Graco 332637C User Manual

Repair-Parts

Reactor® 2 Elite Integrated

Proportioning System

Electric, Heated, Integrated Plural Component Proportioning System With Integrated Generator. For spraying polyurethane foam and polyurea coatings. For professional use only. Not approved for use in explosive atmospheres or hazardous locations.

Important Safety Instructions. Read all warnings and instructions in this manual. Save these instructions.

332637C

PROVEN QUALITY. LEADING TECHNOLOGY.

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

Important Isocyanate Information........................... 9

Models............................................................... 11

Approvals........................................................... 13

Accessories........................................................13

Supplied Manuals............................................... 14

Related Manuals ................................................ 14

Troubleshooting.................................................. 15

Troubleshoot Errors ..................................... 15

Load Center Diagnostics .............................. 50

Pressure Relief Procedure .................................. 60

Shutdown........................................................... 61

Flushing............................................................. 64

Repair................................................................ 65

Before Beginning Repair...............................65

Flush Inlet Strainer Screen ...........................65

Drain Coolant .............................................. 66

Reﬁll Proportioner Coolant Loop ................... 68

Reﬁll Engine Coolant Loop ........................... 69

Coolant Speciﬁcations.................................. 70

Change Pump Lubricant............................... 70

Remove Pump............................................. 71

Install Pump ................................................ 72

Repair Drive Housing ................................... 73

Repair Electric Motor.................................... 76

Repair Circuit Breaker Module ...................... 77

Replace Load Center Relays and

Fuses ............................................ 79

Replace Load Center ................................... 80

Replace Engine Solenoid Relays ..................80

Replace Fluid Inlet Sensor............................81

Replace Pressure Transducers ..................... 81

Replace Fans .............................................. 82

Repair Booster Heater.................................. 84

Repair Heated Hose.....................................87

Repair Flui d Temperature Sensor

(FTS).............................................88

Replace Heat Exchangers............................ 91

Replace Power Supply ................................. 94

Replace Circulation Pump ............................ 95

Repair Filter Housing Filter ........................... 96

Remove Fuel Tank....................................... 96

Replace Battery ........................................... 97

Repair Fusible Link Harness.........................98

Remove Radiator....................................... 100

Replace Advanced Display Module

(ADM).......................................... 100

Replace Engine Control Module .................. 101

Replace Motor Control Module

(MCM) ......................................... 101

Replace Temperature Control Module

(TCM) .......................................... 101

Remove Proportioner ................................. 102

Repair Engine ............................................ 105

12V Charge Alternator................................ 105

Notes ............................................................. 106

Parts................................................................ 107

Electrical Schematics........................................ 154

Repair and Spare Parts Reference .................... 170

Recommended Rebuild Spare Parts .................. 171

Dimensions...................................................... 172

Technical Speciﬁcations.................................... 175

Notes ............................................................. 178

Graco Extended Warranty for Integrated

Reactor® 2 Components ..................... 179

332637C

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation p oi nt symbol alerts you t o a general warning and th e hazard symbols refer to procedure-speciﬁc risks. When t hes e symbols appear in th e body of this manual or on w arning labels, refer back t o these Warnings. Product-speciﬁc hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

ELECTRIC SHOCK HAZARD

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

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

• Connect only to grounded power source.

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

TOXIC FLUID OR FUMES

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

• Read MSDSs to know the s pec i ﬁc hazards of the ﬂuids you are using.

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

• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.

CARBON MONOXIDE HAZARD

Exhaust contains poisonou s carbon monoxi de , which is colorless and odorless. Breathing carbon monoxide can cause death.

• Donotoperateinanenclosedarea.

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipmen t when in the work area to help prevent serious inj ury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:

• Protective eyewear, and hearing protectio n.

• Respirators, protective clothing, and gloves as recommended by the ﬂuid and solvent manufacturer.

332637C 3

Warnings

WARNING

SKIN INJECTION HAZARD

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

treatment

• Do not s pra y without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

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

• Do not put your hand over the spray tip.

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

• Follow the or servicing equipment.

• Tighten all ﬂuid connections before operating the equipment.

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

FIRE AND EXPLOSION HAZARD

Pressure Relief Procedure

when you stop spray i ng an d be fore c l ean ing , ch eck ing ,

Get immediate surgical

Flammable fumes, such as solvent and paint fumes, in prevent ﬁre and explosion:

• Use equipment only in well ventilated area.

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

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

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

• Ground all equipment in the work area. See

• Use only grounded hoses.

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

•

Stop operation immediately

equipment u nti l you identify and correct the problem.

• Keep a working ﬁre extinguisher in the work area.

if static sparking occurs or you feel a shock.Do not use

Grounding

work area

instructions.

canigniteorexplode.Tohelp

332637C

Warnings

WARNING

THERMAL EXPANSION HAZARD

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

• Openavalvetorelievetheﬂuidexpansionduringheating.

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

PRESSURIZED ALUMINUM PARTS HAZARD

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

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

• Many other ﬂuids may contain chemicals that can react with aluminum . Contac t y ou r mate rial supplier for compatibility.

PLASTIC

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

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

•See solvent manufacturer’s MSDSs and recommendations.

PARTS CLEANING SOLVENT HAZARD

Technical Data

in this and all other equipment instruction ma nua ls . Read ﬂuid and

332637C 5

Warnings

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

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

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See

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

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

• Turn off all equip ment and follow the

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

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

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

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

• Route hoses and cab les away from trafﬁc areas, s ha rp edges, moving parts, and hot su rfac es .

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

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

Technical Data

Pressure Relief Procedure

in all equipment manuals.

when equipment is not in use.

6 332637C

WARNING

BATTERY HAZARD

The battery may leak, explode, cause burns, or cause an explosion if mishandled.

Warnings

• Only use the battery type speciﬁed for use with the equipment. See

• Battery maintenance must only be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized person nel away from battery.

• When replacing the battery, use the same lead-acid automotive battery, with 800 CCA minimum, speciﬁed for use with the equipment. See

• Do not dispose of battery in ﬁre. The battery is capable of exploding.

• Follow local ordinances and/or regulations for disposal.

• Donotopenormutilatethebattery. Releasedelectrolytehasbeenknowntobeharmfulto theskinandeyesandtobetoxic.

• Remove watches, rings, or other metal objects.

• Only use tools with insulated handles. Do not lay tools or metal parts on top of battery.

MOVING PARTS HAZARD

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

• Keep clear of moving parts.

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

• Pressurized equipment can start without warning. Be fore checking, m ov ing, or servicing equipment, fol low the

Pressure Relief Procedure

Technical Data

and disconnect all power sources.

Technical Data

332637C

Warnings

WARNING

ENTAGLEMENT HAZARD

Rotating parts can cause serious injury.

• Keep clear of moving parts.

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

• Do not wear l oo se clothing, jewelry or long hair while operating equipment.

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

BURN HAZARD

Equipment surfaces and ﬂuid that is heated can become very hot during operation. To avoid severe burns:

• Do not touch hot ﬂuid or equipment.

CALIFORNIA PROPOSITION 65

The engine exhaust from this product contains a chemical known to the State of California to cause cancer, birth defects or other reproductive harm.

Pressure Relief Procedure

and disconnect all power sources.

8 332637C

Important Isocyanate Information

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

Important Isocyanate Information

Isocyanate Conditions

Spraying or dispensing materials containing isocyanates creates potentially harmful mis ts, vapors, and atomized particulates.

Read material manufacturer’s warnings and material MSDS to know speciﬁc hazards and precautions related to isocyanates.

Prevent i nh ala tio n of isocy ana te mists, vapors, and atomized particulates by providing sufﬁcient ventilation in the work area. If sufﬁc i ent ventilation is not available, a supplied-air respirator is required for everyone in the work area.

To prevent contact with isocyanates, appropriate personal protective equipment, in cluding chemically impermeable gloves, boots , aprons, and goggles, is also required for everyone in the work area.

Keep Components A and B Separate

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

•

Never

interchange component A and component

B wetted parts.

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

Moisture Sensitivity of Isocyanates

Exposure to moisture (such as humidity) will cause ISO to partially cure; forming small, hard, abrasiv e crystals, which become suspended in the ﬂuid. Eventually a ﬁlm will form on the surface and the ISO will begin to gel, increasing in viscosity

Material Self-Ignition

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

NOTICE

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

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

Never

store ISO in an open container.

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

• Use only moisture-proof hoses compatible with ISO.

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

• Always lubricate threaded parts with an appropriate lubrica nt when reassembling.

332637C 9

Important Isocyanate Information

Foam Resins with 245 fa Blowing Agents

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

Changing Materials

NOTICE

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

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

• Always clean the ﬂuid inlet strainers after ﬂushing.

• Check with your materi al manufacturer for chemical compatibility.

• When changing between epoxies and urethanes or polyureas, disassemble and clean all ﬂuid components and change hose s. Epoxies o ften have amines on the B (hardener) side. Polyureas often have amines on the B (resin) side.

10 332637C

Models

Reactor 2 E-30i Elite

All base systems include ﬂuid inlet pressure and temperature sensors and Graco InSite™. For part numbers, see Accessories, page 13

Model

Base Machine Maximum Fluid

Working Pressure psi (MPa, bar)

Approximate Output per Cycle (A+B) gal. (liter)

Max Flow Rate lb/min (kg/min)

Total System Load † (Watts)

Voltage (phase) Available Auxiliary

Current at Volts, 60 Hz*



No Air Compressor/Dryer

E-30i E-30i with heat E-30i E-30i with heat

272079 272080 272089 272090 2000 (13.8, 138) 2000 (13.8, 138) 2000 (13.8, 138) 2000 (13.8, 138)

0.0272 (0.1034) 0.0272 (0.1034) 0.0272 (0.1034) 0.0272 (0.1034)

30 (13.5) 30 (13.5) 30 (13.5) 30 (13.5)

7,400 11,600 13,500 17,700

240 VAC (1) 240 VAC (1) 240 VAC (1) 240 VAC (1) 52 Amps (240) 35 Amps (240) 22 Amps (240)

9 Amps (120)



With Air Compressor/Dryer

5 Amps (240) 9 Amps (120)

Fusion AP Package

(Gun Part No.)

Fusion CS Package

(Gun Part No.)

Probler P2 Package

(Gun Part No.)

Heated Hose 50 ft (15 m)

Heated Whip Hose 10 ft (3 m)



Total system watts used by system, based on maximum heated hose length of 310 ft (94.5 m) for each unit.

* Full load amps available for auxiliary equipment

when all bare-system components are operating at maximum capabilities. Available auxiliary current is based on 310 ft (94.5 m) of heated hose. An additional 3.0 amps (240 VAC) of auxiliary current is available for each 50 ft (15.2 m) section of heated hose that is not used.

liary current at 120 VAC is available on line 1

Auxi

rcuit breaker pin 2), line 2 current at 120 VAC is

(ci

d by the air dryer (circuit breaker pin 4).

use



AP2079

(246102)



CS2079

(CS02RD)

P22079



(GCP2R2)

24K240 24K240 24K240 24K240

24Y240 24Y240 24Y240 24Y240

AP2080

(246102)

CS2080

(CS02RD)

P22080

(GCP2R2)

AP2089

(246102)

CS2089

(CS02RD)

P22089

(GCP2R2)



Available auxiliary current will be less when the engine is de-rated for site altitude. Reduce the Available Auxiliary Current in the chart by 2.5 Amps (240 VAC) per 1000 ft (300 m) elevation increments. If the available auxiliary current is less than zero, the system conﬁguration may not support the full load at that altitude.



Includes Complete Air Compressor/Dryer Kit 24U176.

See Approvals, page 13.



Packages include gun, heated hose, and whip hose.

AP2090

(246102)

CS2090

(CS02RD)

P22090

(GCP2R2)

332637C

Models

Reactor 2 E-XP2i Elite

All base systems include ﬂuid inlet pressure and temperature sensors and Graco InSite™. For part numbers, see Accessories, page 13

Model

Base Machine Maximum Fluid Working Pressure psi

(MPa, bar) Approximate Output per Cycle (A+B)

gal. (liter) MaxFlowRatelb/min(kg/min)

Total System Load † (Watts) Voltage (phase) Available Auxiliary Current at Volts, 60

Hz*



No Air Compressor/Dryer

E-XP2i with heat E-XP2i with heat

272081 272091 3500 (24.1, 241) 3500 (24.1, 241)

0.0272 (0.1034) 0.0272 (0.1034)

30 (13.5) 30 (13.5) 11,600 17,700 240 VAC (1) 240 VAC (1) 35 Amps (240) 5 Amps (240)



With Air Compressor/Dryer

9 Amps (120)

Fusion AP Package

(Gun Part No.)

Probler

(Gun Par

Heated H 50 ft (15

Heated 10 ft (3

P2 Package

t No.)

ose

Whip Hose m)



Total sy maximum for each

* Full load amps available for auxiliary equipment

when all bare-sys tem components are operating at maximum capabilities. Available auxiliary current is based on 310 ft (94.5 m) of heated hose. An additional 3.0 amps (240 VAC) of auxiliary current is available for each 50 ft (15.2 m) section of heated hose that is not used.

Auxiliary current at 120 VAC is available on line 1 (circuit breaker pin 2), line 2 current at 120 VAC is used by the air dryer (circuit breaker pin 4).



stem watts used by system, based on

heated hose length of 310 ft (94.5 m)

unit.

AP2081

(246101)

P22081 (GCP2R1)

24Y241 24Y241

246055 246055

AP2091

(246101)

P22091

(GCP2R1)







ble auxiliary current will be less when the

Availa

is de-rated for site altitude. Reduce the

engine

ble Auxiliary Current in the chart by 2.5

Availa Amps (2 increm less th suppor

Includes Complete Air Compressor/Dryer Kit 24U176.

See Approvals, page 13. Packages include gun, heated hose, and whip

hose.

40 VAC) per 1000 ft (300 m) elevation

ents. If the available auxiliary current is

an zero, the system conﬁguration may not

t the full load at that altitude.

332637C

Approvals

Intertek approvals apply to proportioning systems without hoses.

Model

272079 272089

272080 272081 272090 272091

Proportioning System Approvals:

9902471

Conforms to ANSI/UL Std. 73

Certiﬁed to CAN/CSA Std.

C22.2 No. 68

Note

Heated hoses provided with a system or sold individually are not approved by Intertek.

Accessories

Kit Number Description

15M483 Remote Display Module Protective

Covers (10 pack) 15V551 24K207

24K333 Fuel Line and Cable Extension Kit 24K336 Hose Rack 24K337 Light Tower Kit 24L911 24M174 Drum Level Sticks 24U174 Remote Display Module Kit 24U176 24U177

Cables

ADM Protective Covers (10 pack)

Fluid Temperature Sensor (FTS)

with RTD

Pallet Support Kit

Complete Air Compressor Kit

Feed Pump Shutdown Kit

9902471

rms to ANSI/UL Std. 499

Confo

ﬁed to CAN/CSA Std.

Certi

C22.2

No. 88

121006 150 ft (45 m) cable (for remote

display module) 24N365

24N449

RTD Test Cables (to aide resistance

measurements)

50ft(15m)CANcable(forremote

display module)

332637C 13

Supplied Manuals

The following m anu al s are shipped with the Reac to r. Refer to these manuals for detailed equi pm ent information.

Manuals are also available at www.graco.com.

Manual Description

332636 Reactor 2 Elite Integrated

Proportioning System, Operation

333093 Reactor 2 Elite Integrated

Proportioning System, Startup Instructions

333094 Reactor 2 Elite Integrated

Proportioning System, Shutdown Instructions

SEBU8311–02Perkins® Engine, Repair-Parts

Access at www.perkins.com. Go to Service and Support/manuals. Select engine family and type code “GN”.

Contact Perkins for engine warranty and service.

ST 15825–00

33227482

Mecc Alte Self-Regulating Alternator Series NPE, Repair-Parts

Access at www.meccalte.com. Select “meccalte” logo / Download / Instruction Manuals. Select NPE instruction manual on page 5. Go to Support and enter serial number for Parts List and Help Videos.

Contact Mecc Alte for warranty and service

Air Compressor, Operation/Mainte- nance & Parts list.

Access at www.hydrovaneprod- ucts.com. Go to Warranty & Service tab and select “contact us” to request manuals.

Refrigerated Air Dryer, Instruction manual Access from S e rvice Department (724) 746–1100 or www.spx.com/en/hank i son.

Related Manuals

The following manuals are for accessories used with the Re ac tor.

Component Manuals in English:

Manuals are available at www.graco.com.

System Manuals

332636

Displacement Pump Manual

309577 Electric Reactor Displacement Pump,

Feed System Manuals

309572 Heated Hose, Instructions-Parts 309852

309815 Feed Pump Kits, Instructions-Parts 309827

Spray Gun Manuals

309550 Fusion ™ AP Gun 312666 Fusion ™ CS Gun 313213 Probler®P2 Gun

Accessory Manuals

332733 Air Compressor and Air Dryer Kit,

332738

332740 Remote Display Module,

3A2574 3A1903 Hose Rack, Instructions-Parts

3A1904

3A1905

3A1906

Reactor 2 E-30i and E-XP2i, Operation

Repair-Parts

Circulation and Return Tube Kit, Instructions-Parts

Feed Pump Air Supply Kit, Instructions-Parts

Instructions-Parts Booster Heat R etroﬁt Kit, Instructions-Parts

Instructions-Parts Pallet Support Kit, Instructions-Parts

Fuel Tank/Battery Move Kit, Instructions-Parts Feed Pump Shutdown Kit, Instructions-Parts Light Tower Kit, Instructions-Parts

332637C

Troubleshooting

Troubleshoot Errors

There are three types of errors that can occur. Errors are indicated on the display as well as by the light tower (optional).

Error Description Alarms

A parameter critical to the process has reached a level requiring the system to stop. The alarm needs to be addressed immediately.

Troubleshooting

2. TheQRcodescreenwillbedisplayed. Scan the QR code with your mobile device to be sent directly to online troubleshooting for the active error code. Otherwise, manually navigate to

help.graco.com and search for the active error.

Deviations

Advisories

See Error Codes, page 16 see for causes and solutions to each error code.

To troublesh oot the error:

1. Press the s oft key next to “Help With This Error” forhelpwiththeactiveerror.

A parameter critical to the process has reacheda level requiring attention, but not sufﬁcient enough to stop the system at this time.

A parameter that is not immediately critical to the process. The advisory needs attention to prevent more serious issues in the future.

3. If no i Code T manu code

Note

Press previ

nternet connection is available, see Error

roubleshooting in the system repair

al for causes and solutions for each error

or to return to the

ously displayed screen.

332637C 15

Troubleshooting

Error Codes

Error Location Type Description Cause Solution

A1NM

A4DA Heater A

A4DB Heater B High Current B

MCM

Low Motor Current

High Current A

Loose/broken connection.

Bad Motor. Disconnect motor output

Short circuit in heater wiring.

Bad heater.

Short circuit in heater wiring.

Bad heater.

Check for loose wire terminations at MCM motor connector.

connector from MCM. Conﬁrm less than 8 ohms resistance between each pair of motor power leads (M1toM2,M1toM3,M2to M3). If any readings greater than 8 ohms, check motor wiring for damage and/or loose terminations.

Check wiring for touching wires.

Conﬁrm resistance of heater. Heater re si stanc e should be 23-26 Ω. If out of tolerance, replace heater.

Check wiring for touching wires.

Conﬁrm resistance of heater. Heater re si stanc e should be 23-26 Ω. If out of tolerance, replace heater.

A4DH Hose

High Current Hose Short circuit in

hose wiring.

Check continuity of transformer windings. Normal readings are about

0.2Ω on both primary and secondary. If reading is 0Ω replace transformer.

Check for shorts between the p rimary windin g and the support frame or enclosure.

16 332637C

Troubleshooting

Error Location Type Description

A4NM

A7DA Heater A

A7DB Heater B

A7DH Hose

MCM

High Motor Current

Unexpected CurrentAShorted TCM If error cannot be cleared

Unexpected CurrentBShorted TCM If error cannot be cleared

Unexpected Current Hose

Cause Solution

Short circuit of motor wiring.

Motor will not rotate.

Damaged gear train.

Chemical pump is stuck.

Shorted TCM If error cannot be cleared

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

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

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

Repair or replace chemical pump.

or regenerates consistently, replace module.

A8DA Heater A

A8DB Heater B

A8DH Hose

No Current A

No Current B

No Current Hose

Tripped circuit breaker.

Loose/broken connection.

Tripped circuit breaker.

Loose/broken connection.

Tripped circuit breaker.

Loose/broken connection.

Visually check circuit breaker for a tripped condition.

Check heater wiring for loose wires.

Visually check circuit breaker for a tripped condition.

Check heater wiring for loose wires.

Visually check circuit breaker for a tripped condition.

Check heater wiring for loose wires.

332637C

Troubleshooting

Error Location Type Description

CACM MCM MCM Communica-

tion Error

Cause Solution

Module does not have software.

No 24 VDC supply to module.

Loose or broken CAN cable.

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

Greenlightoneachmodule should be lit. If green light is notlit,checktomakesure each CAN cable connection is tight. Verify the power supply is outputting 24 VDC. If not, check power supply wiring. If wiring is okay, replace the power supply.

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

18 332637C

Troubleshooting

Error Location Type Description

CACT TCM TCM Communication

Error

Cause Solution

Module does not have software.

No 24 VDC supply to module.

Loose or broken CAN cable.

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

Greenlightoneachmodule should be lit. If green light is not lit, check to make sure each CAN cable connection is tight. Verify the power supply is outputting 24 VDC. If not, check powe r supply wiring. If wiring is okay, replace the power supply.

DADX MCM Pump Runaway Flow rate is too

large.

DE0X

EAUX ADM

MCM

Cycle Switch Error

USB Busy USB drive has

Faulty or missing cycle switch.

Missing or out of place cycle switch magnet.

been inserted to the ADM.

Mix ch am ber too large for system selected. Use mix chamber rated for system.

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

No material in pumps. Verify pumps are supplying chemical. If necessary, replace or reﬁll drums.

Inlet ball valves are closed. Open ball valves.

Check wiring between cycle switch and MCM.

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

Do not remove USB drive

until download/upload

is complete.

332637C 19

Troubleshooting

Error Location Type Description

EVCH

EVUX ADM

F9DX

H1MA Heater A Low Frequency A

H1MB Heater B Low Frequency B Line frequency is

ADM

MCM

Manual Hose Mode Enabled

USB disabled USB

High Pressure/Flow Cutback

Cause Solution

Manual hose mode has been enabled in System Setup screen.

download/uploads are disabled.

Mix chamber is too large for set pressure.

Line frequency is below 55 Hz.

below 55 Hz.

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

Enable USB download/up- loadsontheAdvanced Setupscreenbeforeinsert- ing a USB drive.

Reference the pressure ﬂow curves and select a tip size that is the correct size for the set pressure.

Check frequency. If out of tolerance, see supplied 120/240V alternator manual for repair instructions.

H1MH Hose Low Frequency Hose

Line frequency is below 55 Hz.

Check frequency. If out of tolerance, see supplied 120/240V alternator manual for repair instructions.

20 332637C

Troubleshooting

Error Location Type Description

H4MA Heater A High Frequency A

H4MB Heater B High Frequency B

H4MH Hose High Frequency

Hose

K8NM

MCM

Locked Rotor Motor

Cause Solution

Line frequency is above65Hz.

Motor will not rotate.

Damaged gear train.

Chemical pump is stuck.

Check frequency. If out of tolerance, see supplied 120/240V alternator manual for repair instructions.

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

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

Repair or replace chemical pump.

L1AX ADM

L1BX ADM

MMUX

USB

Low Chemical Level A

Low Chemical Level B

Maintenance Due - USB

Low material level.

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

Reﬁll material and update drum level on ADM Maintenance screen. Alarm can be disabled on the System Setup screen.

InsertaUSBdriveintothe ADM and download all logs.

332637C

Troubleshooting

Error Location Type Description

P0AX

MCM

Pressure Imbalance AHigh

Cause Solution

Pressure difference between AandBmaterial is greater than the deﬁned value.

Pressure imbalance is deﬁned too low.

Out of material. Fill tanks with material Fluid leaking from

heater inlet ruptu re disk.

Feed system defective.

Ensure material ﬂow is equally restricted on both material lines.

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

Check if he ate r and PRESSURE RELIEF/SPRAY valve are plugged. Clear. Replace rupture disk. Do not replace withapipeplug.

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

332637C

Troubleshooting

Error Location Type Description

P0BX

MCM

Pressure Imbalance BHigh

Cause Solution

Pressure difference between AandBmaterial is greater than the deﬁned value.

Pressure imbalance is deﬁned too low.

Out of material. Fill tanks with material Fluid leaking from

heater inlet rupture disk.

Feed system defective.

Ensure material ﬂow is equally restricted on both material lines.

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

Check if heater and PRESSURE RELIEF/SPRAY valve are plugged. Clear. Replace rupture disk. Do not replace withapipeplug.

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

P1FA

P1FB

MCM

Low Inlet Pressure A

Low Inlet Pressure B

Inlet pressure lower than deﬁned value.

Value deﬁned too high.

Inlet pressure lower than deﬁned value.

Value deﬁned too high.

Ensure that inlet pressure to the pump i s sufﬁcient.

Ensure that the low pressure alarm level deﬁned on the System Setup screen is acceptable.

Ensure that inlet pressure to the pump i s sufﬁcient.

Ensure that the low pressure alarm level deﬁned on the System Setup screen is acceptable.

332637C 23

Troubleshooting

Error Location Type Description

P2FA

P2FB MCM Low Inlet Pressure B

P4AX

MCM

Low Inlet Pressure A

High Pressure A

Cause Solution

Inlet pressure lower than deﬁned value.

Value deﬁned too high.

Inlet pressure lower than deﬁned value.

Value deﬁned too high.

System pressurized before allowing heat to reach setpoint.

Ensure that inlet pressure to the pump is sufﬁcient.

Ensure that the low pressure alarm level deﬁned on the System Setup screen is acceptable.

Ensure that inlet pressure to the pump is sufﬁcient.

Ensure that the low pressure alarm level deﬁned on the System Setup screen is acceptable.

Pressureinthehoseand pumps wil l increase as the system h eats up. Turn on heat and allow all zones to reach the temperature setpoint before turning on the pump s.

P4BX

MCM

High Pressure B

Bad pressure transducer.

E-XP2i system conﬁgured as E-30i.

System pressurized before allowing heat to reach setpoint.

Bad pressure transducer.

E-XP2i system conﬁgured as E-30i.

Verify the ADM pressure readingandtheanalog guages at th e manifold.

Alarm level is lower for E-30i than for E-XP2i. Ensure dial on MCM is set to position "1" for E-XP2i.

Pressureinthehoseand pumps wil l increase as the system h eats up. Turn on heat and allow all zones to reach the temperature setpoint before turning on the pump s.

Verify the ADM pressure readingandtheanalog guages at th e manifold.

Alarm level is lower for E-30i than for E-XP2i. Ensure dial on MCM is set to position "1" for E-XP2i.

332637C

Troubleshooting

Error Location Type Description

P6AX

P6BX

MCM

Pressure Sensor Error A

Pressure Sensor Error B

Cause Solution

Loose/bad connection.

Bad sensor.

Loose/bad connection.

Bad sensor.

Check to ensure the pressure transducer is properly installed and all wires are properly connected.

Check if the error follows the transducer. Disconnect transducer cables from the MCM (connectors 6 and7). ReverseAandB connections and check if the errors follows. If the error follows the trans du ce r, replace the pressure transducer.

Check to ensure the pressure transducer is properly installed and all wires are properly connected.

P6FA MCM Pressure Sensor

Error Inlet A

332637C 25

Inlet sensors not installed.

Loose/bad connection.

Bad sensor.

If inlet sensors are not installed, inlet sensors should be disabled on the System Setup screen.

Checktoensureinlet sensor is properly installed and all wires are properly connected.

Check if the error follows the inlet sensor. Disconnect inlet sensor cables from the MCM (connectors 8 and9). ReverseAandB connections and check if the errors follows. If the error follows the sensor, replace the inlet sensor.

Troubleshooting

Error Location Type Description

P6FB

P7AX

MCM

Pressure Sensor Error Inlet B

Pressure Imbalance AHigh

Cause Solution

Inlet sensors not installed.

Loose/bad connection.

Bad sensor.

Pressure difference between AandBmaterial is greater than the deﬁned value.

If inlet sensors are not installed, inlet sensors should be disabled on the System Setup screen.

Check to ens ure i nl et sensor is properly installed and all wires are properly connected.

Check if the error follows the inlet sensor. Disconnect inlet sensor cables from the MCM (connectors 8 and9). ReverseAandB connections and check if the errors follo ws . If the error follows the sensor, replace the inlet sensor.

Ensure material ﬂow is equally restricted on both material lines.

Pressure imbalance is deﬁned too low.

Out of material. Fluid leaking from

heater inlet ruptu re disk.

Feed system defective.

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

Fill tanks with material Check if he ate r

and PRESSURE RELIEF/SPRAY valve are plugged. Clear. Replace rupture disk. Do not replace withapipeplug.

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

26 332637C

Troubleshooting

Error Location Type Description

P7BX

MCM

Pressure Imbalance BHigh

Cause Solution

Pressure difference between AandBmaterial is greater than the deﬁned value.

Pressure imbalance is deﬁned too low.

Out of material. Fill tanks with material Fluid leaking from

heater inlet rupture disk.

Feed system defective.

Ensure material ﬂow is equally restricted on both material lines.

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

Check if heater and PRESSURE RELIEF/SPRAY valve are plugged. Clear. Replace rupture disk. Do not replace withapipeplug.

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

T1DE Engine

Heat Exchanger

Low Temperature Coolant Outlet

Radiator fan will not stop.

Engine thermostat is stuck closed.

Replace fan relay.

Replace thermostat.

332637C

Troubleshooting

Error Location Type Description

T2AE Heat Ex. A Low Temperature

Heat Exchanger A

Cause Solution

Coolant circulation pump not working.

Air lock in pump circulation.

Novoltagetocoil of valve.

Check for 240 VAC on pump. If there is the correct voltage, replace circulation pump.

Check for coolan t ﬂow in sight glass.

Turn on the manual valve switch(MV),ontheload center, to manually turn on the solenoids and see if the temperature rises. If not, check volatge output on J6 connectorontheloadcenter andensuretheLEDs are on. Follow Load Center Diagnostic instructions in system repair manual. If necessary, replace the load center board. If voltage is present, measure the resistance of the coil, it should be 12.5 Ω. If coil is open replace coil. If voltage is present, test the coil with screwdriver. The screwdriver should magnetically stick inside the coil . If the screwdriver sticks, then the coil is good. Replace the plunger on valve or replace the complete valve assembly.

28 332637C

Troubleshooting

Error Location Type Description

T2BE Heat Ex. B Low Temperature

Heat Exchanger B

Cause Solution

Coolant circulation pump not working.

Air lock in pump circulation.

Novoltagetocoil of valve.

Check for 240 VAC on pump. If there is the correct voltage, replace circulation pump.

Check for coolant ﬂow in sight glass.

Turn on the manual valve switch (MV), on the load center, to manually turn on the solenoids and see if the temperature rises. If not, check volatge output on J6 connectorontheloadcenter and ensure the LEDs are on. Follow Load Center Diagnostic instructions in system repair manual. If necessary, replace the load center board. If voltage is present, measure the resistance of the coil, it should be 12.5 Ω. If coil is open replace coil. If voltage is present, test the coil with screwdriver. The screwdriver should magnetically stick inside the coil. If the screwdriver sticks, then the coil is good. Rep lac e the plunger on valve or replace the complete valve assembly.

T2DA Heater A Low Temperature A

332637C 29

Flow is too high at current setpoint.

Bad RTD or bad RTD placement against heater.

Bad heater.

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

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

Conﬁrmresistance of heater is 23-26.5 Ω. Repl ace if OL/open loop.

Troubleshooting

Error Location Type Description

T2DB Heater B Low Temperature B

Low Temperature

Exchanger

T2DH Hose Low Temperature

Coolant Outlet

Hose

Cause Solution

Flow is too high at current setpoint.

Bad RTD or bad RTD placement against heat er.

Bad heater.

Radiator fan will not stop.

Engine thermostat is stuck closed.

Flow is too high at current setpoint.

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

Swap A an d B heater o utpu t cables and RTD cables and see if issue follows. If so, replace RTD.

Conﬁrmresistance of heater is 23-26.5 Ω. Replace if OL/open loop.

Replace fan relay.T2DE Heat

Replace thermostat.

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

T2FA MCM Low Temperature

Inlet A

T2FB

MCM

Low Temperature Inlet B

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

Inlet ﬂuid temperature is below the deﬁned level.

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

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

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

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

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

30 332637C

+ 150 hidden pages

Graco 332637C User Manual

Contents

Warnings

Important Isocyanate Information

Isocyanate Conditions

Keep Components A and B Separate

Moisture Sensitivity of Isocyanates

Material Self-Ignition

Foam Resins with 245 fa Blowing Agents

Changing Materials

Models

Reactor 2 E-30i Elite

Reactor 2 E-XP2i Elite

Approvals

Accessories

Supplied Manuals

Related Manuals

Component Manuals in English:

Troubleshooting

Troubleshoot Errors

Error Codes