 6 HEATER T/C A, Y;

Thermocouple (yellow) 5 HEATER T/C A, R;

Thermocouple (red)

4, 3 OVERTEMPERATURE B;

Overtemperature switch B

2, 1 OVERTEMPERATURE A;

Overtemperature switch A

DISPLAY (C) Display

COMMUNICATION (D) Communication to power

boards

PROGRAM (E) Software programming

BOOT (F) Software bootloader

POWER/RELAY (G) Circuit board power input and

contactor control output

ti9875a

ti9843a1

Right Side of

Control Heater Module

Table 6: Temperature Power Module Connections

Connector Description

COMMUNICATION

(H)

POWER (J) Power to heater

Communication to control board

ti9843a4

Bottom of Power Modules

FIG. 5: Temperature Control Module Connections

312066Z 37

Repair

Test SCR Circuit

1. Test the SCR circuit in the on position:

a. Make sure everything is connected, including

the hose.

b. Turn main power ON .

c. Adjust the hose heat setpoint

ent hose temperature.

d. Turn on heat zone by pressing .

e. Hold down to view electrical current.

Hose current should ramp up to 45A. If there is no hose current, see E03: No zone current, page 10. If hose current exceeds 45A, see E02: High zone current, page 9. If hose current stays several amps below 45A, hose is too long or voltage is too low.

above

Replacing Temperature Control Assembly Modules

CAUTION

Before handling assembly, put on a static conductive wrist strap to protect against static discharge which can damage assembly. Follow instructions provided with wrist strap.

the ambi-

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 23.

3. Refer to electrical diagrams; see Electrical Diagrams manual 312067. Temperature control assembly is on left side inside cabinet.

4. Remove bolts that secure transformer assembly and slide assembly to side in cabinet.

2. Test the SCR circuit in the off position:

a. Make sure everything is connected, including

the hose.

b. Turn main power ON .

c. Adjust the hose heat setpoint

ent hose temperature.

d. Turn on heat zone by pressing .

e. Using a voltmeter, carefully measure the volt-

age at the hose connector. You should not get a voltage reading. If you do, the SCR on the temperature control board is bad. Replace the temperature control assembly.

below

the ambi-

5. Put on static conductive wrist strap.

6. Disconnect all cables and connectors from assembly; see Parts - Temperature Control, page 64.

7. Remove nuts and take entire temperature control assembly to workbench.

8. Replace defective module.

9. Install assembly in reverse order.

38 312066Z

Repair

312066Z 39

Repair

Primary Heaters

Heater Element

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 23.

3. Wait for heaters to cool.

4. Remove heater shroud.

5. See F

Total Heater

. 6. Disconnect heater element wires from

heater wire connector. Test with ohmmeter.

Wattage Element Ohms

Line Voltage

The primary heaters output their rated wattage at 230 Vac. Low line voltage will reduce power available and

the heaters will not perform at full capability.

6,000 1500 30-35

7,650 2550 18-21

10,200 2550 18-21

6. To remove heater element, first remove thermocouple (310) to avoid damage, see step 7, page 42.

7. Remove heater element (307) from housing (301). Be careful not to spill any fluid left in housing.

8. Inspect element. It should be relatively smooth and shiny. If there is a crusted, burnt, ash-like material adhered to element or sheath shows pitting marks, replace element.

9. Install new heater element (307), holding mixer (309) so it does not block thermocouple port (P).

10. Reinstall thermocouple, page 42.

11. Reconnect heater element leadwires to heater wire connector.

12. Replace heater shroud.

40 312066Z

305

Repair

313

301

310

311

308

304

313

303

306

304

309

307

315

r_247813_312066

Apply 110009 thermal heatsink compound.

FIG. 6. Heater (7.5 kW Single Zone Heater Shown)

312066Z 41

Repair

Thermocouple

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 23.

3. Wait for heaters to cool.

4. Remove heater shroud.

5. Disconnect thermocouple wires from B on tempera-

ABLE

ture control module. See T 5, page 37.

6. Feed thermocouple wires out of cabinet. Note path as wires must be replaced in the same way.

7. See F

. 7. Loosen ferrule nut (N). Remove thermocouple (310) from heater housing (301), then remove thermocouple housing (H). Do not remove the thermocouple adapter (305) unless necessary. If

5, page 37 and FIG.

adapter must be removed, ensure that mixer (309) is out of the way when replacing the adapter.

8. Replace thermocouple, F

. 7.

a. Remove protective tape from thermocouple tip

(T).

b. Apply PTFE tape and thread sealant to male

threads and tighten thermocouple housing (H) into adapter (305).

c. Push in thermocouple (310) so tip (T) contacts

heater element (307).

d. Holding thermocouple (T) against heater ele-

ment, tighten ferrule nut (N) 1/4 turn past tight.

9. Route wires (S) into cabinet and thread into bundle as before. Reconnect wires to board.

10. Replace heater shroud.

11. Turn on heaters A and B simultaneously to test. Temperatures should rise at same rate. If one heater is low, loosen ferrule nut (N) and tighten thermocouple housing (H) to ensure thermocouple tip (T) contacts element (307).

309

FIG. 7. Thermocouple

Apply PTFE tape and thread sealant.

310

Apply 110009 thermal heatsink compound.

301

307

308

ti7924a

42 312066Z

Repair

Overtemperature Switch

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 23.

3. Wait for heaters to cool.

4. Remove heater shroud.

5. Disconnect one leadwire from overtemperature switch (308), F meter. Resistance must be approximately 0 ohms.

6. If switch fails test, remove wires and screws. Discard failed switch. Apply thermal compound 110009, install new switch in same location on housing (301), and secure with screws (311). Reconnect wires.

. 7. Test across switch with ohm-

4. Using an ohmmeter, check between the two terminals of the connector (D). There should be continuity.

5. If hose fails test, retest at each length of hose, including whip hose, until failure is isolated.

Check FTS Cables

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 23.

3. Disconnect FTS cable (F) at Reactor, F

. 8.

TI10964a

If wires need replacement, disconnect from temperature control board. See T

ABLE

5, page 37 and FIG.

5, page 37.

Heated Hose

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

Check Hose Connectors

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 23.

Whip hose must be connected.

FIG. 8. Heated Hose

4. Test with ohmmeter between pins of cable connector.

Pins Result

1 to 2 approximately 35 ohms per 50 ft (15.2 m) of

hose, plus approximately 10 ohms for FTS

1 to 3 infinity

5. If cable fails test, retest at FTS, page 44.

3. Disconnect hose connector (D) at Reactor, F

312066Z 43

. 8.

Repair

Fluid Temperature Sensor (FTS)

Test/Removal

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 23.

3. Remove tape and protective covering from FTS

(21), F ohmmeter between pins of cable connector.

3 to FTS groundscrew 0 ohms

1 to FTS component A

. 8. Disconnect hose cable (F). Test with

Pins Result

1 to 2 approximately 10 ohms

1 to 3 infinity

infinity

fitting (ISO)

4. If FTS fails any test, replace FTS.

5. Disconnect air hoses (C, L), and electrical connectors (D).

6. Disconnect FTS from whip hose (W) and fluid hoses (A, B).

7. Remove ground wire (K) from ground screw on underside of FTS.

8. Remove FTS probe (H) from component A (ISO) side of hose.

Installation

The Fluid Temperature Sensor (FTS) is supplied. Install FTS between main hose and whip hose. See Heated Hose manual 309572 for instructions.

ISO

WLE

ti17029b

FIG. 9: Fluid Temperature Sensor and Heated Hoses

44 312066Z

Repair

Transformer Primary Check

1. Turn main power OFF .

2. Locate the two smaller (10 AWG) wires coming out of transformer. Trace these wires back to contactor and circuit breaker (911). Use an ohmmeter to test for continuity between two wires; there should be continuity.

Transformer Secondary Check

1. Turn main power OFF .

2. Locate the two larger (6 AWG) wires coming out of transformer. Trace these wires back to large green connector under hose control module and circuit breaker (909). Use an ohmmeter to test for continuity between two wires; there should be continuity.

If you are not sure which wire in green plug under hose module connects to transformer, test both wires. One wire should have continuity with the other transformer wire in breaker (909) and the other wire should not.

3. To verify transformer voltage, turn on hose zone. Measure voltage from 18CB-2 to POD-HOSE-P15-2; see Reactor Electrical Dia-

grams manual 312067.

Model Secondary Voltage

310 ft. 90 Vac*

210 ft. 62 Vac*

* For 230 Vac line voltage.

Replace Transformer

Use this procedure to replace transformer.

1. Turn main power OFF . Disconnect power

supply.

909

. 10: Circuit Breaker Module

911

ti9884a

2. Open Reactor cabinet.

3. Remove bolts holding transformer to cabinet floor. Slide transformer forward.

4. Disconnect the transformer wires; see Reactor Electrical Diagrams manual 312067.

5. Remove transformer from cabinet.

6. Install new transformer in reverse order.

312066Z 45

Repair

Display Module

Temperature and Pressure Displays

CAUTION

Before handling board, put on a static conductive wrist strap to protect against static discharge which can damage board. Follow instructions provided with wrist strap.

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 23.

3. Refer to electrical diagrams.

between cable bushing and cover (504) with screws (512).

Red Stop Button

CAUTION

Before handling board, put on a static conductive wrist strap to protect against static discharge which can damage board. Follow instructions provided with wrist strap.

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 23.

3. Refer to electrical diagrams.

4. Put on static conductive wrist strap.

5. Remove screws (509, 510) and cover (504), F

11.

4. Put on static conductive wrist strap.

5. Disconnect main display cable (20) at lower left corner of display module; see F

. 11.

6. Remove screws (509, 510) and cover (504); see F

. 11.

If replacing both displays, label temperature display cables TEMP and pressure display cables PUMP before disconnecting.

7. Disconnect cable connectors (506 and 511) from back of temperature display (501) or pressure dis-

play (502); see F

. 11.

8. Disconnect ribbon cable(s) (R) from back of display; see F

. 11.

9. Remove nuts (508) and plate (505).

10. Disassemble display, see detail in F

. 11.

11. Replace board (501a or 502a) or membrane switch (501b or 502b) as necessary.

6. Disconnect button cable connectors (506) from back of temperature display (501) and pressure display (502).

7. Remove red stop button (506).

8. Reassemble in reverse order. Be sure display cable ground wire (G) is secured between cable bushing and cover (504) with screws (512).

12. Reassemble in reverse order, see F

. 11. Apply medium strength thread sealant where shown. Be sure display cable ground wire (G) is secured

46 312066Z

Apply medium strength thread sealant.

Repair

511

502

503

504

507

506

512

501

508

505

506

Detail of Membrane Switches and Display Boards

Temperature Display Pressure Display

502c

510

ti2574a

502a

502b

501c

501a

501b

ti3172a

FIG. 11. Display Module

312066Z 47

Repair

Inlet Fluid Strainer Screen

The inlet strainer at each proportioning pump filters out solid matter that can plug the 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.

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.

TI10974a

FIG. 12. Y Strainer Components

* Fluid filter screen (59g) replacements:

Part Description

180199 20 mesh (standard); 1 pack 255082 80 mesh (optional); 2 pack 255083 80 mesh (optional); 10 pack

Pump Lubrication System

1. Close the material supply valve at the pump inlet to prevent material from being pumped while the strainer plug (C) is removed.

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

3. Remove the screen (A) from the strainer manifold. Thoroughly flush the screen with gun cleaner and shake it dry. Inspect the screen for blockage. No more than 25% of the mesh should be restricted. If more than 25% is blocked, replace the screen. Inspect the strainer gasket (B) and replace as required.

4. Ensure the pipe plug (D) is securely screwed into the strainer plug (C). Install the strainer plug with the screen (A) and gasket (B) in place and tighten. Do not overtighten. Let the gasket make the seal.

5. Open the material supply valve, ensure that there are no leaks, and wipe the equipment clean.

6. Proceed with operation.

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. Relieve pressure, page 23.

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

. 13.

48 312066Z

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 into the bracket.

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

Repair

TI10970a

. 13. Pump Lubrication System

TI10969a

312066Z 49

Parts

Reactor Assembly (Model E-XP1 Shown)

121

110

109, 111,

112

115

TI10953a

41, 102

120

TI10960a

122

Strut Channel Style Support Rail

113, 119

TI10977a

Slotted U-Channel

Style Support Rail

65f

65e

TI10961a

50 312066Z

65a

65b, 65c65d

122

TI18608a

123

Parts

Left Side of Cabinet

61, 62

39, 52, 71, 73

TI9835a

Right Side of Cabinet

31, 42

36 (400V models only)

29, 42

TI10968a

312066Z 51

Parts

Detail, Fluid Manifold Area

7, see page 66

817 (Ref)

106

127

Detail, Cabinet Area

107

TI10962a

mounting base (from motor)

TI10978a

52 312066Z

Parts Used on All Models

See pages 54 through 56 for parts that vary by model.

Parts

Ref. Part Description Qty

1 FRAME; page 62 1 2 HEATER; pages 60 and 61 * 3 MODULE, proportioner; page 58 * 4 245974 DISPLAY; page 63 1 5 CONTROL, temperature; page 64 1 6 CONTROL, motor; page 65 * 7 247823 MANIFOLD, fluid; page 66 1 8 TRANSFORMER; pages 54-56 * 9 SHIELD; page pages 54-56 * 10 246976 DOOR, cabinet 1 11† 261669 SENSOR, fluid temperature 1 12 15B456 GASKET, manifold 1 13 115834 FAN 1 14 TUBE, heater component A; pages

15 TUBE, pump, component A; pages

16 TUBE, heater component B; pages

17 TUBE, pump, component B; pages

18† 247787 CABLE, overtemperature; see electrical

19† 15B380 CABLE, hose control; see electrical

20 15B383 CABLE, display 1 21 CONNECTOR, tube; pages 54-56 * 22 116773 CONNECTOR, plug 1 23 C38163 WASHER, lock, external tooth 1 24 15B361 BOOT, wire feed through 1 25 15B510 PLATE, cover, wire 1 26 15B360 GASKET, fan 1 27 255047 STRAIN RELIEF 1 28 MODULE, breaker; pages 54-56 * 29 116149 SPACER 8 31 117666 TERMINAL, ground 1

123969 SWITCH, disconnect 1

★

123967 SWITCH, main power 1

★

34 35 117723 SCREW, machine; 6-32 x 2 in. (51 mm) 4 36 SWITCH, added pole; 380V; page 54 * 38 115492 SCREW, machine; 8-32 x 0.345 in. (9

39 FILTER; 230V; page 54 * 40 117623 NUT, cap; 3/8-16 4 41 113796 SCREW, flanged, hex hd; 1/4-20 x 3/4

42 115942 NUT, hex flange; 1/4-20 15 44 15K817 LABEL, diagnostic codes 1 45 189930 LABEL, caution 3

189285 LABEL, caution 3

▲

51 52 CABLE. harness, filter; pages 54-56 * 53 15B593 SHIELD, membrane switch; pack of 10 1 57 15B775 COVER, wire access 2 58 247524 COVER, heater, back 1 59 256732 COVER, heater, front 1

15G280 LABEL, warning 1

▲

60 61 113505 NUT, hex, keps; 10-24 6 62 112776 WASHER, plain; no. 10 2 65 KIT, fluid inlet 1 65a FITTING, swivel, elbow 2 65b 101078 Y-STRAINER 2 65c† 180199 ELEMENT, 20 mesh 2 65d C20487 NIPPLE, 3/4 npt 2

54-56

diagrams

mm)

in. (19 mm)

LABEL, warning; pages 54-56 *

Ref. Part Description Qty

65e 109077 VALVE, ball; 3/4 npt (fbe) 2 65f 118459 FITTING, union, swivel; 3/4-14 npt(m) x

66 101078 Y-STRAINER; includes 66a 2 66a† 180199 ELEMENT, 20 mesh 1 67 109077 VALVE, ball; 3/4 npt (fbe) 2 68 C20487 NIPPLE; 3/4 npt 2 69 157785 UNION, swivel; 3/4 npt(m) x 3/4

71 SCREW, machine; pages 54-56 *

◆

72 73 WASHER, lock; pages 54-56 * 76 CAPACITOR; pages 54-56 * 77 BRACKET; pages 54-56 *

86 CABLE, overtemperature, jumper;

87 15B807 SHIELD, fan 1 88 186494 CLIP, spring 6

89 205447 COUPLING, hose 2 90 15M338 TUBE, low pressure; 1/4 in. (6 mm) ID;

◆

97 102 STRAP, motor; pages 54-56 * 106 117502 REDUCER; #5 x #8 JIC 1 107 117677 REDUCER; #6 x #10 JIC 1 109 246928 RESERVOIR; includes 110-119; see

110 054826 TUBE; PTFE; 1/4 in. (6 mm) ID;

111 118433 VALVE, check 1 112 118432 VALVE, check 1 113 116746 FITTING, barbed 2 115 15C568 BRACKET, reservoir 1 117 206995 THROAT SEAL LIQUID; 1 qt (1 liter) 1 119 191892 ELBOW; 1/8 npt (m x f) 2 120 121 LABEL; pages 54-56 * 122 INSULATOR, heat; pages 54-56 * 123 247782 SPACER 4 124 247854 COVER, connector, module 1 125 114331 SCREW, machine; 6-32 x 0.375 in. (9.5

▲

171001 LABEL, warning 1

▲

Replacement Danger and Warning labels, tags, and

3/4-14 npt(f)

npsm(f)

BRACKET. heater; pages 54-56 *

pages 54-56

3/8 in. (16 mm) OD; 4 ft (1.2 m); PTFE BOLT; hex hd; pages 54-56 * LOCKWASHER; 3/8; pages 54-56 * NUT, channel; pages 54-56 *

309911

2 ft (0.6 m)

mm)

cards are available at no cost.

* See quantity on referenced pages.

† Not shown.

★

Required for all A-D series models. Included in Knob Repair Kit 258920 (purchase separately).

◆

Not required for slotted U-Channel style heater support rails.

312066Z 53

Parts

Parts that Vary by Model

Use the following tables on this and the next two pages to find parts that vary by model. Find the reference number and of part in left column and Reactor model in top row. Intersection is correct part number.

See page 53 for parts common to all models.

Reactor Models

Ref. Description

259024 E-XP1

259025 E-20

259026 E-30

259028 E-XP2

259029 E-XP1

259030 E-20

259031 E-30

259032 E-XP2

259033 E-XP1

259034 E-20

259035 E-30

259036 E-XP2

Qty

2 HEATER; pages

60 and 61

3 MODULE, pro-

portioner; page 58245956 245956 245957 245959 245956 245956 245957 245959 245956 245956 245957 245959 1

6CONTROL,

motor; page 65

8 TRANS-

FORMER;

9 SHIELD 276878 276878 276879 276879 276878 276878 276879 276879 276878 276878 276879 276879 1

14 TUBE, heater,

component A

15 TUBE, pump,

component A

16 TUBE, heater,

component B

17 TUBE, pump,

component B

21 CONNECTOR,

tube

28 MODULE,

breaker; page 67

36 SWITCH, added

pole; 380V

39 FILTER; 230V 117667 117667 117667 117667 117667 117667 1

247507 247506 247507

24G879 24G879 24G881 24G881 24G879 24G879 24G881 24G881 24G879 24G879 24G881 24G881 1

247840 247840 247812 247812 247840 247840 247812 247812 247840 247840 247812 247812 1

247920 247920 247920 247915 247920 247920 247920 247915 247920 247920 247920 247915 1

247912 247912 247919 247914 247912 247912 247919 247914 247912 247912 247919 247914 1

247918 247918 247918 247917 247918 247918 247918 247917 247918 247918 247918 247917 1

247913 247913 247921 247916 247913 247913 247921 247916 247913 247913 247921 247916 1

121310 121310 121311 121311 121310 121310 121311 121311 121310 121310 121311 121311 2

CCF FBBEEAADD1

247509 (qty: 2)

247507 247506 247507

123968 123968 123968 123968 1

247509 (qty: 2)

247507 247506 247507

247509 (qty: 2)

54 312066Z

Parts

Reactor Models

259024

Ref. Description

51▲ LABEL, warning 198278 198278 198278 198278 198278 198278 1

52 CABLE, harness,

filter

65 KIT, fluid inlet 234366 234366 234367 234366 234366 234366 234367 234366 234366 234366 234367 234366 1

65a ELBOW, swivel;

3/4 npt(m) x 1” npt(f)

71 SCREW,

machine

BRACKET,

◆

heater

BRACKET, heater

73 WASHER, lock

76 CAPACITOR 244733 244733 244733 244733 244733 244733 1

77 BRACKET

86 CABLE, over-

temperature, jumper

BOLT; hex hd;

◆

3/8-16

BOLT; hex hd; 3/8-16

LOCKWASHER;

◆

3/8

LOCKWASHER; 3/8

NUT, channel

◆

NUT, channel

102 STRAP, motor 15B107 15B107 15B108 15B108 15B107 15B107 15B108 15B108 15B107 15B107 15B108 15B108 1

121 LABEL

122 INSULATOR

E-XP1

160327 160327 118463 160327 160327 160327 118463 160327 160327 160327 118463 160327 2

247523 247523 247523

15H187 15H187 15H187 15H187 15H187 15H187 15H187 15H187 15H187

100469 100469 100469

100133 100133 100133

118446 118446 118446

15M504 15M500 15M499 15M501 15M504 15M500 15M499 15M501 15M504 15M500 15M499 15M501

167002 167002 167002

259025 E-20

259026 E-30

15B385 15B385 15B385 15B385 15B385 15B385 1

103181 103181 103181 103181 103181 103181 2

197999 197999 197999 197999 197999 197999 1

259028 E-XP2

--- --- --- --- --- --- 2

247523 247523 247523 4

100469 100469 100469 4

100133 100133 100133 4

118446 118446 118446 4

167002 (qty: 4)

259029 E-XP1

247523 247523 247523 247523 247523 247523 2

100469 100469 100469 100469 100469 100469 2

100133 100133 100133 100133 100133 100133 2

118446 118446 118446 118446 118446 118446 2

167002 167002 167002

259030 E-20

259031 E-30

259032 E-XP2

167002 (qty: 4)

259033 E-XP1

167002 167002 167002

259034 E-20

259035 E-30

259036 E-XP2

167002 (qty: 4)

Qty

312066Z 55

Parts

Parts that Vary by Model (continued)

Reactor Models

259057 E-30

Ref. Description

2 HEATER; pages

60 and 61

3 MODULE, pro-

portioner; page 58245957 245957 245957 1

6CONTROL,

motor; page 65

8 TRANSFORMER; 247812 247812 247812 1

9 SHIELD 276879 276879 276879 1

14 TUBE, heater,

component A

15 TUBE, pump,

component A

16 TUBE, heater,

component B

17 TUBE, pump,

component B

21 CONNECTOR,

tube

28 MODULE,

breaker; page 67

36 SWITCH, added

pole; 380V

39 FILTER; 230V 117667 117667 117667 1

51▲ LABEL, warning 198278 198278 198278 1

52 CABLE, harness,

filter

65 KIT, fluid inlet 234367 234367 234367 1

65a ELBOW, swivel;

3/4 npt(m) x 1” npt(f)

71 SCREW, machine --- --- --- 2

BRACKET, heater

◆

73 WASHER, lock 103181 103181 103181 2

76 CAPACITOR 244733 244733 244733 1

77 BRACKET 197999 197999 197999 1

BOLT; hex hd;

◆

3/8-16

LOCKWASHER;

◆

3/8

LOCKWASHER; 3/8

w/15.3kW

247509 247509 247509 2

24G881 24G881 24G881 1

247915 247915 247915 1

247914 247914 247914 1

247917 247917 247917 1

247916 247916 247916 1

121311 121311 121311 2

15B385 15B385 15B385 1

118463 118463 118463 2

247523 247523 247523 4

100469 100469 100469 4

100133 100133 100133 4

259058 E-30 w/15.3kW

FDE1

259059 E-30 w/15.3kW

123968 1

Qty

Reactor Models

259057 E-30

Ref. Description

NUT, channel

◆

NUT, channel 118446 118446 118446 4

102 STRAP, motor 15B108 15B108 15B108 1

121 LABEL 15M499 15M499 15M499 1

122 Insulator 167002 167002 167002 4

▲

Replacement Danger and Warning labels, tags, and

w/15.3kW

259058 E-30 w/15.3kW

259059 E-30 w/15.3kW

Qty

cards are available at no cost.

◆

Not required for slotted U-Channel style heater support rails.

--- Not for sale.

56 312066Z

Parts

312066Z 57

Parts

Sub Assemblies

Proportioner Module

245956 Module for E-20 and EXP-1

245957 Module for E-30

245959 Module for EXP-2

226

209

217

216

**210

206B

213

211

205

203

215

212

214

202

201

218

*208

208

219

204

214

*207

225

216

210**

211

224

Flat side faces up.

206A

TI2511a

Detail of Cycle Counter Switch

220

221

TI3250a

58 312066Z

Proportioner Assembly

245956 Module, for E-20 and E-XP1

245957 Module, for E-30

245959 Module, for E-XP2

Ref. Part Description Qty

201 24V618 MOTOR; 245956 1

24V500 MOTOR; 245957, 245959 1

202 245968 HOUSING, drive; 245956 2

245969 HOUSING, drive; 245957, 245959 2

203 240523 HOUSING, bearing; 245956 2

241015 HOUSING, bearing; 245959 2 245927 HOUSING, bearing; 245957 2

204 244264 GEAR; includes items 207, 208;

245956

244265 GEAR; includes items 207, 208;

245957, 245959

205 241008 ROD, connecting; includes item 210;

245956

241279 ROD, connecting; includes item 210;

245957, 245959

206A 246830 PUMP, displacement, component A;

245956; see 309577

246831 PUMP, displacement, component A;

245959; see 309577

246832 PUMP, displacement, component A;

245957; see 309577

206B 245970 PUMP, displacement, component B;

245956; see 309577

245971 PUMP, displacement, component B;

245959; see 309577

245972 PUMP, displacement, component B;

245957; see 309577 207* 114699 WASHER, thrust; steel 2 208* 114672 WASHER, thrust; bronze 4 209 114418 SCREW, self-tapping; 8-32 x 1 in. (25

mm); 245956

114818 SCREW, self-tapping; 8-32 x 1-1/4 in.

(31 mm); 245957, 245959 210** 176817 CLIP, wire; 245956 2

183169 CLIP, wire; 245957, 245959 2

211 176818 PIN; 245956 2

183210 PIN; 245957, 245959 2

212 107218 SCREW, cap, socket-hd; 1/4-20 x 2-3/4

in. (70 mm); 245956

114686 SCREW, cap, socket-hd; 5/16-18 x

3-1/4 in. (83 mm); 245957, 245959 213 107210 SCREW, cap, socket-hd; 3/8-16 x 1-1/2

in. (38 mm); 245956

114666 SCREW, cap, socket-hd; 3/8-16 x 2-1/4

in. (57 mm); 245957, 245959 214 105510 WASHER, lock; 1/4; 245956 12

104008 WASHER, lock; 5/16; 245957, 245959 12 215 106115 WASHER, lock; 3/8 size 8 216 192723 NUT, retaining; 245956 2

193031 NUT, retaining; 245959 2

193394 NUT, retaining; 245957 2 217 179899 COVER; 245956 2

241308 COVER; 245957, 245959 2 218 116191 WASHER, thrust; 245956 2

116192 WASHER, thrust; 245957, 245959 2 219 100644 SCREW, cap, socket-hd; 1/4-20 x 3/4

in. (19 mm); 245956

101864 SCREW, cap, socket-hd; 5/16-18 x 1 in.

(25 mm); 245957, 245959

220 116618 MAGNET 1

Ref. Part Description Qty

221 117770 SWITCH, cycle counter 1 223 100643 SCREW, cap, socket-hd; 1/4-20 x 1 in.

(25 mm); 245956

102962 SCREW, cap, socket-hd; 5/16-18 x

1-1/4 in. (31 mm); 245957, 245959 224 104765 PLUG 2 225 15C587 GUARD, finger; 245956 1

15C588 GUARD, finger; 245959 1

226 15M507 LABEL; 245956 1

15M508 LABEL; 245957, 245959 1

* Parts included in Gear Kit 244264 (245956) or

244265 (245957, 245959).

** Parts included in Connecting Rod Kit 241008

(245956) or 241279 (245957, 245959).

Parts

312066Z 59

Parts

Fluid Heaters

247506, 6.0 kW Fluid Heaters 247507, 10.2 kW Fluid Heaters

301

303

310

314

305

306

308

311

313

304

309

r_247507_312408

307

Apply 110009 thermal heatsink compound.

315

Ref Part Description Qty.

301 HOUSING, heater

303 121309 ADAPTER

304 15H304 PLUG

305 15H306 ADAPTER, thermocouple

306 120336 O-RING; fluoroelastomer

307 HEATER, immersion

310 117484 SENSOR

311 100518 SCREW, machine, pan hd

313 15H305 PLUG, hollow

314 247520 DISC, rupture

315 124132 O-RINGS

16A110 2550W; 10.2kW heater only

16A112 1500 W; 6.0 kW heater only

308 15B137 SWITCH, overtemperature

309 15B135 MIXER, immersion heater

60 312066Z

7.65 kW Single Zone Fluid Heater

(Two Per Machine)

Part 247509

Parts

304

313

303

314

306

305

310

301

313

311

308

304

309

307

r_247813_312066

315

Ref. Part Description Qty

301 HOUSING, heater 303 121309 ADAPTER 304 15H304 PLUG 305 15H306 ADAPTER, thermocouple 306 120336 O-RING; fluoroelastomer 307 16A110 HEATER, immersion; 2550 W 308 15B137 SWITCH, overtemperature 309 15B135 MIXER, immersion heater

312066Z 61

Apply 110009 thermal heatsink compound.

Ref. Part Description Qty

310 117484 SENSOR

311 100518 SCREW, machine, pan hd

313 15H305 PLUG, hollow

314 247520 DISC, rupture; not shown

315 124132 O-RING

3 1 3

1 2 5 1 3

Parts

Reactor Frame

405

406

401

404

Ref. Part Description Qty

401 FRAME 1 402 116478 WHEEL 2 403 101242 RING, retaining 2 404 116477 WASHER, flat; nylon 4 405 112125 PLUG 2 406 116411 SPRING 2 407 154636 WASHER, flat 4

402

404

403

TI2513a

407

62 312066Z

Display

502

503

Parts

511

504

507

506

502b

508

505

506

501

510

512

20 (Ref)

ti2574a

502c502a

501c

501a

501b

Ref. Part Description Qty.

501 24G884 DISPLAY, pressure; includes

501a-501c 501a 24G882 .BOARD, circuit 501b 246479 .SWITCH, membrane 501c 112324 .SCREW 502 24G883 DISPLAY, temperature; includes

502a-502c 502a 24G882 .BOARD, circuit 502b 246479 .SWITCH, membrane 502c 112324 .SCREW 503 15B293 GASKET 504 15B292 COVER

312066Z 63

Ref. Part Description Qty.

505 15B291 PLATE

506 246287 HARNESS, wire, red stop button 507 117499 HANDLE

508 117523 NUT, cap; 10-24

510 --- SCREW, machine, pan-hd; M5 x

4 1

0.8; 16 mm 511 15B386 CABLE, display 512 195853 SCREW, machine; M2.5 x 6

1 1

--- Not for sale.

4 1 1

ti3172a

1 1 2 8 4

1 2

Parts

Temperature Control

602

605

606

601

603

604

603

604

To B Heater Module

To A Heater Module

To Hose Heater Module

604

603

TI9843a

Ref. Part Description Qty.

601 247772 PANEL, module mounting 602 247827 HOUSING, control module 603 247828 HOUSING, heater module 604 115942 NUT, hex 605 247801 CABLE, communication 606 247825 KIT, cover, connector with screws

64 312066Z

1 1 3 4 1 1

Motor Control

24G879 Motor Control for E-20 and EXP-1

703

702

Parts

Apply 110009 thermal heatsink compound to mating surfaces.

Motor harness (609) plugs in here.

701

TI3153a

707

24G879 Motor Control for E-20 and EXP-1

Ref. Part Description Qty.

701 15B297 HEAT SINK 1 702 24G878 BOARD, motor control 1 703 107156 SCREW, machine; 6-32 7

24G881 Motor Control for E-30 and EXP-2

703

705

702

TI2576a

24G881 Motor Control for E-30 and EXP-2

Ref. Part Description Qty.

701 16F745 HEAT SINK 1 702 --- BOARD, motor control 1 703 --- SCREW, machine;

704 117526 SPACER 3 705 117683 SCREW, 6-32 x 1-1/2 in. (38 mm) 2 707 15C007 INDUCTOR 1 709 15B408 CABLE, harness, motor 1

6-32 x 3/8 in. (10 mm)

701

704

--- Not for sale.

312066Z 65

Parts

Fluid Manifold

Torque to 355-395 in-lb (40.1-44.6 N•m).

Apply sealant (113500) to threads.

Valve must be closed with handle position as shown on drawing.

** Apply PTFE tape or thread sealant to tapered threads.

808

802

802b

818

802a

806

805

803

814

815

804

801

812

813

Ref. Part Description Qty.

801 247837 MANIFOLD, fluid 802† 247824 VALVE, drain cartridge 802a† 158674 . O-RING 802b† 247779 . SEAL, seat, valve 803 102814 GAUGE, pressure, fluid 804 162453 FITTING, 1/4 npsm x 1/4 npt 805 24K999 TRANSDUCER, pressure, control 806 247788 HANDLE, red 807 247789 HANDLE, blue 808† 112309 NUT, hex, jam 812 117556 NIPPLE, #8 JIC x 1/2 npt 813 117557 NIPPLE, #10 JIC x 1/2 npt

816

807

814

817

Ref. Part Description Qty.

814 121312 ELBOW, 90 degrees

815 100840 ELBOW, street; 1/4 npsm x 1/4 npt

816 111457 O-RING, PTFE

817▲ 189285 LABEL, caution

818† 150829 SPRING, compression

▲

2 1 1 2 1 1

Replacement Warning labels, signs, tags, and cards

are available at no cost.

† Included in the following complete valve kits*:

ISO Valve Kit (left/red handle) 255149. Resin Valve Kit (right/blue handle) 255150. Valve Set Kit (both handles and grease gun) 255148.

* Complete valve kits also include thread sealant.

(Purchase kits separately).

TI10959a

2 2 2 1 2

66 312066Z

Circuit Breaker Modules

A - 230V, 3 Phase Circuit Breaker Modules (E-20, EXP-1)

For wiring and cable connections, refer to electrical diagrams manual 312067, supplied. See page 70 for parts.

903, 904

920

905

906

910

911

914

Parts

917

915

916

918

B - 400V, 3 Phase Circuit Breaker Modules (E-20, E-XP1)

For wiring and cable connections, refer to electrical diagrams manual 312067, supplied. See page 70 for parts.

902

920

905

906

910

238CR

911

178CB

907

187CB

909

917

168BR

197CB

172CB

912

922

913

908

901

919

903, 904

908

902

901

919

918

916

238CR

178CB

187CB

197CB

172CB

913

912

909

907

312066Z 67

922

Parts

C - 230V, 1 Phase Circuit Breaker Modules (E-20, EXP-1)

For wiring and cable connections, refer to electrical diagrams manual 312067, supplied. See page 70 for parts.

903, 904

902

920

905

906

910

911

914

168BR

917

915

908

916

918

D - 230V, 3 Phase Circuit Breaker Modules (E-30, EXP-2)

For wiring and cable connections, refer to electrical diagrams manual 312067, supplied. See page 70 for parts.

920

905

906

238CR

910

178CB

907

911

187CB

909

914

197CB

172CB

912

917

922

913

901

919

903, 904

"2

915

908

902

918

916

2#

#"

#"

909

907

#"

#"

913

912

922

68 312066Z

901

919

E - 400V, 3 Phase Circuit Breaker Modules (E-30, E-XP2)

For wiring and cable connections, refer to electrical diagrams manual 312067, supplied. See page 70 for parts.

903, 904

902

916

920

905

906

Parts

910

917

911

908

2#

#"

#"

#"

#"

901

918

F - 230V, 1 Phase Circuit Breaker Modules (E-30, EXP-2)

For wiring and cable connections, refer to electrical diagrams manual 312067, supplied. See page 70 for parts.

903, 904

916

902

920

905

907

906

2#

909

910

911

#"

#"

912

914

"2

#"

913

919

922

917

915

908

901

#"

918

909

907

312066Z 69

912

919

922

913

Parts

Circuit Breaker Modules Parts List

E-20 and EXP-1 Models E-30 and EXP-2 Models

Breaker Modules

Ref. Description

901 RAIL, mounting

902 CLAMP, block, end

903 HOLDER, fuse terminal, block

904 FUSE

905 TERMINAL, block

906 TERMINAL, end cover

907 BRIDGE, plug in, jumper

908 BLOCK, terminal ground

909 BREAKER, 1 pole, 50A

910 CONTACTOR, relay, 65A

911 BREAKER, 2 phase, 40A

912 BREAKER, 2 phase, 25A

BREAKER, 2 phase, 40A

913 BREAKER, 2 phase, 20A

914 CONNECTOR, power lug

CONNECTOR, power lug

915 BAR, power buss, 3 phase

BAR, power buss, 1 phase

916 CABLE, harness lower

917 CABLE, harness upper

918 CONNECTOR, 2 pin large

919 CONNECTOR, 3 pin

920 CONNECTOR, 4 pin

922 CABLE, harness

230V,

3 phase

255028 255028 255028 255028 255028 255028 1

255045 255045 255045 255045 255045 255045 1

255043 255043 255043 255043 255043 255043 2

255023 255023 255023 255023 255023 255023 2

255042 255042 255042 255042 255042 255042 4

--- --- --- --- --- --- 1

255044 255044 255044 255044 255044 255044 2

255046 255046 255046 255046 255046 255046 1

255026 255026 255026 255026 255026 255026 1

255022 255022 255022 255022 255022 255022 1

247768 247768 247768 247768 247768 247768 1

255050 255050 255050 255050 255050 255050 2

247768 247768 247768 247768 247768 247768 2

255049 255049 255049 255049 255049 255049 1

117679 117679 3

117805 117805 1

247802 247802 247802 247802 247802 247802 1

247805 247806 247804 247805 247806 247804 1

255027 255027 255027 255027 255027 255027 3

247522 247522 247522 247567 247567 247567 1

255031 255031 255031 255031 255031 255031 1

247791 247791 247791 247791 247791 247791 1

400V,

3 phase

230V,

1 phase

117679 117679 2

117678 117678 1

230V,

3 phase

400V,

3 phase

230V,

1 phase

Qty

--- Not for sale.

70 312066Z

248669 Conversion Kit

Convert and phase E-XP2 to and E-30 with 15.3 kW of heat by changing displacement pumps, bearings, and changing the Motor Control DIP settings to that of an E-30. For removal and installation of displacement pumps and bearings, see Pump Removal (page 24) and Pump Installation (page 26). For changing Motor Control DIP settings, see Motor Control Board, page

34.

248669 Conversion Kit

Ref. Part Description Qty.

65 118463 ELBOW, swivel; 3/4 npt(m) x 1 in.

npt(f) 303 245927 HOUSING, bearing 2 306A 246832 PUMP, displacement, component

A; see 309557 306B 245972 PUMP, displacement, component

B; see 309577 316 193394 NUT, retaining 2

303

316

306B

306A

24G881 Motor Control Board DIP Switch (SW2) need to be set for an E-30. 1,2,3, ON 4 OFF. See page

34.

TI10966a

312066Z 71

Dimensions

Dimension in. (mm)

A 46.0 (1168) B 31.0 (787) C 33.0 (838)

TI10953a

72 312066Z

Technical Data

Category Data

Maximum Fluid Working Pressure Models E-20 and E-30: 2000 psi (14 MPa, 140 bar)

Model E-XP1: 2500 psi (17.2 MPa, 172 bar)

Model E-XP2: 3500 psi (24.1 MPa, 241 bar) Maximum Fluid Temperature 190°F (88°C) Maximum Output Model E-20: 20 lb/min (9 kg/min)

Model E-30: 30 lb/min (13.5 kg/min)

Model E-XP1: 1 gpm (3.8 liter/min)

Model E-XP2: 2 gpm (7.6 liter/min) Output per Cycle (A and B) Model E-20 and E-XP1: 0.0104 gal. (0.0395 liter)

Model E-30: 0.0272 gal. (0.1034 liter)

Model E-XP2: 0.0203 gal. (.0771 liter) Line Voltage Requirement Parts 259024, 259025, 259026, 259028, 259057: 195-264 Vac, 50/60 Hz

Parts 259029, 259030, 259031, 259032, 259059: 338-457 Vac, 50/60 Hz

Parts 259033, 259034, 259035, 259036, 259058: 195-264 Vac, 50/60 Hz Amperage Requirement See Table 1, page 9. Heater Power Model E-20: 6000 Watts

Model E-30 and E-XP1: 10200 Watts

Models E-XP2 and E-30 with 15.3kW of heat: 15300 Watts Sound Power, per ISO 9614-2 Model E-20: 80 dB(A) at 2000 psi (14 MPa, 140 bar), 0.5 gpm (1.9 lpm)

Model E-30: 93.5 dB(A) at 1000 psi (7 MPa, 70 bar), 3.0 gpm (11.4 lpm)

Model E-XP1: 80 dB(A) at 2000 psi (14 MPa, 140 bar), 0.5 gpm (1.9 lpm)

Model E-XP2: 83.5 dB(A) at 3000 psi (21 MPa, 210 bar), 1.0 gpm (3.8 lpm) Sound Pressure, 1 m from equipment Model E-20: 70.2 dB(A) at 2000 psi (14 MPa, 140 bar), 0.5 gpm (1.9 lpm)

Model E-30: 83.6 dB(A) at 1000 psi (7 MPa, 70 bar), 3.0 gpm (11.4 lpm)

Model E-XP1: 70.2 dB(A) at 2000 psi (14 MPa, 140 bar), 0.5 gpm (1.9 lpm)

Model E-XP2: 73.6 dB(A) at 3000 psi (21 MPa, 210 bar), 1.0 gpm (3.8 lpm) Fluid Inlets 3/4 npt(f), with 3/4 npsm(f) union Fluid Outlets Component A (ISO): -8 (1/2 in.) JIC, with -5 (5/16 in.) JIC adapter

Component B (RES): -10 (5/8 in.) JIC, with -6 (3/8 in.) JIC adapter Fluid Circulation Ports 1/4 npsm(m), with plastic tubing; 250 psi (1.75 MPa, 17.5 bar) maximum Weight Model E-20 and E-XP1: 342 lb (155 kg)

Model E-30: 400 lb (181kg)

Models E-XP2 and E-30 with 15.3kW of heat: 438 lb (198 kg) Wetted Parts Aluminum, stainless steel, zinc plated, carbon steel, brass, carbide, chrome,

chemically resistant o-rings, PTFE, ultra-high molecular weight polyethylene

All other brand names or marks are used for identification purposes and are trademarks of their respective owners.

312066Z 73

Graco Standard Warranty

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.

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

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to

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

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

FOR GRACO CANADA CUSTOMERS

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

Graco Information

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

TO PLACE AN ORDER,

Phone: 612-623-6921 or Toll Free: 1-800-328-0211, Fax: 612-378-3505

All written and visual data contained in this document reflects the latest product information available at the time of publication.

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

contact your Graco distributor or call to identify the nearest distributor.

Graco reserves the right to make changes at any time without notice.

For patent information, see www.graco.com/patents.

Original instructions.

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

This manual contains English. MM 312066

www.graco.com

Revision Z - January 2015

Graco 312066z User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Models

Supplied Manuals

Related Manuals

Warnings

Temperature Control Diagnostic Codes

E01: High fluid temperature

E02: High zone current

E03: No zone current

E05: Circuit board overheated

E04: Fluid Temperature Sensor (FTS) or thermocouple disconnected

E06: Communication cable unplugged

Motor Control Diagnostic Codes

Alarms

Warnings

E21: No component A transducer

E22: No component B transducer

E23: High fluid pressure

E24: Pressure Imbalance

E25: High line voltage

E26: Low line voltage

E27: High Motor Temperature

E28: High current in motor

E29: Brush Wear

E31: Motor Control Failure (E-30 and E-XP2 only)

Communication Diagnostic Codes

E30: Momentary loss of communication

E99: Loss of communication

Troubleshooting

Reactor Electronics

Primary Heaters (A and B)

Hose Heat System

Repair

Before Beginning Repair

Pressure Relief Procedure

Flushing

Pump Removal

Pump Installation

Drive Housing

Motor Brushes

Capacitor Test

Circuit Breaker Module

Electric Motor

Motor Control Board

Transducers

Electric Fan

Temperature Control Module

Primary Heaters

Heated Hose

Fluid Temperature Sensor (FTS)

Display Module

Inlet Fluid Strainer Screen

Pump Lubrication System

Parts

Reactor Assembly (Model E-XP1 Shown)

Parts Used on All Models

Parts that Vary by Model

Sub Assemblies

Proportioner Module

Fluid Heaters

7.65 kW Single Zone Fluid Heater

Reactor Frame

Display

Temperature Control

Motor Control

Fluid Manifold

Circuit Breaker Modules

248669 Conversion Kit

Dimensions

Technical Data

Graco Standard Warranty

Graco Information