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

Troubleshooting

Error Location Type Description

T8DA Heater A No Temperature

Rise A

T8DB Heater B No Temperature

Rise B

Cause Solution

Bad RTD or bad RTD placement against heater.

Bad heater rod or loose heater wire.

Started spraying before heater reached operating temperature.

Bad RTD or bad RTD placement against heater.

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.

Wait until operating temperature has b een reached before spraying or recirculating.

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

T8DH Hose No Temperature

Rise Hose

V1CM MCM Low Voltage MCM

Bad heater rod or loose heater wire.

Started spraying before heater reached operating temperature.

Loose/bad connection or tripped circuit breaker.

Low incoming line voltage.

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.

Wait until operating temperature has b een reached before spraying or recirculating.

Check wiring for loose connection or tripped circuit breaker.

Measure voltage at circuit breaker and ensure voltage is greater than 195 VAC.

333024F 31

Troubleshooting

Error Location Type Description

V1IT

V2IT

V2MA

V2MB

TCM

Low Voltage CAN Bad 24 VDC power

Low Voltage A

Low Voltage B

Cause Solution

Check voltage of power

supply.

Loose connection or tripped circuit breaker.

Low incoming line voltage.

Loose connection or tripped circuit breaker.

Low incoming line voltage.

supply. Voltage should be 23-25 VDC. If out of tolerance, replace power supply.

Check voltage of power supply. Voltage should be 23-25 VDC. If out of tolerance, replace power supply.

Check wiring for loose connection or tripped circuit breaker.

Measure voltage at circuit breaker and ensure voltage is greater than 195 VAC.

Check wiring for loose connection or tripped circuit breaker.

Measure voltage at circuit breaker and ensure voltage is greater than 195 VAC.

V2MH

V3IT

V3MA

TCM

Low Voltage Hose

High Voltage CAN Bad 24 VDC power

High Voltage A Incoming l ine

Loose connection or tripped circuit breaker.

Low incoming line voltage.

supply.

voltage is too high.

Check wiring for loose connection or tripped circuit breaker.

Measure voltage at circuit breaker and ensure voltage is greater than 195 VAC.

Check voltage of power supply. Voltage should be 23-25 VDC. If out of tolerance, replace power supply.

Ensure incoming system power is wired properly. Verify voltage at each circuit breaker is between 195 and 264 VAC.

32 333024F

Troubleshooting

Error Location Type Description

V3MB

V3MH

V4CM MCM High Voltage MCM Incoming line

V4IT

V4MA

TCM

High Voltage B Incoming line

High Voltage Hose Incoming line

High Voltage CAN Bad 24 VDC power

High Voltage A Incoming line

Cause Solution

voltage is too high.

supply.

voltage is too high.

Ensure incoming system power is wired properly. Verify voltage at each circuit breaker is between 195 and 264 VAC.

Check voltage of power supply. Voltage should be 23-25 VDC. If out of tolerance, replace power supply.

Ensure incoming system power is wired properly. Verify voltage at each circuit breaker is between 195 and 264 VAC.

V4MB

V4MH

TCM

High Voltage B Incoming line

voltage is too high.

High Voltage Hose Incoming line

voltage is too high.

Ensure incoming system power is wired properly. Verify voltage at each circuit breaker is between 195 and 264 VAC.

333024F 33

Troubleshooting

Error Location Type Description

WBC0 MCM Software Version

Error

WMI0

WSUX USB Conﬁguration Error

WXUD ADM

WXUU ADM

TCM

TCM Fan Error Fan inside TCM

USB

USB Download Error

USB Upload Error Custom language

Cause Solution

Incorrect software version.

MCM does not have line voltage.

is not operating properly.

Avalid conﬁguration ﬁle can't be found for the USB.

Log download failed.

ﬁlefailedtoupload.

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

If V1CM also exists, see troubleshooting for V1CM. The software version cannot be read if the MCM does not have line voltage.

Check for debris in the TCM fan and clear with forced air if necessary.

Inset a system token into the ADM and cycle power. Wait until the lights on the USB port stop ﬂashing before removing token.

Backup and reformat the USB drive. Retry download.

Perform normal USB download and use the new disptext.txtﬁletouploadthe custom language.

34 333024F

Troubleshooting

System

Before performing any troubleshooti ng proc edu res:

1. Relieve Pressure. See Pressure Relief Procedure, page 43.

2. Turn main power switch OFF.

3. Allow equipment to cool.

Problem Cause Solution

Reactor ADM does not turn on.

Electric motor does not operate.

Electric motor runs erratically. Failed motor bearing. Replace motor, see

No power. Failed 24 V power supply. Replace power supply. Failed surge protector. Replace surge protector. Loose connections. Tripped circuit breaker (CB02). Reset breaker, see Repair Circuit

d windings. Replace motor, see

Shorte

Turn main power switch ON.

Check MCM

Breaker Module, page 55.Check

240VAC at output of breaker.

Repair Electric Motor, page 54.

connection 13.

333024F 35

Troubleshooting

Problem Cause Solution

Cooling fans not working.

Pump output low.

Fluidleakinpumppackingnut area.

No pressure on one side.

Loose wire.

Fan blade obstructed. Remove obstruction. Defective fan. Replace. See

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

Worn throat seals.

Fluid leaking from heater inlet rupture disk (372).

Check. See

Electrical Schematics, page 91.

Replace Motor Fan, page 57.

Open, clear; use hose with larger ID.

Seepumpmanual.

increase. Replace. See pump manual.

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

36 333024F

Hose Heat System

Before performing any troubleshooti ng proc edu res:

1. Relieve Pressure. See Pressure Relief Procedure, page 43.

2. Turn main power switch OFF.

3. Allow equipment to cool.

Troubleshooting

Problem

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

Hose do temper

es not maintain

ature while spraying.

Cause Solution

Ambient temperature is too cold. Relocate hoses to a warmer area

or recirculate heated ﬂuid through the hose.

FTS failed or not installed correctly. Check FTS, see Check RTD

Cables and FTS, page 65.

Low supply voltage.

A and B s

Ambient temperature is too cold. Increase A and B setpoints to

Flow too high. Use smaller mix chamber.

Hose was not fully preheated. Wait for hose to heat to correct

etpoints too low.

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

seAandBsetpoints.

Increa Hose is temper

increase ﬂuid temperature and keep it steady.

Decrease pressure.

temperature before spraying.

designed to maintain

ature, not to increase it.

Low supply voltage.

333024F 37

ify line voltage . Low line

Ver

tage signiﬁcantly reduces

vol

er available to the hose heat

pow

tem, affecting longer hose

sys

ngths.

Troubleshooting

Problem

Hose temperature exceeds setpoint.

Cause Solution

A and/or B heaters are overheating material.

Faulty FTS connections. Verify that all FTS connectio ns are

Ambient temperature is too high.

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

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

Electrical Schematics, page 91.

snug and that pins of connectors are clean. Unplug and re-plug RTD wires, cleaning off any debris.

Cover hoses or move to a location with a lower ambient temperature.

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

38 333024F

Troubleshooting

Problem

Erratic hose temperature.

Hose does not heat.

Cause Solution

Faulty FTS connections. Verify that all FTS connections are

snug and that pins of connectors are clean. Unplug and re-plug FTS wires along length of hose, cleaning off any debris.

FTS not installed correctly. FTS should be installed close to

end of hose i n same environment as gun. Verify FTS installation, see Repair Fluid Temperature

Sensor (FTS), page 66.

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

FTS failed. Check FTS, see Repair Fluid

FTS not installed correctly. FTS should be installed close to

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

Temperature Sensor (FTS), page

66.

end of hose i n same environment as gun. Verify FTS installation, see Repair Fluid Temperature

Sensor (FTS), page 66.

Loose hose electrical connections.

Circuit breakers tripped. Reset breakers (CB01 ), see

Hose zone not turned on. Turn on hose heat zone. A and B temperature setpoints too

low.

Check connections. Repair as necessary.

Repair Circuit Breaker Module, page 55.

Check. Increase if necessary.

333024F 39

Troubleshooting

Problem

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

Low hose heat.

Cause Solution

Shorted connection or failed hose heating element.

A and B temperature setpoints too low.

Hose temperature setpoint too low.

Flow too high. Use smaller mix chamber.

Low current; FTS not installed. Install FTS, see operation manual. Hose heat zone not turned on long

enough to reach setpoint. Loose hose electrical connections.

With power off, check the hose resistance with and without the whip hose attached. With the whip hose attached, the reading shouldbelessthan3ohm. With- out the whip hose attached, the readingshouldbeOL(openloop). See Check Hose Heat Power

Connectors, page 64.

Increase A and B setpoints. Hose designed to maintain temperature, not increase temperature.

Check. Increase if necessary to maintain heat.

Decrease pressure.

Allow hose to heat up, or preheat ﬂuid.

Check connections. Repair as necessary.

Ambient temperature is to low Relocate hoses to a warmer area

or increase A and B setpoints.

40 333024F

Primary Heater

Before performing any troubleshooti ng proc edu res:

Troubleshooting

1. Relieve Pres

2. Turn main pow

3. Allow equip

Problems

Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Also, determine that all circui t break ers, s wi tch es , a nd co ntrol s are prope rly set an d wiri ng is c orrec t befo re assuming there is a problem.

Primary Heater(s) does not heat.

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

sure. See Pressure Relief Procedure, page 43.

er switch OFF.

ment to cool.

Problem Cause Solution

Heat turned off. Temperat Signal f Dirty RTD connections. Examine RTD cables connected

RTD not contacting heater element.

ure control alarm.

ailure from RTD.

Turn on heat zones. Check ADM for error codes. Signal f

to TCMs. Conﬁrm RTDs are not plugged into opposite heat zone. Unplug and re-plug RTD connectors. Unplug and re-plug RTD connectors. Ensure RTD tip contacts the heater element.

Loosen ferrule nut, push in RTD so tip contacts heater element. Holding RTD tip against heater element, tighten ferrule nut 1/4 turn past tight.

ailure from RTD.

333024F

Failed heater element.

Signal failure from RTD. See (T6DA, T6DB), Error Codes.

See

Replace Heater Element, page 60.

Troubleshooting

Graco InSite

Problem

NomodulestatusLEDsare illuminated.

Has not identiﬁed GPS location (green module status LED ﬂashing).

Has not established cellular connection (orange module status LED ﬂashing).

Cannot view data for my unit(s) on website.

Temperature data not displayed on website. Hose zone temperature data not displayed on website.

Pressure data not displayed on website.

Cause Solution

No power to cellular module.

Still identifying location. Wait a few minutes for the unit to

Unable to identify location. In a location where GPS lock cannot occur. Buildings and warehouses often prevent GPS locks.

Still estab li sh ing cellular connection. Unable to establish cellular connection.

Graco InSite unit has not been activated.

Reactor temperature measurement is not working. The RTD or thermocouple is not correctly installed on the hose or is broken. Reactor pressure measurement is not working.

Turn Reactor ON. Ensure unit is properly installed. Verify 24V at output of the power

supply. Make sure the M8, 4–pin to M12, 8–pin cable is installed between cellular module and power supply.

identify the location. Move system to a location with a clear view of the sky. Use extension cable 16X521 and move cellular module to a location with a clear view of the sky. Wait a few minutes for the unit to establish the connection. Move system to a location with cellular service to establish cellul ar connection. Use extension cable 16X521 and move cellular module to a location with a clear view of the sky. Activate unit. See Registering and Activating the Graco InSite section. See System troubleshooting section. See RTD or Thermocouple repair section.

See System troubleshooting section.

333024F

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized ﬂuid, such as skin injection, splashing ﬂuid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing equipment.

The Fusion AP gun is shown.

1. Relieve pres sure in gun and perform gun shutdown procedure. See gun manual.

2. Close gun ﬂuid inlet valves A and B.

4. Route ﬂuid to waste containers or supply tanks. Turn PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION

. Ensure gauges drop to 0.

5. Engage gun piston safety lock.

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

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

333024F 43

Shutdown

Shutdown system to avoid electric shock. All electrical wiring must be done by a qualiﬁed electrician and comply with all local c odes and regulations. To help prevent serious injury from pressurized ﬂuid, such as skin injection, splashing ﬂuid and moving parts, follow the Pressure Relief Procedure when you sto p sp ray ing a nd b efore cleaning, checking, or servicing equipment.

NOTICE

Proper system setup, startup, and shutdown procedures are critical to electrical equipment reliability. The following procedures ensure s tead y voltage. Failure to follow these procedures will cause voltage ﬂuctuations that can damage electrical equipment and void the warranty.

4. Press to park the Component A Pump. The park operation is complete when green dot goes out. Verify the park operation is comp lete before moving to next step.

5. Press to deactivate the system.

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

1. Press to stop the pumps.

2. Turn of

3. Relieve pressure. See

Pressure Relief Procedure, page 43.

f all heat zones.

7. Turn main power switch OFF.

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

333024F

Shutdown

8. Close all ﬂuid supply valves. 9. Engage gun piston safety lock then close ﬂuid

inlet valves A and B.

Fusion Probler

333024F 45

Flushing

To avoid ﬁre and explosion:

• Flush equipment only i n a well-ventilated area.

• Do not turn on heaters until ﬂuid lines are clear of solvent.

• Flush out o ld ﬂuid with new ﬂuid, or ﬂush out old ﬂuid with a compatible solvent before introducing new ﬂuid.

• Use the lowest possible pressure when ﬂushing.

• All wetted parts are compatible with common solvents. Use only moisture-free solvents.

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

RELIEF/CIRCULATION lines (N).

To ﬂush entire system, circulate through gun ﬂuid manifold (with manifold removed from gun).

To prevent moisture from reacting with isocyanate, always leave the system ﬁlled with a moisture-free plasticizer or oil. Do not use water. Never leave the system dry. See Important Isocyanate Information.

. Flush through bleed

46 333024F

Repair

Repairing this equipment requires access to parts that may cause electric shock or other serious injury if work is not performed properly. Be sure to shut off al l power to eq uip men t before repairing.

Before Beginning Repair

NOTICE

Proper system setup, startup, and shutdown procedures are critical to electrica l equipment reliability. The following procedures ensure steady voltage. Failure to follow these procedures will cause voltage ﬂuctuations that can damage electrical equipment and void the warranty.

1. Flush if necessary. See Flushing, page 46.

1. Close the ﬂuid inlet valve on the y-strainer inlet and shut off the appropriate feed pump. This prevents material from being pumped while cleaning the screen.

2. Pl ac e a container under the strainer bas e to catch drain off when removing the strainer plug (C).

3. Remove the screen (A) from the strainer manifold. Thoroughly ﬂush the screen with compatible solvent and shake it dry. Inspect the screen.Nomorethan25%ofthemeshshould be restricted. If more than 25% of the mesh is blocked, replace the screen. Inspect the o—ring (B) and replace as required.

4. Ensurethepipeplug(D)isscrewedintothe strainer plug (C). Install the strainer plug with the screen (A) and o—ring (B) in place and tighten. Do not overtighten. Let the gasket make the seal.

5. Open the ﬂuid inlet valve, ensure that there are no leaks, and wipe the equipment clean. Proceed with operation.

2. See Shutdown, page 44.

Flush Inlet Strainer Screen

The inlet strainers ﬁlter out particles that can plug the pump inlet check valves. Inspect the screens daily as part of the startup routine, and clean as required.

Isocyanate can crystallize from moisture contamination or from freezing. If the chemicals u sed are clean and proper storage, transfer, and operating procedures are followed, there shoul d be minimal contamination of the A-side screen.

Note

Clean the A-side screen only during daily startup. This minimizes moisture contamination by immediately ﬂushing out any isocyanate residue at the start of dispensing operations.

Figure 1

333024F

Repair

Change Pump Lubricant

Check the condition of the ISO pump lubricant daily. Change the lubricant if it becom es a gel , i ts colo r darkens, or it bec ome s 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 lubri cation system minimizes exposure to moisture, but some contaminat ion 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 of ten than every 3 or 4weeks.

To change pump lubricant:

1. Follow Pressure Relief Procedure, page 43.

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

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

5. Thread the res ervoir onto the cap assembly and placeitinthebracket.

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

Pump Lubrication System Figure 2

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

48 333024F

Remove Pump

Pump rod and connecting rod move during operation. Moving parts can cause serious injury such as pinching or amputation. Keep hands and ﬁngers away from connecting rod during operation.

Note

See manual 309577 for pump repair instructions.

Repair

1. Press

2. Turn off heat zo nes.

3. Flush pump.

4. Press

5. Press

6. Turn main power switch off.

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

valves.

to stop the pumps.

to park the pumps in the down position.

to deactivate the system.

8. Route ﬂuid to waste containers or supply tanks. Turn PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION

. Ensure gauges drop to 0.

333024F 49

Repair

Note

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

Note

Steps 9–11 apply to pump A. To disconnect pump B, go to steps 12 and

13.

9. Disconnect ﬁttings at ﬂuid inlet (C) and outlet (D). Also disconne ct s te el outl et tub e from h eate r inlet.

10. Disconnect (U) from wet

tubes (T). Remove bo th tube ﬁttings

-cup.

11. Loosen locknut (G) by hitting ﬁrmly with a non-sparking hammer. Unscrew pump far enough to expose rod retaining pin. Push retaining wire clip up. Push pin out. Continue unscrewing pump.

Pump B Figure 4

Flat side faces up. Lubricat

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

e threads with ISO oil or grease.

Pump A Figure 3

Flat side faces up.

Lubricate threads with ISO oil or grease.

Pump top threads must be nearly ﬂush with

bearing face (N).

Note

Steps 12 and 13 apply to pump B.

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

13. Push retaining wire clip (E) up. Push pin (F) out. Loos en loc kn ut (G) by hitting ﬁrmly with a non-sparking hammer. Unscrew pump.

Install Pump

Note

Steps 1–5 apply to pump B. To reconnect pump A, proceed to step 6.

1. Ensure locknut (G) is screwed on pump with ﬂat side up. Screw pump into bearing housing (M) until pin holes align. Push pin (F) in. Pull retaining wire clip (E) down. See Fig. 4 for view and assembly notes.

2. Continue screwing pump into housing until ﬂuid outlet (D) is aligned with steel tube and top threads are +/- 1/16 in. (2 mm) of bearing face (N).

3. Ti ght en locknut (G) by hitting ﬁrmly with a non-sparking hammer.

4. Reconnect ﬂuid inlet (C) and outlet (D).

5. Go to step 13.

Note

Steps 6–12 apply to pump A only.

6. Ensure star-shaped locknut (G) is screwed on pump with ﬂat side up. Carefully twist and extend displacement rod 2 i n. (51 mm) abov e wet-cup.

50 333024F

Repair

11. Apply thin ﬁlm of TSL to barbed ﬁttings. Using

two hands, support tubes (T) while pushing straight onto barbed ﬁttings. Secure each tube withawiretiebetweentwobarbs.

Note

Do not let tubes kink or buckle.

12. Reconnect ﬂuid inlet (C).

13. Purge air and prime the system. See Reactor

operation manual.

Repair Drive Housing

Removal

Figure 5

7. S tart threading pump into bearing housing (M). When pin holes align, insert pin. Pull retaining wire clip down.

8. Con tin ue threading pum p into bearing housing (M) until top threads are +/- 1/16 in. (2 mm) of bearing face (N). Ensure that barbed ﬁttings at wet-cup ﬂush ports are accessible.

9. Connect component A outlet tube loosely at pump and at heater. Line up tube, then tighten ﬁttings securely.

10. Tighten star-shaped locknut (G) by hitting ﬁrmly with a non-sparking hammer.

1. Press to stop the pumps.

2. Turn off heat zo nes.

3. Flush pump.

4. Press

5. Press

6. Turn main power switch off.

to park the pumps in the down position.

to deactivate the system.

333024F 51

Repair

7. Perform Pressure Relief Procedure, page 43.

8. Remove the system frame from the ﬂoor and L-brackets.

NOTICE

Do not drop gear cluster (104) when removing drive housing (102). Gear cluster may stay engaged in motor front end bell or drive housing.

14. Remove screws (112, 119) and washers (114) and pull drive housing (102) off motor (101).

Note

The A side drive housing includes cycle counter switch (121). If replacing this housing, remove screws (122) and switch. Reinstall screws and switch on new drive housing.

9. Remove two bolts and nuts and fold the electrical enclosure backward.

10. Remove screws (21) and motor shroud (11). Rest the motor shroud behind the motor without straining the fan power cable.

Note

Examine beari ng housing (103) and connecting rod (105). If these parts need replacing, ﬁrst remove the pump (106), see Remove Pump, page 49.

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

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

13. Disconnect pump inlet and outlet lines. Remove screws (113 ), washers (115 ), and bearing housing (103).

Figure 6

52 333024F

Repair

Installation

1. Apply heavy duty extreme pressure grease

liberally to washers (107, 108, 118), all gea rs, and inside drive housing (102).

2. Ins ta ll one bronze washer (108) in drive housing,

then install steel wa shers (107, 118) as shown.

3. Install second bronze washer (108) on gear

cluster (104) and insert gear cluster in drive housing.

Note

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

4. Push drive housing (102) onto motor (101). Install screws (112) and washers (114).

Note

If bearing housing (103), connecting rod (105), or pump (106) were removed, reassemble rod in housing and install pump, see Install Pump, page 50 .

5. Rou te cycl e counter switch cable (121) around the motor fan and reattach to housing (102) with screws (122).

6. Install bearing housing (103), screws (113), and washers (114). Pumps must be i n phase (both at same position in stroke).

7. Install cover (60) and screws (21).

8. Install motor shield (11) and screws (21).

Figure 7

333024F 53

Repair

Repair Electric Motor

Removal

NOTICE

Be careful not to drop or damage the motor. The motor is heavy and ma y require two people to lift.

1. Remove the system frame from the ﬂoor and L-brackets.

2. Remove drive housing and pump assemblies. See Repair Drive Housing, page 51.

3. Disconnect electric motor (101) power cable from port #15 on the MCM. Remove connector by loosening four terminal screws.

4. Remove motor shroud (11). Rest the motor shroud asse mb ly behind the motor without straining the fan power cable.

5. D is co nne ct ove r tempe rature c ab le from port #2 on MCM. Cut tie wraps around harness to remove cable.

6. Remove four screws (25) holding motor (101) to bracket. Lift motor off unit.

Installation

1. Place motor on unit. Thread motor cables into con dui t as be fore. See

Electrical Schematics, page 91.

2. Fasten motor with screws (25) until screws are fully threaded in frame. Do not tighten screws until drive housing and pumps are connected to the motor.

3. In st all drive housing and pump assemblies, see

Installation, page 53.

4. Route motor (101) power cord from motor through conduit and connect to port #15 on MCM. Route over temperature cable up from motor and connect to port #2 on MCM. Insert cables in conduit and use tie wraps to secure the conduit together.

5. Connect motor shroud assembly to motor (101).

6. Install drive housing covers and motor cover.

7. Return to service.

54 333024F

Repair

Repair Circuit Breaker Module

1. See Before Beginning Repair, page 47.

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

a. Refer to Electrical Schematics, page 91,and

circuit breaker table.

b. Follow Shutdown instructions. See

Shutdown, page 44.

c. Refer to circuit breaker identiﬁc ation tabl e

and electrical diagrams in Reactor repair manual.

d. Loosen two screws connecting wires and bus

bar to circuit breaker that will be replaced. Disconnect wires.

new circuit breaker. Insert wires and tighten down all screws.

Figure 8

Circuit Breakers

Ref. Size Component

CB01 CB02

CB03 CB04 CB05 40 A Hose Heat Transformer

50 A Heated Hose 20 A

40 A 40 A

Motor Control Module (MCM)

ISO Heater RES Heater

e. Pull locking tab out 1/4 in. (6mm) and pull

circuit breaker away from the din rail. Install

333024F 55

Repair

Replace Fluid Inlet Sensor

Note

For Elite models only.

1. Perform Shutdown, page 44.

2. Perform Pressure Relief Procedure, page 43.

3. Disconnect inlet sensor cable from the ﬂuid inlet assembly. Inspect cable for dam age and replace if necessary. SeeElectrical Schematics, page 91.

5. Replace sensor (602).

Replace Pressure Transducers

1. Perform Shutdown, page 44.

2. Perform Pressure Relief Procedure, page 43.

3. Disconnect transducer cables (405) from #6 and #7 connectors on the MCM.

4. Remove wire ties constraining transducer cable and remove cable from cabinet.

5. Install o-ring (416) on new transducer (405).

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

7. Route new cable into cabinet and thread into bundle as before. Attach cable ties to bundle as before.

8. Connect A side pressure transducer cable to MCM port #6. Connect B side pressure transducer cable to MCM port #7.

Figure 9 Fluid Inlet Sensor

4. To replace sensor cable:

a. O p en wire bundle and remov e sensor cable. b. C ut any wire ties and disconne ct from MCM.

See Electrical Schematics, page 91.

NOTICE

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

56 333024F

Replace Fans

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

Replace Motor Fan

1. Perform Shutdown, page 44.

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

Electrical Schematics, page 91.

3. Remove four s crews (21) from motor cover (11). If necessary, fold frame (1) to remove motor cover (10). See Repair Drive Housing, page 51, steps 1–10.

4. Cut tie wraps to remove cable.

Repair

5. Remove nuts (39), screws (22), washers (34) and fan (32). Install new fan in reverse order.

Note

Ensure fan (32) blows onto motor.

Figure 10

Replace Electrical Enclosure Fan

1. Perform

2. Open electrical enclosu re door (401). Loosen four nuts (421) and remove fan (404).

3. Install new fan (404) in reverse order of disassembly so that the fan blows out of the electrical enclosure.

333024F 57

Repair

Figure 11

58 333024F

Repair

Replace Transformer Fan

1. Perform Shutdown, page 44.

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

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

4. Disconnect fan and transformer connections from terminal blocks. Connections are on left sidelabeled: V+,V-,1,2,3,and4.

5. Remove four nuts (27) holding metal transformer cover (8) to frame. Carefully remove cover while slidingwiresthroughholeincover.

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

7. Install fan in reverse order.

Figure 12

333024F 59

Repair

Repair Primary Heater

8. Wait for heater to cool.

Replace Heater Element

1. Press to stop the pumps.

2. Turn off heat zones.

3. Flush pump.

4. Press The park operation is complete when g reen dot goes out. Verify the park operation is complete before moving to next step.

to park the pumps in the down position.

9. Re mo ve four bolts (23) and shroud (10).

10. Remove screw (20) and lower din rail cover (48).

11. Disconnect heater wires:

a. A Side: Disconnect A side heater wires,

transformer, and transformer fan wires from lower din rail (33).

b. B Side: Disconnect B side heater wires and

remove lower din rail (33) from B side heater (5).

5. Press to deactivate the system.

6. Turn main power switch off.

7. Relieve pressure. See

Pressure Relief Procedure, page 43.

60 333024F

12. Test heater wires with ohmmeter.

em Total

Syst

Heater Wattage

E-30 (10 kw)

E-XP2, E-30 (15 kw)

To prevent a short circuit or lowering the transformer life, do not splash ﬂuid on transformer. Cover transformer with a plastic sheet or piece of cardboard.

10,200 2,550 18–21 per

15,300 2,550 18–21 per

Element

NOTICE

Ohms

element

Repair

13. Remove nuts (27) and transformer cover

(8). Cover transformer with plastic sheet or cardboard.

14. Disconnect overtemperature switches (209) from

cable.

15. Loosen ferrule nut (N). Remove RTD (212) from

heater housing. Do not remove adapter (206) unless necessary. If adapter must be removed, ensure that mixer (210) is out of the way when replacing adapter.

16. Disconnect inlet and outlet ﬂuid tubes from

heater.

17. Remove two bolts (23) and lift heater over

transformer.

18. Place heater block (201) in a vise. Use a wrench

to remove heater element (208).

19. Inspect element. It should be relatively smoo th

and shiny. Replace element if there is a crusted,

burnt, ash-like material adhered to element, or sheath shows pitting marks.

20. Install new heater element (208), holding mixer (210) so it does not block RTD port.

21. Secure heater to frame with bolts (23).

22. Reinstall RTD (212),

Repair Primary Heater, page 60.

23. Reconnect cable to overtemperature switches (209).

24. Reconnect wires to lower din rail. If necessary, install lower din rail (33).

25. Install lower din rail cover (48).

Line Voltage

The heater outputs its rated wattage at 240 VAC. Low line voltage will reduc e power available and the heater will not perform at full capacity.

Figure 13

333024F 61

Repair

Repair Overtemperature Switch

1. Perform Shutdown, page 44.

2. Wait for heaters to cool.

3. Remove heater cover (10).

4. Disconnect overtemperature switches (209) from cable (46). Test across spade termin al s wi th ohmmeter.

a. If the resistance

the overtemperature switch needs to be replaced. Go to step 5.

b. If the resistanceisapproximately 0 ohms,

inspect cable (46) to ensure it is not cut or open. Reconnect the overtemperature switch (209) and cable (46). Disconnect cable from TCM. Test from pin 1 to 3 and 1 to 4. If resistance is not approximately 0, and switches are 0. Replace cable in place of original cable.

5. If switch fails test, remove screws. Discard failed switch. Apply a thin layer of thermal compound

is not

approximately 0 ohms,

110009, install new switch in same location on housing (201), and secure with screws (213). Reconnect cables.

62 333024F

Repair

Replace RTD

1. Perform Shutdown, page 44.

2. Wait for heater to cool.

3. Remove heater cover (10).

4. Cut cable ties around the woven wrap with the

RTD cable (212).

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

6. Loosen ferrule nut (N). Remove RTD (212) from

heater housing (201), then remove RTD housing (H). Do not remove the adapter (206 ) unless necessary. If adapter must be removed, ensure that mixer (210) is out of the way when replacing the adapter.

7. Remove RTD c able (212) from woven wrap.

8. Replace RTD (212).

a. Apply PTFE tape and thread sealant to male

pipe threads and tighten RTD housing (H) into adapter (206).

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

element (208).

c. Holding RTD (212) against heater element,

tightenferrulenut(N)3/4turnpast ﬁnger-tight.

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

10. Replace heater shroud (10).

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

Figure 14

333024F 63

Repair

Repair Heated Hose

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

Check Hose Heat Power Connectors

1. Perform Shutdown, page 44.

Note

Whip hose must be c on nec ted .

2. Disconnect po wer harness (PM) from hose termination box terminal block (TB).

3. For Series A only: Disconnect hose connector (D) at Reactor.

Figure 16

4. Using an ohmmeter, check between the connectors (D). There should be continuity.

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

Figure 15

64 333024F

Check RTD Cables and FTS

1. Perform Shutdown, page 44.

2. Disconnect RTD cable (C) at Reactor.

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

Note

Do not touch outer ring with test probe.

Repair

Pins Result

3 to 1 approximately 1090

ohms

3 to 4 approximately 1090

ohms 1 to 4 0.2 - 0.4 ohms 2toany

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

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

6. If the FTS reads properly at the ma nifold but not at the end of the ho se, check cable (C) connections. Verify they are tight.

inﬁnity (open)

Heated Hose Figure 17

Note

To assist in taking readings, order RTD Test Kit 24N365. Kit includes two cables: one cable with a compatible female M8 connector and another cable with a male M8 connector. Both cables have stripped wire at the other end for easy test probe access.

Pins / Wire Color

3 to 1 / brown to blue approximately 1090

3to4/bluetoblack approximately1090

1to4/browntoblack 0.2-0.4ohms 2 to any / N/A inﬁnity (open)

Result

ohms

333024F 65

Repair

Repair Fluid Temperature Sensor (FTS)

Installation

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

Figure 18

Test/Removal

1. Perform Shutdown, page 44.

2. Remove tape and protective covering from FTS. Disconnect hose cable (F).

3. If FTS is not reading properly at the end of the hose, see Check RTD Cables and FTS, page 65.

4. If FTS fails, replace FTS.

a. Disconnect air hoses (C,L) and electrical

connectors (D).

b. Di s co nnect FTS from whip hose (W) and

ﬂuid hoses (A, B).

c. Remove ground wire (K) from ground screw

on underside of FTS.

d. Remove FTS probe (H) from component A

(ISO) side of hose.

66 333024F

Repair

Transformer Primary Check

See Electrical Schematics, page 91.

1. Check wires and transformer:

a. See Shutdown, page 44. b. Shut off CB05. c. Use an ohmmeter to test for continuity

between terminals 2 and 4 of CB05. If there is no continuity, check transformer.

2. Check transformer:

a. See Shutdown, page 44. b. Remove lower shroud. c. Locate the two smaller (10 AWG) wires,

labeled 1 and 2, coming out of transformer. Trace these wires back to terminal blocks TB15 and TB16.

d. Use an ohmmeter to test for continuity

between two wires; there should be continuity.

Transformer Secondary Check

See Electrical Schematics, page 91.

1. Check wires and transformer:

a. Disconnect 7 pin green connector from TCM. b. Use an ohmmeter to test for continuity

between terminals 6 an d 7 on the TCM 7 pin green connector. There should be continuity. If there is no continuity, check transformer.

c. Reconnect 7 pin green connector to TCM

2. Check transformer:

indicator on the ci rcu it breaker GREEN. Use an ohmmeter to test for c ontinuity between two transformer wires in terminal blocks TB17andTB18;thereshouldbecontinuity.

c. Close the circuit breaker CB01.

Figure 19 d. Apply incoming power to system. e. To verify voltage on the secondary leads

of the transformer, measure between the

terminals terminals 3 and 4 on TB17 and

TB18. Verify voltage is approximately 90

VAC for 240 VAC input. f. SeetheDiagnosticRunScreenonthe

ADM. The Diagnostic Run Screen displays

the incoming (90 Vac) to the TCM “Hose

Voltage”. The diagnostic screen will show if

the circuit breaker has been tripped for the

incoming power to the TCM.

a. Remove lower shroud. b. Locate the two larger (6 AWG) wires,

labeled 3 and 4, coming out of transformer. Trace these wires back to TB17 and TB1 8. Open circuit breaker CB01 to turn the col or

333024F 67

Repair

Replace Transformer

1. Perform Shutdown, page 44.

2. R emo ve four bolts (23) and shroud (10).

3. Remove lower dinrail cover (48).

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

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

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

7. Install transformer (17) in reverse order.

Figure 20

68 333024F

Replace Power Supply

1. Perform Shutdown, page 44.

2. Di sc onnec t input and output cables from

both sides of the power supply. See

Electrical Schematics, page 91.

3. Insert a ﬂat head screw driver in the mounting

tab on the bottom of the power supply to remove from the din rail.

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

Repair

Figure 22 Surge Protector

Replace Advanced Display Module (ADM)

1. Loosen four screws (70) on inside of electrical enclosure door (61). Lift up and pull out to remove ADM (88).

Figure 21 24 VDC Power Supply

Replace Surge Protector

1. Loosen connections on terminals 1 and 3 on CB02.

2. Loosen connections on input to power supply (535) on N and L connections.

3. Remove two screws (413) and surge protector (505) from enclosure.

4. Install n ew surge protector (505) in reverse order.

Note

2. Di sc onnec t CAN cable (475).

3. Inspect ADM (88) for damage. Replace if necessary.

Figure 23

Wire on both the circuit breaker and power supply are interchangeable.

333024F 69

Repair

Replace Motor Control Module (MCM)

1. Perform Shutdown, page 44.

2. Disconnect connectors from MCM (63). Disconnect two po w er cables. See

Electrical Schematics, page 91.

3. Remove nuts (91) and MCM (63).

4. Set rotary switch. 2= E–30 and 3= E-XP2.

5. Replace MCM in enclosure.

6. Connect cables to MCM. See

Electrical Schematics, page 91.

Replace Temperature Control Module (TCM)

1. Perform Shutdown, page 44.

2. Open electrical enclosure door (61).

3. Disconnect all connectors from the TCM (453).

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

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

Figure 24 Replace MCM

Software Update Procedure

NOTICE

Repair kit GCA modules are shipped pre-programmed and software loading is not necessary. If software version upgrade is necessary, follow the procedure in the manual provided.

Figure 25 Replace TCM

70 333024F

Parts

Proportioners

Parts

333024F

Parts

Apply anaerobic polyacrylate pipe sealant to all

non-swiveling pipe threads. Apply grease to tube ﬁtting threads. Torque to

43 ft-lbs (58 N•m). Safety and warning labels are from label sheet

(68).

333024F

Parts

Part Description

1 2

3 246995 BOTTLE, assembly,

4 16X531 5

6 24U704 MANIFOLD, ﬂuid; see

8 24R684

---

24U843 HEATER, 10kw, 2

24U842 HEATER, 7.5kw,

16W654

FRAME 111111 ENCLOSURE, electrical;

see Electrical Enclosure,

page 84

complete BRACKET, tsl, bottle

zone, RTD; see

Fluid Heater, page 80

1 zone, RTD; see

Fluid Heater, page 80

Fluid Manifold, page 82

INSULATOR, foam, heater

COVER, transformer

QuantityRef

272010 272011 272012 272110 272111 272112

111111

111111 11

22 22

111111

244244

111111

9+ 261821

10 24U841 11 16W765 1216W764COVER,heater,rear 111111

24U837 TUBE, b-side, inlet 1 1 1 113 24U838 TUBE, b-side, inlet, 10kw 1 1 24U839 TUBE, b-side, outlet 1 1 1 114 24U840 TUBE, b -si de, outle t,

24U834 TUBE, a-side, inlet 1 115 24U833 TUBE, a-side, inlet 1 1 1 1 24U836 TUBE, a-side, outlet 1 116 24U835 TUBE, a-side, outlet 1 1 1 1

17 15K742

1815B456GASKET,manifold 111111 19 125643

CONNECTOR, wire, 6awg

COVER, heater COVER, motor

10kw

TRANSFORMER, 4090va, 230/90

FITTING, elbow, 3/8 npt x#8jic

111111

111111 111111

111111

222222

20 119865

333024F 73

SCREW, mch, hex serrated; 3/8 i n. x 1/4–20

999999

Parts

Part Description

272010 272011 272012 272110 272111 272112

21 118444

22 117683

23 113796

24112731NUT,hex,ﬂanged 666666 25 111800

26 111218 27 110996 28 104859

29 103181 30100020WASHER,lock 222222 31 115836 32 24U847 FAN, cooling, 120mm,

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

SCREW, mch, phil pan hd; 1.5 in. x #6–32

SCREW, ﬂanged, hex hd; 3/4 in. x 1/4–20

SCREW, cap, hex hd; 7/32 in. x 5/16–18

CAP, tube, square NUT, hex, ﬂange hea d SCREW, tapping pnhd;

5/16 in. x #10–16 WASHER, lock ext

GUARD, ﬁnger

24vdc

12 12 12 12 12 12

888888

11 13 13 11 13 13

444444

222222 888888 222222

444444

111111 222222

QuantityRef

33 24R685

33a

24U849

33b 16W667

33c

33d

34 151395 35120685GROMMET 222222 36 114269 37 125625 38 127277

39127278NUT,keps,hex 444444 40127282GROMMET,rubber 444444 41 16X095

---

113505

ENCLOSURE, lower, dinrail; includes 33a-33d

KIT, module, din rail, heater; see Heater and

Transformer Terminal Block Module, page 87

INSULATOR, FOAM COVER, bottom, dinrail NUT, keps, hex hd WASHER, ﬂat

GROMMET, rubber TIE, cable, ﬁr tree BOLT, carriage, 1/2-13 x

3.5 l

CONNECTOR, power, male, 4 pin

111111

444444

111111 5 444444

111111

42 43

★

125871TIE,cable,7.5in. 252525252525 24K207

KIT, fts, rtd, single h ose

111111

333024F

Parts

Part Description

★



47 104765 48 16V268 49 15Y118 50

24R725

106569TAPE,electrical 111111 24T242 CABLE, over-temp, 10

24P970

24V150

24V151 PROPORTIONER,

BRIDGE, plug-in jumper, ut35

kW Reactor CABLE, over-temp, 15

kW Reactor PLUG, pipe headless COVER, top, dinrail LABEL, made in the USA PROPORTIONER,

module, E-30; see

Proportioner Module, page 78

module, E-XP2; see

Proportioner Module, page 78

QuantityRef

272010 272011 272012 272110 272111 272112

444444

1146

11 11

222221 111111 111111 11 11





55 56 191892

24U321 KIT, asm, pair,

24U320 KIT, assembly, pair,

16X118

24T050 CABLE, m8 4p f to m12

16W130

24U845

116746

16W218 LABEL, branding, e-30 1 1 16W321 LABEL, branding, e-30,

elite, reactor; see

Fluid Inlet Kits, pag e 89

std, reactor; see

Fluid Inlet Kits, pag e 89

MODULE, cellular, gps, temp

8p m 1.5m CABLE, m12 5p, fem -

male, 2.0m TUBE, pressure relief FITTING, elbow, street,

90 deg; 1/8 npt FITTING, barbed, plated;

1/8–27 npt x 1/4 in . hose I.D.

elite

111

222

222222 222222

222222

16W215 LABEL, branding, e-xp2 1 16W322 LABEL, branding, e-xp2,

elite

333024F 75

Parts

Part Description

272010 272011 272012 272110 272111 272112

★

60 61 16W766 6216W596LATCH,door 222222

★

68 16X250 70 127296

71 16X129

16U530

15G349 COVER, drive, plastic

24U832 24U831 206995FLUID,tsl,1qt. 111111 206994FLUID,tsl8ozbottle 111111 114225 TRIM, edge protection;

MODULE, system surge protector (spare)

COVER, control, box

MODULE, MCM MODULE, MCM

1.6 ft (0.48 m) LABEL, identiﬁcation SCREW, mchn, pnh,

w/ext tooth wash; M4 x

0.7 SCREW, mach, phillips,

tooth wash; 5/16 x 8–32

111111

222222 111111

111

111111

111111 444444

10 10 10 10 10 10

QuantityRef

11163

72 117502 FITTING, reducer #5 x #8

(JIC)

73 117677

74 299521

79+ 8116V806BRACKET,wall,mount222222 82 15V551

★

85 127276 BOLT, carriage, 1/2-13 x

88 24U854

299520

★

261843FLUID,oxideinhibitor 111111

24K409 BAR, 55 gal chem.

24K411 BAR, 55 gal chem.

16W967

FITTING, reducer #6 x #10 (JIC)

CAP, 1/2-20 jic cap-aluminum

CAP, 9/16-18 JIC cap-aluminum

SHIELD, membrane, ADM (10 pack)

measure; A side

measure. B side

2.5 l MODULE, ADM FITTING, swivel, 3/4 npt

x1npsm

111111

222222

111111 22 2289

118459

76 333024F

FITTING, union, swivel, 3/4 in.

Parts

Part Description

272010 272011 272012 272110 272111 272112

9016W213LABEL,branding,reactor222222 91 115942 92



★

94 127377 TIE, cable, 6 in. 1 1 1 95 16X154 96

★

98*

99* 17C258 ENCLOSURE, cover 100* 101*

15D906 SUPPRESSOR, round

127368

333091 MANUAL, quick guide,

333092 MANUAL, quick guide,

24W204

189930LABEL,caution 111111

▲

172953LABEL,ground 111111

NUT, hex, ﬂ ange head

snap ferrite .260 SLEEVE, split, wire, 1.50

LABEL, InSite

startup

shutdown ENCLOSURE, terminal

block

444444 111111

222222

111111

QuantityRef

111

102* 103*

▲

★



17D955 113161

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

Not shown. Parts included in Graco Insite Kit 24T280.

BRACKET, mounting SCREW, ﬂange, hex hd

111111 222222



See Electrical Schematics, page 91.

Part applies to Series A only.

Part applies to Series B only.

333024F

Parts

Proportioner Module 24V150, Module for E-30

24V151, Module for E-XP2

Torque to 190–120 in-lbs (21–24 N•m).

Lubricate threads with ISO oil or grease. Assemble pump cylinders ﬂush to one full thread under-ﬂush of

housing surface.

Apply grease to all gear teeth proportionally, motor pinion and drive housing.

Torque to 20–30 ft-lbs (27–40.6 N•m).

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

Torque to 70–80 ft-lbs (95–108 N•m).

Flat side faces up.

78 333024F

Parts

Ref Part Description

101

102

104 287290

105 241279

106★

107 114699

108 114672

110 183169

111 183210

112

24U050

---

257355

245927

MOTOR, brushless, double ended, 2 HP

HOUSING, drive, Mark VII

HOUSING, bearing

KIT, repair, gear

KIT, rod, connecting

245971

245972

PUMP, displacement B

WASHER, thrust; copper colored

WASHER, thrust; steel colored

SPRING, retaining

PIN, str, hdls

15C753 SCREW, machine, hex wash hd; 1.25 in. x

5/16–18

113 114666

114 106115

SCREW, cap, socket head; 2.25 x 3/8–16

WASHER, lock (hi-collar)

24V150 E-30

24V151 E-XP2

2103

10 10

115★

118 116192

120 116618

121

122 127301

125 187437

126▲

▲

★



246831

246832

193031

193394

PUMP, displacement, A

NUT, retaining

WASHER, thrust (1595)

MAGNET

24P728

SWITCH, reed, M8 4-pin

SCREW, hexhead, thread cut, 4-40 x 0.375

LABEL, torque

192840

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

See pump repair manual 30957 7 for repair kits. Spring (110) included in Connecting Rod Kit

241279.

LABEL, warning

2116



Gear Repair Kit includes washers (107 ) and (108).



Drive Housing Repair Kit includes housing (1), screws (5), and washer (1) to replace one end.

333024F 79

Parts

Fluid Heater

24U843 — 10kW, 2–zone 24U842 — 7.5 kW, 1–zone

Torque to 120 ft-lbs (163 N•m).

Torque to 23 ft-lbs (31 N•m).

Torque to 40 ft-lbs (54 N•m).

Apply thermal paste.

Apply pipe sealant and PTFE tape to all non-swiveling threads and threads without o-rings.

Apply lithium grease lubricant to o-rings before assembling in block (1).

Remove tape from probe tip and Orientate sensor as shown. Insert probe until it bottoms on heating element.

Tighten ferrule on sensor probe one turn past ﬁnger tight or 16 ft-lbs (21.6 N•m).

80 333024F

Parts

Ref Part

201

15J090 HEATER, machined, 1 zone

Description

15K825 HEATER, machined, dual zone

202 124132

203

15H305

204 121309

205

206

15H304

15H306

207 120336

208

209

210

211*

212*

16A110 HEATER, immersion, 2550W, 230V

15B137

15B135 MIXER, immersion heater

---

213 124131

214

15M178

Included in 24L973 Hea ter RTD Repair Kit.

O-RING

FITTING, plug, hollow, hex, 1-3/16 sae

FITTING, adapter, sae-orb x jic

FITTING, plug 9/16 sae

ADAPTER, 9/16 x 1/8

O-RING, packing

SWITCH, over temperature

FITTING, compression

SENSOR, RTD

SCREW, machine, pnhd; 5/16 in. x #6–32

HOUSING, rupture disc

24U843 24U842

333024F 81

Parts

Fluid Manifold

24U844

Torque to 355–395 in.-lbs (40–44.6 N●m)

Apply sealant (113500) to threads.

Valve must be closed with handle position as

shown on drawing.

Apply PTFE tape and thread sealant to gauge

threads. Apply grease on valve.

Apply PTFE tape or thread sealant to tapered threads.

82 333024F

24U844, Fluid Manifold

Parts

Ref Part Description Qty

401 255228 MANIFOLD, ﬂuid 1 402

★

247824 KIT, valve, cartridge, drain 2

402a

★

158674 O-RING, BUNA-N 1

402b

★

247779 SEAL, seat, valve 1 403 102814 GAUGE, press, ﬂuid 2 404 162453 FITTING, 1/4 NPSM X 1/4

NPT

405 15M669

406 247788 HANDLE, red 1 407 247789 HANDLE, blue 1 408 112309 NUT, hex, jam 2 411 117556 412 121312

SENSOR, pressure, ﬂuid outlet

NIPPLE, #8 JIC x 1/2 NPT FITTING, elbow, 3/4 SAE

x1/2JIC

Ref Part Description Qty

413 100840 FITTING, elbow, street 2 414 111457 O-RING, PTFE 2 415

▲

189285 LABEL, caution 1 416 150829 SPRING, compression 2 419 117557 NIPPLE, #10 JIC x 1/2

▲

Replacement Warning labels, signs, tags,

1 1

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 handle s and grease gun)

255148.

NPT

333024F 83

Parts

Electrical Enclosure

84 333024F

Electrical Enclosure

Parts

Ref Part

451

453

454

455

457 117666

458 120859

459 120858

460 123967

461 115942

462 103181

463 124131

464 194337

466 113505

▲

24U087

24U855

24U848 FAN, cooling, 80 mm,

24R736

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

See Electrical Schematics, page 91.

Description

ENCLOSURE

MODULE, TCM

24VDC 1 SWITCH, disconnect, door mounted 1 TERMINAL, ground

NUT, strain relief, M40 thread 1 BUSHING, strain relief, M40 thread 1 KNOB, operator disconnect 1 NUT, hex, ﬂange head

WASHER, lock external

SCREW, machine, pan head; 5/16 in. x #6–32 2 WIRE, grounding, door

NUT, keps, hex head

Qty

Ref Part

468 111218

469 114269

470 127282

471 127278

472

473

474

475 127068

476

477 127290

478▲

479▲

16W925

16W926

24R735

24U850

16X050

16X049

Description

CAP, tube, square

GROMMET, rubber

NUT, keps, hex

GASKET, enclosure, foam 2 GASKET, enclosure, foam 2 CABLE, CAN power, M12 female, pigtail

CABLE, CAN, female/female 1.0 meter 2 MODULE, breaker

CABLE, 4-pin, male/female, 1.3 meter, molded (hose RTD) LABEL, safety; enclosure

LABEL, safety; multi

Qty

333024F 85

Parts

System DIN Rail and Harness Module Kit

24U850, System DIN Rail and Harness Module Kit

See Electrical Schematics, page 91.

Torque to 6–8 in.-lbs (0.7–1 N●m)

Torque to 28–33 in.-lbs (3–3.8 N●m)

rque to 23–26 in.-lbs (2.6–3 N●m)

86 333024F

Parts

Ref Part

501

502

503

16U529

16V515

16U522

Description Qty

HARNESS, breaker module 1 HARNESS, hose out

MODULE, din rail, term blk, power sup; see

System Circuit Breaker Module, page 88

Ref Part

504

505

Heater and Transformer Terminal Block Module

24U849

16U526

16U530

Description Qty

MODULE, din rail, circuit breakers; see

Power Supply and Terminal Block Module, page 88

MODULE, sys surge protector

Ref Part

511

512 126811

513 126383

514 126382

24T315 RAIL, DIN; 35 mm x 7.5

Description Qty

mm x 7 in. BLOCK, clamp, end

COVER, end

BLOCK, terminal

Ref Part

515 120570

516

517

24R758

24R759

Description Qty

BLOCK, terminal

BLOCK, terminal, UT-2.5, red BLOCK, terminal, UT-2.5, black

333024F 87

Parts

System Circuit Breaker Module 16U526

Ref Part Description Qty

521 514014

522 120838

523

17A319

RAIL,DIN;35mmx

7.5 mm x 8.625 in. TERMINAL, end stop

CIRCUIT, breaker, 1 pole,50A,CCurve

Power Supply and Terminal Block Module 16U522

Ref Part Description Qty

524

525

17A314

17A317

CIRCUIT, breaker, 2P, 20A, UL489

CIRCUIT, breaker, 2P, 40A, UL489

Ref Part Description Qty

531 514014

532 120838

533

88 333024F

24R722

RAIL,DIN;35mmx7.5 mm x 8.625 in.

TERMINAL, end stop

BLOCK, terminal PE, quad, ABB

Ref Part Description Qty

534

535 126453

536

24R723

24R724

BLOCK, terminal, quad M4, ABB

POWER SUPPLY, 24V

BLOCK, terminal, UT35

Fluid Inlet Kits

24U320, Standard 24U321, Elite

Parts

Apply sealant to all tapered pipe threads. Apply

sealant to female threads. Apply to at least the ﬁrst four threads and approximately 1/4 turn wide. Apply thermal paste to the stem of dial before

assembling into housing.

333024F 89

Parts

Part Description

601 160327 602 118459 603



247503 604 24U852 THERMOMETER, dial 2 2 605 24U853 606

★

607

★

608



609



610 15D757 613 109077 VALVE, ball 3/4 npt 1 2 614 614 624545 615 24U851 TRANSDUCER, pressure, temperature (includes foam) 2

Optional 80 mesh ﬁlter 255082 (2 pack)

★

Included in 24V020 Inlet Filter and Seal Kit, 20 mesh (2 pack).



Included in 247503 Manifold Repair Kit.

--- C20203 PACKING, o-ring, 1.17, ﬂuoroelastome r 16V879 555808 PLUG, 1/4mp w/ hex hd 2 2

C20487 FITTING, nipple, hex

FITTING, union adapter, 90° FITTING, union, swivel, 3/4 in. MANIFOLD, strainer, inlet

GAUGE, press, ﬂuid FILTER, replacement 2 2

CAP, ﬁlter

HOUSING, thermometer, viscon hp

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

QuantityRef

24U320 24U321

22 22 22

22 22

90 333024F

Electrical Schematics

Reactor 2 E-30

Reactor 2 E-XP2

To T CM

Electrical Schematics

24U831 24U832

16X118

333024F 91

Electrical Schematics

PS-L

PS-N

CB-B

CB-A

ti22680b

92 333024F

24U855

Electrical Schematics

16U526

15D906

16U529

16V515

Locate near TCM.

Heated hose wire termination enclosure (series

B only).

TO HTD HOSE

ELEC ENCL GND STUD

ti22678b

333024F 93

Reactor 2 Repair SparePartsReference

Reactor 2 Repair Spare Parts Reference

Recommended Common Spare Parts

Ref

106, 115

606, 607

402 247824 403 102814 405 15M669 211,

212

Part Description

15C852 E-30 Pump Repair Kit Pump

15C851

246963

246964 E-30 Wet Cup Repair Kit Pump

24V020

24L973 RTD Repair Kit Heater

24K207 24N450 24N365

Part of Assembly

E-XP2 Pump Repair Kit Pump

E-XP2 Wet Cup Repair Kit

Y-Strainer Filter and Gasket Kit (pack of two each)

Drain Valve Cartridge Fluid Manifold Fluid Pressure Gauge Fluid Manifold Pressure Sensor Fluid Manifold

Hose FTS RTD Cable (50 ft. repl ac eme nt) RTD Cable Test Kit (To assist measureing

RTDs and RTD cable resistances)

Pump

Y-Strainer

Hose Hose Hose

94 333024F

Performance Charts

Use these charts to help identify the proportioner that will work most efﬁciently with each mix chamber. Flow rates are based on a material viscosity of 60 cps.

NOTICE

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

Proportioners For Foam

2000

(138)

AR4242

(01)

PRESSURE

psi (bar)

150 0

(103)

100 0

(69)

500

(34)

(2.3)

AR5252

(02)

(4.5)

(6.8)

(9.1)

FLOW lbs/min (kg/min)

AR6060

(03)

AR7070

(04)

(11.3)

(13.6)

E-30

(15.9)

(18.1)

333024F 95

Performance Charts

Proportioners For Coatings

Table 1 Fusion Air Purge, Round Pattern

3500

(241)

3000

(207)

2500

(172)

PRESSURE

psi (bar)

2000

(138)

150 0

(103)

100 0

(69)

500

(34)

0 0.5

Table 2 Fusion Air Purge, Flat Pattern

3500

(241, 24.1)

3000

(207, 20.7)

2500

(174, 17.4)

PRESSURE

2000

(138, 13.8)

psi (bar)

1500

(103, 10.3)

1000

(69, 6.9)

AR2020

(000)

AR2929

(00)

(1.9)

1.0

(3.8)

FLOW gal./min (l/min)

AF2020

(FTXX24 TIP)

AR4242

(01)

AF2929

(FTXX38 TIP)

AF4242

(FTXX38 TIP)

AF5252

(FTXX48 TIP)

E-XP2

1.5

(5.7)

E-XP2

2.0

(7.6)

500

(35, 3.5)

0 0.5

(1.9)

1.0

(3.8)

1.5

(5.7)

2.0

(7.6)

FLOW gal./min (l/min)

96 333024F

Table 3 Fusion Mechanical Purge, Round Pattern

3500

(241, 24.1)

3000

PRESSURE

(207, 20.7)

2500

(174, 17.4)

2000

(138, 13.8)

XR2323

(RTM040)

psi (bar)

1500

(103, 10.3)

1000

(69, 6.9)

500

(35, 3.5)

0 0.5

(1.9)

(RTM040)

XR3535

(RTM055)

E-XP2

XR2929

(3.8)

MR3535

(RTM040)

XR4747

(RTM055)

MR4747

(RTM055)

1.5

(5.7)

Performance Charts

2.0

(7.6)

FLOW gal./min (l/min)

Table 4 Fusion Mechanical Purge, Flat Pattern

3500

(241, 24.1)

(1.5)

XF2323

(FTM424)

MF2929

(FTM424)

XF2929

(FTM424)

(FTM638)

0.6

(2.3)

XF3535

PRESSURE

psi (bar)

3000

(207, 20.7)

2500

(174, 17.4)

2000

(138, 13.8)

1500

(103, 10.3)

1000

(69, 6.9)

500

(35, 3.5)

0 0.4

XF1313

(FTM424)

XF1818

(FTM424)

0.2

(0.7)

MF1818

FLOW gal./min (l/min)

MF3535

(FTM638)

0.8

(3.0)

(3.8)

MF4747

(FTM638)

XF5757

(FTM638)

MF5757

(FTM638)

1.2

(4.5)

1.4

(5.3)

1.6

(6.0)

E-XP2

1.8

(6.8)

2.0

(7.6)

333024F 97

Technical Speciﬁcations

Reactor 2 E-30 and E-XP2 Proportioning System

U.S.

Maximum Fluid Working Pressure

E-30 2000 psi 14 MPa, 140 bar E-XP2 3500 psi 24.1 MPa, 241 bar

Maximum Fluid Temperature

E-30 E-XP2

Maximum Flow Rate

E-30 30 lb/min 13.5 kg/min E-XP2 2 gpm 7.6 lpm

Maximum Inlet Temperature

E-30 E-XP2

Maximum Inlet Fluid Pressure

E-30 300 psi 2.1 MPa, 21 bar E-XP2 300 psi 2.1 MPa, 21 bar

Maximum Heated Hose Length

Length

Output per Cycle

ISO and RES E-30 0.0272 gal. 0.1034 liter

E-XP2 0.0203 gal. 0.0771 liter

Operating Ambient Tempera ture Range

Temperature

Line Voltage Requirement

Nominal 200–240 VAC, 1 Phase, 50/60 Hz

Nominal 200–240 VAC, 3 phase, DELTA, 50/60 Hz

Nominal 350–415 VAC, 3 phase, WYE, 50/60 Hz

Heater Power

(at 230 VAC rated voltage) E-30 10 kW 10,200 Watts

E-30, 15 kW 15,300 Watts E-XP2 15 kW 15,300 Watts

190°F 88°C 190°F 88°C

150°F 66°C 150°F 66°C

310 ft

20° to 120°F -7° to 49°C

195–265 VAC

340–455 VAC

Metric

94 m

98 333024F

Technical Speciﬁcations

Sound Pressure

Sound Pressure measured per ISO-9614–2.

E-30

Measured from 3.1 ft (1 m), at 1000 psi (7 MPa, 70 bar), 3 gp m (11.4 lpm)

E-XP2 Measured from 3.1 ft (1 m), at 3000 psi (21 MPa, 207 bar), 1 gpm (3.8 lpm)

Sound Power

E-30 Measured from 3.1 ft (1 m), at 1000 psi (7 MPa, 70 bar), 3 gpm (11.4 lpm)

E-XP2 Measured from 3.1 ft (1 m), at 3000 psi (21 MPa, 207 bar), 1 gpm (3.8 lpm)

Fluid Inlets

Component A ISO) and Component B (RES)

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

Size 1/4 NPSM(m) Maximum Pressure 250 psi 1.75 MP a, 17.5 bar

Dimensions

Width 26.3 in. 668 mm Height 63 in. 1600 mm Depth 15 in. 381 mm

Weight

E-30, 10 kW 315 lb 143 kg E-30, 15 kW 350 lb 159 kg E-30, 10 kW Elite 320 lb 145 kg E-30, 15 kW Elite 355 lb 161 kg E-XP2 345 lb 156 kg E-XP Elite 350 lb 159 kg

Wetted Parts

Material Aluminum, stainless steel, zinc plated carbon steel, brass,

carbide, chrome, chemically resistant o-rings, PTFE, ultra-high

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

molecular weight polyethylene

87.3 dBA

79.6 dBA

93.7 dBA

86.6 dBA

333024F 99

Notes

100 333024F

Graco 333024F User Manual

Specifications and Main Features

Frequently Asked Questions

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

System

Hose Heat System

Primary Heater

Graco InSite

Pressure Relief Procedure

Shutdown

Flushing

Repair

Before Beginning Repair

Flush Inlet Strainer Screen

Change Pump Lubricant

Remove Pump

Install Pump

Repair Drive Housing

Removal

Installation

Repair Electric Motor

Removal

Installation

Repair Circuit Breaker Module

Replace Fluid Inlet Sensor

Replace Pressure Transducers

Replace Fans

Replace Motor Fan

Replace Electrical Enclosure Fan

Replace Transformer Fan

Repair Primary Heater

Replace Heater Element

Repair Overtemperature Switch

Replace RTD

Repair Heated Hose

Check Hose Heat Power Connectors

Check RTD Cables and FTS

Repair Fluid Temperature Sensor (FTS)

Installation

Test/Removal

Transformer Primary Check

Transformer Secondary Check

Replace Transformer

Replace Power Supply

Replace Advanced Display Module (ADM)

Replace Surge Protector

Replace Motor Control Module (MCM)

Replace Temperature Control Module (TCM)

Software Update Procedure

Parts

Proportioners

Fluid Heater

24U843 — 10kW, 2–zone 24U842 — 7.5 kW, 1–zone

Fluid Manifold

24U844

24U844, Fluid Manifold

Electrical Enclosure

Electrical Enclosure

System DIN Rail and Harness Module Kit

24U850, System DIN Rail and Harness Module Kit

Heater and Transformer Terminal Block Module