Graco 333024F User Manual

Repair-Parts

Reactor 2 E-30 and E-XP2

Proportioning System

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

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

333024F

PROVEN QUALITY. LEADING TECHNOLOGY.

WLE

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

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

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

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

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

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

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

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

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

Pressure Relief Procedure .................................. 43

Shutdown...........................................................44

Flushing............................................................. 46

Repair................................................................ 47

Before Beginning Repair...............................47

Flush Inlet Strainer Screen ........................... 47

Change Pump Lubricant............................... 48

Remove Pump............................................. 49

Install Pump ................................................ 50

Repair Drive Housing...................................51

Repair Electric Motor.................................... 54

Repair Circuit Breaker Module......................55

Replace Fluid Inlet Sensor............................ 56

Replace Pressure Transducers ..................... 56

Replace Fans ..............................................57

Repair Primary Heater..................................60

Repair Heated Hose..................................... 64

Repair Fluid Temperature Sensor

(FTS)............................................. 66

Replace Power Supply.................................69

Replace Surge Protector .............................. 69

Replace Advanced Display Module

(ADM) ............................................ 69

Replace Motor Control Module (MCM)........... 70

Software Update Procedure.......................... 70

Replace Temperature Control Module

(TCM)............................................ 70

Parts.................................................................. 71

Electrical Schematics.......................................... 91

Reactor 2 Repair Spare Parts Reference ............. 94

Performance Charts............................................ 95

Technical Speciﬁcations...................................... 98

Notes ............................................................. 100

Graco Extended Warranty for Reactor® 2

Components ....................................... 101

333024F

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-speciﬁc risks. When these symbols appear in the body of this manual or on warning labels, refe r back to these Warnings. Product-speciﬁc hazard symbols and warnings not c overed in this section may appear throughout the body of this manual where appli c abl e.

WARNING

ELECTRIC SHOCK HAZARD

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

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

• Connect only to grounded power source.

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

• Do not expose to rain. Store indoors.

TOXIC FLUID OR FUMES

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

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

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

Protective Equipment

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

PERSONAL PROTECTIVE EQUIPMENT

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

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

• Protective eyewear and hearing protecti on.

warnings in this manual.

Personal

333024F 3

Warnings

WARNING

SKIN INJECTION HAZARD

High-pressure ﬂuid from gun, hose leaks, or rup tured com ponents will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation.

treatment

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

• Engage trigger lock when not spraying.

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

• Do not put your hand over the spray tip.

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

• Follow the 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 spraying an d before cleaning, checking,

Get immediate surgical

Flammable fumes, such as solvent and pain t 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 unplug power cords, or turn power or light switches on or off when ﬂammable fumes are present.

• Ground all equipment in the work area. See

• Use only grounded hoses.

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

•

Stop operation immediately

equipment until you identify and correct the problem.

• Keep a working ﬁre extinguisher in the work area.

THERMAL EXPANSION HAZARD

Fluids subjected to heat in conﬁned spaces, including hoses, can create a rapid rise in pressure due to the thermal expansion. Over-pressurization can result in eq u ipment 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.

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

Grounding

work area

instructions.

canigniteorexplode.Tohelp

333024F

Warnings

WARNING

PRESSURIZED ALUMINUM PARTS HAZARD

Use of ﬂ ui ds that are incompatible with aluminum in pressu riz ed 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 co ntain chemicals that can react with aluminum. Contact your material supplier for compatibility.

PLASTIC PARTS CLEANING SOLVENT HAZARD

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

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

•See

Technical Data

solvent manufacturer’s MSDSs and recommendations.

in this and all other equipment instruction manuals. Read ﬂuid and

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 distribu tor or retailer.

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

• Turn off all equipment 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 equipmen t. Alterations or modiﬁcations may void agency approvals and create safety hazards.

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

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

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

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

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

MOVING PARTS HAZARD

Technical Data

Pressure Relief Procedure

in all equipment manuals.

when equipment is not in use.

Moving parts can pinch, cut or amp utate 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

333024F 5

Pressure Relief Procedure

and disconnect all power sources.

Warnings

WARNING

BURN HAZAR D

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

• Do not touch hot ﬂuid or equipment.

6 333024F

Important Isocyanate Information

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

Isocyanate Conditions

Spraying or dispensing ﬂuids that contain isocyanates creates potentia lly harmful mists, vapors, and atomized particulates.

• Read and understand the ﬂuid manufacturer’s warnings and Safety Data Sheet (SDS) to know speciﬁc hazards and precautions related to isocyanates.

• Use of isocyanates involves potentially hazardous procedures. Do not spray with this equipment unless you are trained, qualiﬁed, and have read and understood the information in this manual and in the ﬂuid manufacturer’s application instructions and SDS.

• Use of inco rrectly maintained or mis-adjusted equipment may result in improperly cured material, which could cause off gassing and offensive odors. Equipmen t must be carefully maintained and adjusted according to instructions in the manual.

• To prevent inhalation of isocyanate mists, vapors and atomized particulates, everyone in the work area must wear appropriate respiratory protection. Always wear a properly ﬁtting respirator, which may include a supplied-air respirator. Ventilate the work area according to instructions in the ﬂuid manufacturer’s SDS.

• Avoid all skin contact with isocyanates. Everyone in the work area must wear chemically impermeable gloves, protective clothing and foot coverings as recommended by the ﬂuid manufacturer and local regulatory authority. Follow all ﬂuid manufactu rer recommendations, including those regarding handling of contaminated clothing. After spraying, wash hands and face before eating or drinking.

• Hazard from exposure to is ocyanates continues after spraying. Anyone without appropriate personal protective equipment must stay out of the work area during application and after application for the time period speciﬁed by the ﬂ uid manufactu rer. Generally this time period is at least 24 hours.

• Warn others who may enter work area of hazard from exposure to isocyanates. Follow the recommendations of the ﬂuid manufacturer and local regulatory authority. Posting a placard such as the following outside the work area is recommended:

333024F

Important Isocyanate Information

Material Self-Ignition

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

Keep Components A and B Separate

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

•

Never

interchange component A and component

Bwettedparts.

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

Moisture Sensitivity of Isocyanates

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

NOTICE

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

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

Never

store ISO in an open container.

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

• Use only moisture-proof hoses compatible with ISO.

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

Changing Materials

NOTICE

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

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

• Always clean the ﬂuid inlet strainers after ﬂushing.

• Check with your material manufacturer for chemical compatibility.

• When changing between e poxies and urethanes or polyureas, disassemble and clean a ll ﬂuid components and change hoses. Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the B (resin) side.

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

NOTE:

crystallization varies depending on the blend of ISO, the humidity, and the temperature.

The amount of ﬁlm formation and rate of

Foam Resins with 245 fa Blowing Agents

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

8 333024F

Models

Reactor 2 E-30 and E-30 Elite

All elite systems include ﬂuid inlet pressure and temperature sensors, Graco InSite™, and Xtreme-Wrap 50 ft (15 m) head hose. For part numbers, see Accessories, page 11

Model

Proportioner

★ 272010 272011 272110 272111

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) Conﬁgurable Voltage Phase



Full Load Peak Current*

Fusion AP Package

(Gun Part No.)

Fusion CS Package

(Gun Part No.)

Probler P2 Package

(Gun Part No.)

d Hose

Heate

15 m)

50 ft (

40 (scuff guard)

24K2

40 (Xtreme-Wrap)

24Y2

Heated Whip Hose 10 ft (3 m)

Graco Insite Fluid Inlet Sensors (2)

™



E-30 Model E-30 Elite Model

10 kW 15 kW 10 kW 15kW

2000 (14, 140) 2000 (14, 140) 2000 (14, 140) 2000 (14, 140)

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)

17,900 23,000 17,900 23,000

2301Ø230

3Ø∆

400 3ØY

2301Ø230

3Ø∆

400 3ØY

2301Ø230

3Ø∆

400 3ØY

2301Ø230

3Ø∆

400 3ØY

78 50 34 100 62 35 78 50 34 100 62 35

AP2010

(246102)

CS2010

(CS02RD)

P22010

(GCP2R2)

24K24

Qty:

246050 246050 246050 246050

AH2010

(246102)

CH2010

(CS02RD)

PH2010

(GCP2R2)

24K24

Qty:

AP2011

(246102)

CS2011

(CS02RD)

P22011

(GCP2R2)

24K24

Qty:

AH2011

(246102)

CH2011

(CS02RD)

PH2011

(GCP2R2)

24K24

Qty:

AP2110

(246102)

CS2110

(CS02RD)

P22110

(GCP2R2)

24Y24

Qty:

✓✓ ✓✓

AH2110

(246102)

CH2110

(CS02RD)

PH2110

(GCP2R2)

24Y24

Qty:

AP2111

(246102)

CS2111

(CS02RD)

P22111

(GCP2R2)

24Y24024Y24

Qty:

AH2111

(246102)

CH2111

(CS02RD)

PH2111

(GCP2R2)

Qty:

Full load amps with all devices operating at

maximum capabilities. Fuse requirements at various ﬂow rates and mix chamber sizes may be less.



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

• E–30andE–XP2series: 310ft(94.5m) maximum heated hose length, including whip hose.

★

See Approvals, page 11.



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



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

Voltage Conﬁgurations Key

Phase

Ø ∆

DELTA

YWYE

333024F 9

Models

Reactor 2 E-XP2 and E-XP2 Elite

All elite systems include ﬂuid inlet p ressure and temperature sensors, Graco InSite™, and Xtreme-Wrap 50 ft (15 m) head hose. For part numbers, see Accessories, page 11

Model

Proportioner Maximum Fluid Working

Pressure psi (MPa, bar) Approximate Output per

Cycle (A+B) gal. (liter) Max Flow Rate gpm/min

(l/min) Total System Load †

(Watts) Conﬁgurable Voltage

Phase Full Load Peak Current

(amps)

Fusion AP Package

(Gun Part No.)

Probler P2 Package

(Gun Part No.)

Heated Hose 50 ft (15 m)

Heated Whip Hose 10 ft (3 m)

Graco InSite Fluid Inlet Sensors (2)

★ 272012 272112





™

E–XP2 Model E–XP2 Elite Model

15 kW 15 kW

3500 (24.1, 241) 3500 (24.1, 241)

0.0203 (0.0771) 0.0203 (0.0771)

2(7.6) 2(7.6)

23,000 23,000

230 1Ø 230 3Ø∆ 400 3ØY 230 1Ø 230 3Ø∆ 400 3ØY

100 62 35 100 62 35

AP2012

(246100)

P22012

(GCP2R0)

24K241 (scuff guard)

246055 246055

AP2112

(246100)

P22112

(GCP2R0)

24Y241 (Xtreme-Wrap)

✓ ✓

Full load amps with all devices operating at

maximum capabil iti es . Fuse requirements at various ﬂow rates and mix chamber sizes may be less.



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

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

★

See Approvals, page 11.

10 333024F



Packages include gun, heated hose, and whip hose. Elite packages also include GracoInSiteandﬂuidinletsensors.



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

Voltage Conﬁgurations Key

Phase

Ø ∆

DELTA

YWYE

Approvals

Intertek approvals apply to proportioners without hoses.

Proportioner Approvals:

9902471

Conforms to ANSI/UL Std. 499

Certiﬁed to CAN/CSA Std. C22.2 No. 88

Accessories

Kit Number Description

24U315 24U314 Wheel and Handle Kit 24T280 16X521

24N449 50 ft (15 m) CAN cable (for remote

24K207

24U174 Remote Display Module Kit 24K337 Light Tower Kit 15V551 ADM Protective Covers (10 pack) 15M483 Remote Display Module Protective

24M174 121006

Air Manifold Kit (4 outlets)

GracoInSiteKit Graco InSite Extension cable 24.6 ft

(7.5 m)

display module) Fluid Temperature Sensor (FTS)

with RTD

Covers (10 pack) Drum Level Sticks 150 ft (45 m) CAN cab le (for remote

display module)

24N365

RTD Test Cables (to aide resistance measurements)

333024F

Supplied Manuals

The following manuals are shipped with the Reactor

2. Refer to these manuals for detailed equipment information.

Manuals are also available at www.grac o.com.

Manual Description

333023 Reactor 2 E-30 and E-XP2

Operation

333091

333092 Reactor 2 E-30 and E-XP2

Reactor 2 E-30 and E-XP2 Startup Quick Guide

Shutdown Quick Guide

Related Manuals

The following manuals are for accessories used with the Reactor.

Component Manuals in English:

Manuals are available at www.graco.com.

System Manuals

333023

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 312666 313213

Accessory Manuals

3A1905

3A1906 Light Tower Kit, Instructions-Parts 3A1907 Remote Display Module Kit,

332735 332736 Handle and Wheel Kit,

333276

Reactor 2 E-30 and E-XP2 Operation

Repair-Parts

Circulation and Return Tube Kit, Instructions-Parts

Feed Pump Air Supply Kit, Instructions-Parts

Fusion ™ AP Gun Fusion ™ CS Gun

Probler

Feed Pump Shutdown Kit, Instructions-Parts

Instructions-Parts Air Manifold Kit, Instructions-Parts

Instructions-Parts Graco InSite ™ Kit, Instructions-Parts

P2 Gun

333024F

Troubleshooting

Troubleshoo

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

Deviations

t Errors

A paramete the proces a level req system to s alarm nee addresse

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

rcriticalto

s has reached

uiring the

top. The

ds to be

dimmediately.

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

Note

Press or to return to the previously displayed screen.

2. TheQRcodescreenwillbedisplayed.Scan theQRcodewithyoursmartphonetobesent directly to online troubleshooti ng for the active error code. Otherwise, manually navigate to http://help.graco.com and search for the active error.

Advisories

See Error Codes, page 13 for causes and solutions to each error code.

oubleshoot the error:

To tr

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 internet connection is available, see

Error Codes, page 13 for c auses and solutions

for each error code.

Error Codes

Note

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

333024F 13

Troubleshooting

Error Location Type Description

A1NM

A4DA Heater A

MCM

Low Motor Current

High Current A

Cause Solution

Loose/broken connection.

Bad Motor. Disconnect motor output

Short circuit in heater wiring.

Bad Heater. Conﬁrm resistance of

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.

heater. Heater resistance should be 18–21 Ω for each heater element, 9–12 Ω combined for 10 kW systems, and 6-8 Ω for 15 kW systems. If out of tolerance, replace heater element.

A4DB Heater B

A4DH Hose

High Current B

High Current Hose Short circuit in

Short circuit in heater wiring.

Bad Heater.

hose wiring.

Check wiring for touching wires.

Conﬁrm resistance of heater. Heater resistance should be 9-12 Ω for 10 kW systems and 6-8 Ω for 15 kW systems. If out of tolerance, replace heater.

Check continuity of transformer windings. Normal readings are about

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

Check for shorts between the primary winding and the support frame or enclosure.

333024F

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.

333024F 15

Troubleshooting

Error Location Type Description

A8DA Heater A

A8DB Heater B

A8DH Hose

CACM MCM MCM Communica-

No Current A

No Current B

No Current Hose

tion Error

Cause Solution

Tripped circuit breaker.

Loose/broken connection.

Tripped circuit breaker.

Loose/broken connection.

Tripped circuit breaker.

Loose/broken connection.

Module does not have software.

Visually check circuit breaker for a tripped condition.

Check heater wiring for loose wires.

Visually check circuit breaker for a tripped condition.

Check heater wiring for loose wires.

Visually check circuit breaker for a tripped condition.

Check heater wiring for loose wires.

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

Dial set to wrong position.

No 24 VDC supply to module.

Loose or broken CAN cable.

Ensure the MCM dial is set to the correct position: 2 for E-30, 3 for E-XP2

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

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

16 333024F

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.

DADX MCM Pump Runaway Flow rate is too

large.

DE0X

MCM

Cycle Switch Error

Faulty or missing cycle switch.

Missing or out of place cycle switch magnet.

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

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

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

Inlet ball valves are closed. Open ball valves.

Check wiring betwe en cycle switch and MCM.

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

333024F

Troubleshooting

Error Location Type Description

EVCH

EAUX ADM

EVUX ADM

F9DX

H2MA Heater A Low Frequency A Line frequency is

H2MB Heater B Low Frequency B

ADM

MCM

Manual Hose Mode Enabled

USB Busy USB drive has

USB disabled USB

High Pressure/Flow Cutback

Cause Solution

Manual hose mode has been enabled in System Setup screen.

been ins erted to the ADM.

download/uploads are disabled.

Mix chamber is too large for set pressure.

below 45 Hz

Line frequency is below 45 Hz

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

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

Enable USB download/up- loads on the Advanced Setupscreenbeforeinsert- ing a USB drive.

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

Ensure line frequency of incoming power is between 45and65Hz.

H2MH Hose Low Frequency Hos e

H3MA Heater A High Frequency A

H3MB Heater B High Frequency B

H3MH Hose High Frequency

Hose

K8NM MCM Locked Rotor Motor

Line frequency is below 45 Hz

Line frequency is above65Hz

Motor will not rotate.

Damaged gear train.

Chemical pump is stuck.

Ensure line frequency of incoming power is between 45and65Hz.

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

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

Repair or replace chemical pump.

18 333024F

Troubleshooting

Error Location Type Description

L1AX ADM

L1BX ADM

MMUX

P0AX

USB

MCM

Low Chemical Level A

Low Chemical Level B

Maintenance Due - USB

Pressure Imbalance AHigh

Cause Solution

Low material level.

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

Pressure difference between AandBmaterial is greater than the deﬁned value.

Reﬁll material and update drum level on ADM Maintenance screen.

Alarm can be disabled on the System Setup screen.

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.

Ensure material ﬂow is equally restricted on both material lines.

Pressure imbalance is deﬁned too low.

Out of material. Fluid leaking from

heater inlet rupture disk.

Feed system defective.

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

Fill tanks with material Check if heater

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

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

333024F 19

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 restricte d on b oth 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.

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

P1FA

P1FB

P2FA

MCM

Low Inlet Pressure A

Low Inlet Pressure B

Low Inlet Pressure A

Inlet pressure lower than deﬁned value.

Value deﬁned too high.

Inlet pressure lower than deﬁned value.

Value deﬁned too high.

Inlet pressure lower than deﬁned value.

Value deﬁned too high.

Ensure that inlet pressure to the pump is sufﬁcient.

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

Ensure that inlet pressure to the pump is sufﬁcient.

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

Ensure that inlet pressure to the pump is sufﬁcient.

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

20 333024F

Troubleshooting

Error Location Type Description

P2FB

P4AX MCM High Pressure A

MCM

Low Inlet Pressure B

Cause Solution

Inlet pressure lower than deﬁned value.

Value deﬁned too high.

System pressurized before allowing heat to reach setpoint.

Bad pressure transducer.

E-XP2 system conﬁgured as E-30.

Ensure that inlet pressure to the pump is sufﬁcient.

Ensure that the low pressure alarm level deﬁned on the System Setup screen is accep tab le.

Pressure in the hose and pumps will increase as the system heats up. Turn on heat and allow all zones to reach the temperature setpoint before turning on the pumps.

Verify the ADM pressure readingandtheanalog gauges at the manifold.

Alarm level is lower for E-30 than for E-XP2. Ensure dial on MCM is set to position "3" for E-XP2.

P4BX

MCM

High Pressure B

System pressurized before allowing heat to reach setpoint.

Bad pressure transducer.

E-XP2 system conﬁgured as E-30.

Pressure in the hose and pumps will increase as the system heats up. Turn on heat and allow all zones to reach the temperature setpoint before turning on the pumps.

Verify the ADM pressure readingandtheanalog guages at the manifold.

Alarm level is lower for E-30 than for E-XP2. Ensure dial on MCM is set to position "3" for E-XP2.

333024F

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 fo llows the transducer. Disconnect transducer cables from the MCM (connectors 6 and7). ReverseAandB connections and check if the errors follows. If the error follows the transducer, replace the pressure transducer.

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

P6FA MCM Pressure Sensor

Error Inlet A

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.

Check to ensure inlet sensor is properly installed and all wires are properly connected.

Check if the error fo llows the inlet sensor. Disconnect inlet sens or 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.

333024F

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.

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

Check if the error fol lows the inlet sensor. Disconnect inlet sensor cables from the MCM (connectors 8 and9). ReverseAandB connections and check if the errors follows. If th e 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 rupture disk.

Feed system defective.

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

Fill tanks with material Check if heater

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

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

333024F 23

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 restricte d on b oth 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.

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

T2DA Heater A Low Temperature A

Flow is too high at current setpoint.

Bad RTD or bad RTD placement against heater.

Bad heater rod or loose heater wire.

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

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

Conﬁrm resistance of heater. Heater resistance should be 9-12 Ω for 10 kW systems and 6-8 Ω for 15 kW systems. If out of tolerance, check for loose heater rod wire(s). Reconnect wires or replace heater rod if necessary.

333024F

Troubleshooting

Error Location Type Description

T2DB Heater B Low Temperature B

T2DH Hose Low Temperature

Hose

Cause Solution

Flow is too high at current setpoint.

Bad RTD or bad RTD placement against heater.

Bad heater rod or loose heater wire.

Flow is too high at current setpoint.

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

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

Conﬁrm resistance of heater. Heater resistance shouldbe9-12Ωfor10 kW systems and 6-8 Ω for 15 kW systems. If out of tolerance, check for loose heater rod wire(s). Reconnect wires or replace heater rod if necessary.

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

T2FA

T2FB MCM Low Temperature

MCM

Low Temperature Inlet A

Inlet B

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

Inlet ﬂuid temperature is below the deﬁned level.

Recirculate heated chemical back to drum in cold c ond iti on s 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.

333024F 25

Troubleshooting

Error Location Type Description

T3CH

T3CT TCM TCM Cutback

Hose

Hose Cutback

Cause Solution

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

High ambient temperature.

Enclosure fan not operating.

Module fan not operating.

Hose setpoint higher than A and B setpoints. Decrease hose setpoint.

Hose FTS is in a colder environment than the rest of the hose. Expose FTS to thesameenvironmentas therestofthehose.

Ensure ambient temperature is below 120°F(48°C) before using the system.

Ensure fan in electrical enclosure is spinning. If it is not, check fan wiring or replace fan.

If a TCM fan error (WMI0) has occurred, fan inside the module is not working properly. Check TCM fan for debris and clear with forced air if necessary.

T3NM

T3CM MCM MCM Temperature

T4CM MCM

MCM

Motor Temperature Cutback

Cutback

High Temperature MCM

Motor is operating outside of the pressure ﬂow curve.

Motor temperature is too high.

Motor control temperature is too high.

High ambient temperature.

Enclosure fan not operating.

The system is running at a lower setpoint to preserve motor life. Run the system at a lower duty cycle or with a smaller mix chamber.

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

Verify that all fans are working.

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

Verify that all fans are working.

Ensure ambient temperature is below 120°F(48°C) before using the system.

Ensure fan in electrical enclosure is spinning. If it is not, check fan wiring or replace fan.

26 333024F

Troubleshooting

Error Location Type Description

T4CT TCM

T4DA Heater A High Temperature A

High Temperature TCM

Cause Solution

High ambient temperature.

Enclosure fan not operating.

Module fan not operating.

Bad RTD or bad RTD placement against heater.

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

Ensure ambient temperature is below 120°F(48°C) before using the system.

Ensurefaninelectrical enclosure is spinning. If it is not, check fan wiring or replace fan.

If a TCM fan error (WMI0) has occurred, fan inside themoduleisnotworking properly. Check TCM fan for debris a nd clear with forced air if necessary.

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

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

T4DB Heater B High Temperature B

Bad RTD or bad RTD placement against heater.

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

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

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

333024F

Troubleshooting

Error Location Type Description

T4DH Hose High Temperature

Hose

T4EA Heater A High Temperature

Switch A

Cause Solution

Hose portion exposed to an excessive heat source, like hot sun or coiled hose, can pass ﬂuid more than 27°F (15°C) over hose temperature settingtotheFTS.

Setting the A or B setpoint much higher than hose setpoint can cause ﬂuid more than 27°F (15°C) over hose temperature settingtoreachthe FTS.

Overtemperature switch sensed a ﬂuid temperature above 230°F (110°C).

Shade exposed hose from hot sun or expose FTS to same environment when at rest. Uncoil entire hose before hea tin g to avoi d self-heating.

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

Heater was delivered too much power, causing the overtemperature switch to open. RTD is not reading properly. After the heater cools down, replace RTD. Switch closes and the error canbeclearedwhenthe heater temperature falls below 190°F (87°C).

Disconnected or loose overtemperature switch cable/connection.

Overtemperature switch failed in the open position.

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

Replace overtemperature switch.

28 333024F

Troubleshooting

Error Location Type Description

T4EB Heater B High Temperature

Switch B

T4NM MCM High Temperature

Motor

Cause Solution

Overtemperature switch sensed a ﬂuid temperature above 230 °F (110°C).

Disconnected or loose overtemperature switch cable/connection.

Overtemperature switch failed in the open position.

Cooling fan is not operating properly.

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

Replace overtemperature switch.

Check to see that the motor fan is moving. Measure voltagetofan.Thereshould be24VDC. If no voltage is measured, check fan wiring. If the fan has voltage but is not moving, replace fan. If necessary use an air hose to blow out around the fan housings and remove any built-up debris.

Disconnected or loose motor temperature cable.

High ambient temperature.

Bad electric motor. Replace electric motor.

T6DA Heater A Sensor Error A

333024F 29

Disconnected or loose RTD cable or connection.

Bad RTD.

Verify wiring between th e motor temperature sensor and the MCM.

Ensure ambient temperature is below 120°F(48°C) before using the system.

Check all wiring and connection to RTD.

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

Troubleshooting

Error Location Type Description

T6DB Heater B

T6DH Hose

Sensor Error B

Sensor Error Hose

Cause Solution

Disconnected or loose RTD cable or connection.

Bad RTD.

Disconnected or shorted RTD cable in hose or bad FTS.

Check all wiring and connection to RTD.

Switch the RTD with another and see if the error messagefollowstheRTD. ReplaceRTDiftheerror follows the RTD.

Expose each hose RTD connection to check and retighten any loose con- nector. Measure hose RTD cable and FTS continui ty . See Repair Heated Hose,

page 64.OrderRTDTest

kit 24N365 for measure- ment.

Disconnect hose RTD and usemanualhosemodeto ﬁnish job until repair can be completed.

T6DT

TCM

Sensor Error TCM

Shorted RTD cable in hose or FTS.

Shorted A or B Heater RTD

Expose each hose RTD connection to check for exposed and shorted RTD wires. Measure hose RTD cable and FTS continui ty . See Repair Heated Hose,

page 64.OrderRTDTest

kit 24N365 for measure- ment.

Disconnect hose RTD and usemanualhosemodeto ﬁnish job until repair can be completed.

If the error still occurs with the hose FTS unplugged, one of the heater RTDs is bad. Unplug the A or B RTD from the TCM. If unplugging an RTD ﬁxes the T6DT error, replace the RTD.

30 333024F

+ 72 hidden pages

Graco 333024F User Manual

Contents

Warnings

Important Isocyanate Information

Isocyanate Conditions

Material Self-Ignition

Keep Components A and B Separate

Moisture Sensitivity of Isocyanates

Changing Materials

Foam Resins with 245 fa Blowing Agents

Models

Reactor 2 E-30 and E-30 Elite

Reactor 2 E-XP2 and E-XP2 Elite

Approvals

Accessories

Supplied Manuals

Related Manuals

Component Manuals in English:

Troubleshooting

Error Codes