Graco 3A1705J User Manual

Operation

3A1705J

Reactor® E-30i and E-XP2i

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

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

EN

PROVEN QUALITY. LEADING TECHNOLOGY.

Contents

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

Important Two-Component Material

Information ............................................. 7

Proportioner Models ............................................. 9

Systems............................................................. 10

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

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

Related Man

Typical Installation, with circulation ...................... 13

Typical Installation, without circulation.................. 14

Component

Generator
Proportio
Air Compr
Advanced
Motor Con
Engine Co
Load Cen
Tempera
Circuit

Overview............................................................ 30

Setup................................................................. 33

Locate Reactor ............................................ 33

Trailer Setup Guidelines............................... 35

Install Wall (optional).................................... 36

Connect Battery........................................... 38

Add Fuel ..................................................... 38

General Equipment Guidelines ..................... 38

Electrical Connections.................................. 39

Connect Feed Pumps................................... 39

Breathing Air................................................ 39

Connect Pressure Relief Lines...................... 40

Install Fluid Temperature Sensor .................. 40

Connect Heated Hose.................................. 40

Close gun fluid manifold valves A and

Connect Whip Hose to Gun Or Gun Fluid

Pressure Check Hose .................................. 41

Connect Remote Display Module .................. 41

Grounding ................................................... 41

Supply Wet Cups With Throat Seal Liquid

vanced Display Module (ADM)

Ad

uals ................................................ 12

Identification..................................... 15

.................................................... 17

ner Control Panel ........................... 18

essor............................................ 18

Display Module (ADM).................. 19

trol Module (MCM)........................ 23

ntrol Module ................................. 24

ter ................................................ 25

ture Control Modules....................... 26

Breakers ........................................... 28

B ................................................... 41

Manifold......................................... 41

(TSL) ............................................. 42

eration.............................................. 43

Op

Advanced Setu

System........................................................ 47

Recipes....................................................... 47

Run Mode ................................................... 48

Startup............................................................... 55

Temporary Manual Hose Temperature

Control ................................................. 58

Fluid Circulation.................................................. 59

Circulation Through Reactor ......................... 59

Circulation Through Gun Manifold................. 60

Jog Mode........................................................... 60

Spraying ............................................................ 61

Spray Adjustments....................................... 62

Shutdown........................................................... 63

Pressure Relief Procedure .................................. 64

Flushing............................................................. 65

Maintenance ...................................................... 66

Preventative Maintenance Schedule ............. 66

Proportioner Maintenance ............................ 66

Engine Maintenance .................................... 67

Fuel Tank .................................................... 67

Flush Inlet Strainer Screen ........................... 67

Pump Lubrication System............................. 68

Drain Coolant .............................................. 69

Refill Proportioner Coolant Loop ................... 70

Refill Engine Coolant Loop ........................... 72

Coolant Specifications.................................. 72

Errors ................................................................ 73

View Errors.................................................. 73

Troubleshoot Errors ..................................... 73

Troubleshooting.................................................. 74

Error Codes and Troubleshooting.................. 74

USB Data........................................................... 89

USB Logs.................................................... 89

System Configuration Settings ...................... 90

Download Procedure.................................... 91

Custom Language File ................................. 91

Upload Procedure........................................ 92

Appendix A: Engine Control Module..................... 93

Dimensions........................................................ 96

Performance Charts............................................ 99

Technical Specifications.................................... 102

aco Standard Warranty.................................. 106

Gr

p Screens ............................. 46

2

3A1705J

Warnings

Warnings

The following
exclamation p
risks. When th
hazard symbo
where applic

warnings are for the setup, use, grounding, maintenance and repair of this equipment. The
oint symbol alerts you to a general warning and the hazard symbol refers to procedure-specific

ese symbols appear in the body of this manual refer back to these Warnings. Product-specific

ls and warnings not covered in this section may appear throughout the body of this manual

able.

WARNING

ELECTRIC SHOCK HAZARD

This equip
cause elec

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

• Connect o

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

TOXIC FLUID OR FUMES
Toxic fluids or fumes can cause serious injury or death if splashed in the eyesoronskin,
inhaled, or swallowed.

• Read MSDSs to know the specific hazards of the fluids you are using.

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

ment must be grounded. Improper grounding, setup, or usage of the system can

tric shock.

nly to grounded power source.

CARBO
Exhau
carbo

• Do not operate in an enclosed area.

PERS
You m
oper
hear

• Protective eyewear, and hearing protection.

•Res

N MONOXIDE HAZARD

st contains poisonous carbon monoxide, which is colorless and odorless. Breathing

n monoxide can cause death.

ONAL PROTECTIVE EQUIPMENT

ust wear appropriate protective equipment when operating, servicing, or when in the
ating area of the equipment to help protect you from serious injury, including eye injury,
ing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited to:

pirators, protective clothing, and gloves as recommended by the fluid and solvent

ufacturer.

man

3A1705J 3

Warnings

WARNING

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce
skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get
immediate surgical treatment.

• Engage trigg

• Do not point dispensing device at anyone or at any part of the body.

• Do not put your hand over the fluid outlet.

• Do not stop o

• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning,
checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hose

FIRE AND EXPLOSION HAZARD

Flammabl
prevent fi

• Use equipment only in well ventilated area.

•Donotfil
flammabl

• 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 p
are pre

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

•Holdg

• If there is static sparking or you feel a shock, stop operation immediately. Do not use
equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

er lock when not dispensing.

r deflect leaks with your hand, body, glove, or rag.

s and couplings daily. Replace worn or damaged parts immediately.

e fumes, such as solvent and paint fumes, in work area can ignite or explode. To help

re and explosion:

l fuel tank while engine is running or hot; shut off engine and let it cool. Fuel is
e and can ignite or explode if spilled on hot surface.

lug or unplug power cords, or turn light switches on or off when flammable fumes

sent.

un firmly to side of grounded pail when triggering into pail.

MAL EXPANSION HAZARD

THER

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

• Open a valve to relieve the fluid expansion during heating.

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

4

3A1705J

Warnings

WARNING

PRESSURIZED ALUMINUM HAZARD

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

• Do not use 1,1
solvents or fl

• Many other fluids may contain 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 co
parts.

•SeeTechnical Data in this and all other equipment instruction manuals. Read fluid and
solvent manufacturer’s MSDSs and recommendations.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not op

• Do not exceed the maximum working pressure or temperature rating of the lowest rated
system component. See Technical Data in all equipment manuals.

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

•Donot
equip

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

• Do not alter or modify equipment.

•Usee

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

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

•Keep

• Comply with all applicable safety regulations.

leave the work area while equipment is energized or under pressure. Turn offall

ment and follow the Pressure Relief Procedure when equipment is not in use.

quipment only for its intended purpose. Call your distributor for information.

children and animals away from work area.

,1-trichloroethane, methylene chloride, other halogenated hydrocarbon

uids containing such solvents.

mpatible water-based solvents to clean plastic structural or pressure-containing

erate the unit when fatigued or under the influence of drugs or alcohol.

3A1705J 5

Warnings

WARNING

BATTERY HAZARD

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

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

• Battery maintenance must only be performed or supervised by personnel knowledgeable of
batteries and the required precautions. Keep unauthorized personnel awayfrombattery.

• When replaci
minimum, spe

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

• Follow local ordinances and/or regulations for disposal.

• Do not open o
the skin and

• Remove watches, rings, or other metal objects.

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

ng the battery, use the same lead-acid automotive battery, with 800 CCA

cified for use with the equipment. See Technical Data.

r mutilate the battery. Released electrolyte has been known to be harmful to

eyes and to be toxic.

MOVING PA

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

• Keep clear of moving parts.

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

•Pressur
equipme

ENTAGLEMENT HAZARD

ng parts can cause serious injury.

Rotati

• Keep clear of moving parts.

•Donoto

• Do not wear loose clothing, jewelry or long hair while operating equipment.

• Equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure and disconnect all power sources.

BURN HAZARD

pment surfaces and fluid that’s heated can become very hot during operation.Toavoid

Equi

re burns:

seve

• Do not touch hot fluid or equipment.

RTS HAZARD

ized equipment can start without warning. Before checking, moving, or servicing

nt, follow the Pressure Relief Procedure and disconnect all power sources.

perate equipment with protective guards or covers removed.

6 3A1705J

Important Two-C

omponent Material Information

Important Two-Component Material Information

Isocyanate Conditions

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

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

Prevent inhalation of isocyanate mists, vapors,
and atomized particulates by providing sufficient
ventilation in the work area. If sufficient ventilation
is not available, a supplied-air respirator is required
for everyone in the work area.

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

Moisture Sensitivity of Isocyanates

Cross-contamination can result in cured
material in fluid lines which could cause serious
injury or damage equipment. To prevent
cross-contamination of the equipment’s wetted
parts, never interchange component A (isocyanate)
and component B (resin) parts.

Isocyanates (ISO) are catalysts used in two
component foam and polyurea coatings. ISO will
react with moisture (such as humidity) to form small,
hard, abrasive crystals, which become suspended in
the fluid. Eventually a film will form on the surface
and the ISO will begin to gel, increasing in viscosity. If
used, this partially cured ISO will reduce performance
and the life of all wetted parts.

The amount of film formation and rate of crystallization
varies depending on the blend of ISO, the humidity,
and the temperature.

Material Self-Ignition

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

Keep Components A and B Separate

Cross-contamination can result in cured
material in fluid lines which could cause serious
injury or damage equipment. To prevent
cross-contamination of the equipment’s wetted
parts, never interchange component A (isocyanate)
and component B (resin) parts.

To prevent exposing ISO to moisture:

• 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 lube pump 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.

• Always lubricate threaded parts with ISO pump oil
or grease when reassembling.

3A1705J

7

Important Two-C

omponent Material Information

Foam Resins wi
Agents

Some foam blow
above 90°F (3
especially i
preheating i

ing agents will froth at temperatures

3°C) when not under pressure,

f agitated. To reduce frothing, minimize

n a circulation system.

th 245 fa Blowing

Changing Mate

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

• When changin
multiple tim

• Always clean

•Checkwithy
compatibil

• When changi
or polyure
component
have amine
often have

es to ensure it is thoroughly clean.

ity.

as, disassemble and clean all fluid

s and change hoses. Epoxies often

s on the B (hardener) side. Polyureas

amines on the B (resin) side.

rials

g materials, flush the equipment

the fluid inlet strainers after flushing.

our material manufacturer for chemical

ng between epoxies and urethanes

8 3A1705J

Proportioner Models

E-30i Series

Proportioner Mo

dels

Auxiliary
Current at
240 V, 60
Hz*

259079

259080

259089 

259090 

50 Amps 240 V (1)

32 Amps

30 Amps

12 Amps

E-XP2i Series

Auxiliary
Current at
240 V, 60
Hz*

259081

259091 

32 Amps

12 Amps

Includes:Part Available

Booster
Heat
(4000
Watts)





Includes:Part Available

Booster
Heat
(4000
Watts)





Air
Compressor
(5000 Watts)



Air
Compressor
(5000 Watts)

Voltage
(phase)

240 V (1)

240 V (1)

240 V (1)

Voltage
(phase)

240 V (1)

240 V (1)

Total
System
Load †
(Watts)

7,700

11,700

7,700

16,700

Total
System
Load †
(Watts)

11,700

16,700

Max Flow
Rate lb/min
(kg/min)

30 (13.5)

30 (13.5)

30 (13.5)

30 (13.5)

Max Flow
Rate gpm
(lpm)

2.0 (7.6)

2.0 (7.6)

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

0.0272
(0.1034)

0.0272
(0.1034)

0.0272
(0.1034)

0.0272
(0.1034)

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

0.0203
(0.0771)

0.0203
(0.0771)

Maximum
Fluid
Working
Pressure
psi (MPa,
bar)
2000 (13.8,

138)
2000 (13.8,

138)
2000 (13.8,

138)
2000 (13.8,

138)

Maximum
Fluid
Working
Pressure psi
(MPa, bar)

3500 (24.1,

241)
3500 (24.1,

241)



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

* Full load amps available for auxiliary equipment when all bare-system components are operating

at maximum capabilities. Available auxiliary current is based on 310 ft (94.5 m) of heated hose.
An additional 3.0 amps of auxiliary current is available for each 50 ft (15.2 m) section of heated
hose that is not used.





lable auxiliary current will be less when the engine is de-rated for site altitude. Reduce the

Avai

lable Auxiliary Current in the chart by 2.5 Amps per 1000 ft (300 m) elevation increments. If the

Avai

lable auxiliary current is less than zero, the system configuration may not support the full load

avai

at altitude.

at th

Includes Complete Air Compressor Kit 24K335.

Refer to Circuit Breaker Configuration Options, page 29.

e Approvals, page 10.

Se

3A1705J 9

Systems

Approvals

Model Approvals:

259079

Conforms to ANSI/UL Std. 73 Certified to CAN/CSA Std. C22.2 No. 68

259080

259081

Conforms to ANSI/UL Std. 499 Certified to CAN/CSA Std. C22.2 No. 88

Systems

Maximum

Part

AP9079

AP9080

AP9081

AP917

AP918

AP91

CS9079 2000 (13.8, 138)

CS9080 2000 (13.8, 138)

CS9081 3500 (24.1, 241)

CS9179 2000 (13.8, 138)

CS9180 2000 (13.8, 138)

CS9181 3500 (24.1, 241)

P29079

P29080

P29081

P29179

P29180

P29181

Fluid Working
Pressure psi
(MPa, bar)

2000 (13.8, 138)

2000 (13.8, 138)

3500 (24.1, 241)

9

2000 (13.8, 138)

0

2000 (13.8, 138)

81

3500 (24.1, 241)

2000 (13.8, 138)

2000 (13.8, 138)

3500 (24.1, 241)

2000 (13.8, 138)

2000 (13.8, 138)

3500 (24.1, 241)

Remote

Proportioner

259079 24K240 246050 Fusion™

259080 24K240 246050 Fusion

259081 24K241 246055 Fusion

9

25907

0

25908

81

2590

79

2590

080

259

081

259

9079

25

59080

2

59081

2

259079 24K240 246050

259080 24K240 246050

259081 24K241 246055

259079 ✓ 24K394 246050

259080 ✓ 24K394 246050

259081 ✓ 24K395 246055

Display
Module Kit

✓ 24K39

✓ 24K39

✓24K3952460

✓24

✓2

✓2

Heated Hose

50 ft (15

24K2

24K

24K

4K394

4K395

m)

4

4

40

240

241

K394

10 ft (3 m

0

24605

0

24605

55

50

2460

050

246

055

246

6050

24

46050

2

46055

2

Gun

) Model Part

™AP

™AP

n™ AP

Fusio

n™ AP

Fusio

on™ AP

Fusi

Fusion™ CS CS0101

Fusion™ CS CS0101

Fusion™ CS CS0000

Fusion™ CS CS0101

Fusion™ CS CS0101

Fusion™ CS CS0000

Probler® P2 GCP2R1

Probler® P2 GCP2R1

Probler® P2 GCP2R0

Probler® P2 GCP2R1

Probler® P2 GCP2R1

Probler® P2 GCP2R0

AP

246101

246101

246100

24610

24610

00

2461

1

1

10 3A1705J

Accessories

Systems with A

Maximum

Part

AP9089

AP9090

AP9091

AP9189

AP9190

AP9191

CS9089 2000 (13

CS9090 2000 (13

CS9091 3500 (2

CS91892000 (

CS91902000 (

CS91913500

P29089

P29090

P29091

P29189

P29190

P29191

Fluid Working
Pressure psi
(MPa, bar)

2000 (13.8, 1

2000 (13.8,

3500 (24.1,

2000 (13.8

2000 (13.

3500 (24.

.8, 138)

.8, 138)

4.1, 241)

13.8, 138)

13.8, 138)

(24.1, 241)

(13.8, 138)

2000

0(13.8,138)

200

0(24.1,241)

350

00 (13.8, 138)

20

000 (13.8, 138)

2

500 (24.1, 241)

3

ir Compressor

Proportioner

259089 ✓ 24K240 246050 Fusion™ AP 246101

38)

259090 ✓ 24K240 246050 Fusion™ AP 246101

138)

259091 ✓ 24K241 246055 Fusion™ AP 246100

241)

,138)

8, 138)

1, 241)

259089 ✓ ✓ 24K394 246050 Fusion™ AP 246101

259090 ✓ ✓ 24K394 246050 Fusion™ AP 246101

259091 ✓ ✓ 24K395 246055 Fusion™ AP 246100

259089 ✓ 24K240 246050

259090 ✓ 24K240 246050

259091 ✓ 24K241 246055

259089 ✓ ✓ 24K394 246050

259090 ✓ ✓ 24K394 246050

259091 ✓ ✓ 24K395 246055

259089 ✓ 24K240 246050

259090 ✓ 24K240 246050

259091 ✓ 24K241 246055

259089 ✓ ✓ 24K394 246050

259090 ✓ ✓ 24K394 246050

259091 ✓ ✓ 24K395 246055

Air
Compressor

Remote
Display
Module Kit

Heated Hose

50 ft
(15 m)

10 ft
(3 m)

Gun

Model Part

Fusion™

Fusion™

Fusion

Fusio

Fusio

Fusi

Prob

Pro

Pro

obler® P2

Pr

robler® P2GCP2R1

P

robler® P2GCP2R0

P

CS

CS

™CS

n™ CS

n™ CS

on™ CS

ler® P2

bler® P2

bler® P2

CS0101

CS0101

CS0000

CS010

CS010

CS00

GCP2

GCP

GCP

P2R1

GC

1

1

00

R1

2R1

2R0

Accessories

Kit Number Description

24N449

24K207

24K338 Remote Display Module Kit

24K335

125970

24M490

24M125

24M178

24M258

24K336 Hose Rack

50 ft (15 m) CAN cable (for remote
display module)

Fluid Temperature Sensor (FTS)
with RTD

Complete Air Compressor Kit

Air Compressor (without air supply
tank)

Air Compressor (mounted 30 gallon
tank)

Air Tank (12 gallons, 113.5 liters)

Air Dryer (desiccant)

Compressor Rack (frame only)

Kit Number Description

15V551

15M483 Remote Display Module Protective

24K334

24K333

24K337 Light Tower Kit

24M174

24L911

121006

24N365

ADM Protective Covers (10 pack)

Covers (10 pack)

Feed Pump Shutdown Kit

Fuel Line and Cable Extension Kit

Drum Level Sticks

Pallet Support Kit

150 ft (45 m) cable (for remote
display module)

RTD Test Cables (to aide resistance
measurements)

3A1705J

11

Supplied Manual

s

Supplied Manuals

The following
Refer to these
information.

Manuals are also available at www.graco.com.

Manual Description

3A1705 Reactor E-30i and E-XP2i,

16K761

16K913 Reactor E-

SEBU8311–02Perkins® Engine, Repair-Parts

–

F3231, ver

16

manuals are shipped with the Reactor.

manuals for detailed equipment

Operation
Reactor E-30i and E-XP2i, Startup
Instructions

30i and E-XP2i,

Shutdown I

nstructions

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

Contact Perkins for engine warranty
and service.

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

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

Contact Mecc Alte for warranty and
service.

pion Air Compressor,

Cham

ation/Maintenance & Parts list.

Oper

arranty and service call

For w

dner-Denver Customer Serivce

Gar

6) 276–3440 or Champion (815)

(86

–3321.

875

Related Manuals

The following manuals are for accessories used with
the Reactor.

Manuals are av

Component manuals in English:

System Manuals

3A1706 Reactor E-30i and E-XP2i,

Displacement Pump Manual

309577 Electric Reactor Displacement Pump,

Feed System Manuals

309572 Heated Hose, Instructions-Parts

309852

309815 Feed Pump

309827

Spray G

309550

312666

313213

Accessory Manuals

3A1902

3A1903 Hose Rack, Instructions-Parts

3A1904 Fuel Tank/Battery Move Kit,

05

3A19

3A1906 Light Tower Kit, Instructions-Parts

3A1907 Remote Display Module,

3A2574

ailable at www.graco.com

Repair-Parts

Repair-Parts

Circulation and Return Tube Kit,
Instructions-Parts

Kits, Instructions-Parts

Feed Pump Air Supply Kit,
Instructions-Parts

un Manuals

Fusion

Fusion

Proble

Compr

Instructions-Parts
Feed Pump Shutdown Kit,
Instructions-Parts

Instructions-Parts
Pallet Support Kit, Instructions-Parts

™APGun

™CSGun

rP2Gun

essor Rack, Instructions-Parts

2

1

3A1705J

Typical Installation, with circulation

K

M

H

G

J

R

M

K

G

Typical Install

L

ation, with circulation

R

J

A

D

E

S

P

C*

Figure 1

* Shown exposed for clarity. Wrap with tape during operation.

A Reactor Proportioner

BHeatedHose

CFlui

D Heated Whip Hose

E

F

GFee

H

d Temperature Sensor (FTS)

ion Spray Gun

Fus

Air Supply Hose

Gun

d Pump Air Supply Lines

tator Air Supply Line

Agi

J

K Feed Pumps

L Agitator

M Desiccant Dryer

P

R Recirculation Lines

SRe

F

d Supply Lines

Flui

Fluid Manifold (part of gun)

Gun

mote Display Module (optional)

B

3A1705J 13

Typical Install

ation, without circulation

Typical Installation, without circulation

K

H

G

J

L

J

M

K

A

G

F

N

D

E

N

S

P

C*

Figure 2

* Shown exposed for clarity. Wrap with tape during operation.

A Reactor Proportioner

B Heated Hose

CFlui

D HeatedWhipHose

E

F

GFee

H

d Temperature Sensor (FTS)

ion Spray Gun

Fus

Air Supply Hose

Gun

d Pump Air Supply Lines

tator Air Supply Line

Agi

J

K Feed Pumps

L Agitator

M Desiccant Dryer

N Bleed Lines

P

SRe

B

d Supply Lines

Flui

Fluid Manifold (part of gun)

Gun

mote Display Module Kit (optional)

4

1

3A1705J

Component Ident

ification

Component Ide

GB SB

GA

SA

FA

HA

BA

ntification

FB

BB

HB

HC

SC

(FM)

PA

PB

PC

GG

DG

EM

Front V
Figure

iew

3

BA

BB

DG Drive

DB Electrical Enclosure

EM Electric Motor

FA

FB

FM

GA Com

GB Com

GG Gen

HA

HB

Compon

Compo

Comp

Comp

Reac

Com

Co

ent A Pressure Relief Outlet

nent B Pressure Relief Outlet

Gear Housing

onent A Fluid Manifold Inlet

onent B Fluid Manifold Inlet

tor Fluid Manifold

ponent A Pressure Gauge

ponent B Pressure Gauge

erator, page 17

ponent A Hose Connection

mponent B Hose Connection

PT

DB

HC Heated Hose Electrical Connectors

MP

PA

PB

PC Prop

PT Pallet

SA Com

SB Com

SC Fl

TA

T

Main Power Switch

Component A Pump

Component B Pump (behind Electrical
Enclosure)

ortioner Control Panel, page 18

ponent A PRESSURE

IEF/SPRAY Valve

REL

ponent B PRESSURE

IEF/SPRAY Valve

REL

uid Temperature Sensor (FTS) Cable

mponent A Pressure Transducer

Co

ehind gauge GA)

(b

B

Component B Pressure Transducer
(behind gauge GB)

MP

3A1705J 15

Component Ident

FF

ification

MM

LM

HM

EC

Back Vi
Figure

ew

4

CP Circul

EC Elect

FF

Y-str
tempe

FH

Booster Fluid Heater (not included with all
models)

FV

HE

Fluid Inlet Valve (A side shown)

Heat Exchangers (heat exchanger coolant
loop)

HM

Hi
(H

VC

CP

VB

ation Pump

ricalCordStrainRelief

ainer (includes pressure gauge and

rature gauge)

gh Power Temperature Control Module

PTCM) Cable Connections, page 26

HE

HEVA

LM

Low Power Module (LPTCM) Cable
Connections, page 26 (not included with

all models)

LR

MM

ISO Pu

Moto

SG Sigh

VA

VB

Comp

Comp

VC Byp

FF

FH

SG

FV

LR

mp Lubricant Reservoir

r Control Module (MCM), page 23

tGlass

onent A Control Valve

onent B Control Valve

ass Control Valve

16 3A1705J

Generator

EX

Component Ident

FH

HB

RF

ification

ER

RC

BE

DF

ST

GD

FS

FT

WS

EA

AF

FJ

GL

HF

EB

OD

HE

TR

OL

EE

FD

FP

ED

Figure 5

AF Air Filter

BE

ery (not supplied)

Batt

DF Diesel Fuel Filter

EA

EB

harge Alternator

12V C

ne Coolant Expansion Bottle

Engi

EE Engine

ED

ine Oil Dipstick

Eng

ER Radiator

EX Exhaust

FD

l Shutoff Solenoid

Fue

FH Filter Housing

FJ Fuel Injector

FP Fuel Pump

FS Di

esel Fuel Fill Cap

OF

FT Diesel Fuel Tank

GD Generator Power Distribution Box

GL Glow Plugs

HB

Heat Exchanger Coolant Expansion Bottle

HE Heat Exchanger

HF

Heat Exchanger Coolant Fill Bottle

OD Oil Drain

OF Oil Filter

OL Oil Fill

OS Oil Pressure Switch

RC Engine Coolant Radiator Cap

RF Radiator Fan

ST Starter

TR

Coolant Temperature Sensor

WS Over-Temperature Switch

OS

3A1705J

17

Component Ident

ification

Proportioner

PN

PF*

PG*

PH*

PJ*

Figure 6

Control Panel

PL

PE

PM

PP

PK

PR

PD

ti17151a

PD

PE

PF* Component A Feed Pump Air Outlet

PG* Component B Feed Pump Air Outlet

PH* Agitator Air Outlet

PJ* Gun Air Outlet

PK

PL

PM

PN

PP

PR

*Notforb

Advanced Display Module (ADM), page 19

Engine Control Module, page 24

Component A Feed Pump Air Regulator

Component B Feed Pump and Agitator Air
Regulator
Gun Air Reg

Componen

Componen
Pressure
Gun Pressure Gauge

ulator

t A Feed Pump Pressure Gauge

t B Feed Pump and Agitator

Gauge

reathing air use.

Air Compressor

Select
To ord

Figure 7

models are supplied with an air compressor.

er as an accessory, see Accessories, page 11.

CA Air Com

CB

CC 12 Gal

CD Air Ou

CE

CF Desi

CG Powe

CH

CJ Air T

CK Mai

CL

CM

CN

Power Box

tlet

Desiccant Dryer Assembly

ccant Dryer Air Outlet

rCable

Water Auto Drain Valve

ank Pressure Gauge

n Shutoff Valve

Dryer Inlet Valve

WaterAutoDrainAirValve

Water Manual Drain Valve

pressor

lon Tank

18 3A1705J

Component Ident

ification

Advanced Disp

lay Module (ADM)

NOTICE

To prevent damage to the softkey buttons, do not
press buttons with sharp objects such as pens,
plastic cards, or fingernails.

A

D

B

C

D

E

H

G

Component Identification — Front
Figure 8

Call
out
A Power

B

C Stop Stops all system processes.

D

Button Function

Powers system on and off.

ff

On/O
System
Status
Indicator
Light

Soft Keys Selects the specific screen

Displays system status.

Is not a safety or emergency
stop.

or operation shown on the
display directly next to each
key.

F

Call
out
E

F Enter Acknowledges a value

GLoc

HNa

Button Functi

l

Cance

k/Setup

vigation

on

ls a selection or

Cance
numbe

change or makes a selection.
Toggles between run and
setup screens. If setup
screens are password
protected, button toggles
between run and password
entry screens.
Na
to

r entry in progress.

vigates within a screen or

a new screen.

3A1705J 19

Component Ident

CJ

CS

CR

ification

CK

CL

CM

CN

CP

Compone
Figure 9

CJ Flat Panel Mount (VESA 100)

CK Model and Serial Number

CL USB Port and Status LEDs

CM CAN Cable Connection

CN Module Status LEDs

CP Accessory Cable Connection

CR Token Access Cover

CS Battery Access Cover

nt Identification — Back

System Status Indicator (B)
Cond

Green Solid — Run Mode, System On

Gre

Yellow Solid - Run Mode, System Off

Yellow Flashing - Setup Mode, System Off

itions

en Flashing - Setup Mode, System On

USB Modu

le Status LEDs (CL)

Conditions

Green F

Yellow Solid - Downloading information to USB

Green and Yellow Flashing -ADMisbusy,USB
cannot transfer information when in this mode

Modul

Green Solid - Power applied to module

Yell

Red Steady Flashing - Software upload from token
in progress

Red Random Flashing or Solid -Moduleerrorexists

lashing - Data recording in progress

e Status LEDs (CN) Conditions

ow Solid - Active Communication

20 3A1705J

Component Ident

ification

ADM Display Details

Power Up Screen

The following screen appears when the ADM is
powered up. It remains on while the ADM runs through
initialization and establishes communication with other
modules in the system.

Menu Bar

The menu bar appears at the top of each screen. (The
following image is only an example.)

Alarm/Deviation

The current sy
the menu bar. T

stem error is displayed in the middle of

here are four possibilities:

Icon Function
No Icon

No information or no error has occurred

Advisory

Deviation

Alarm

Status

The curren
of the menu

t system status is displayed at the lower right

bar.

Soft Keys

Icons next to the soft keys indicate which mode or
action is associated with each soft key. Soft keys that
do not have an icon next to them are not active in the
current screen.

NOTICE

To prevent damage to the soft key buttons, do not
press buttons with sharp objects such as pens, plastic
cards, or fingernails.

Date and Time

The date and time are always displayed in one of the
following formats. The time is always displayed as a
24-hour clock.

• DD/MM/YY HH:MM

• YY/MM/DD HH:MM

• MM/DD/YY HH:MM

Arrows

The left and right arrows indicate screen navigation.

Screen Menu

The screen menu indicates the currently active screen,
which is highlighted. It also indicates the associated
screens that are available by scrolling left and right.

System Mode

The current system mode is displayed at the lower left
of the menu bar.

Jump In/Jump Out

In screens that have editable fields, press to access
the fields and make changes. When changes are

complete press again to exit edit mode.

Navigation within Screens

Press to open drop-down menus on Setup screens.

Press

Press

navigate left and right within a screen. Press
select digits to change within a field.

Press

up and down within a screen. Also press
move between fields within a drop-down menu, and to
increment or decrement numbers within a field.

to enter changes or make a selection.

to navigate to new screens and to

to navigate to new screens and to navigate

to

to

3A1705J

21

Component Ident

Icons

ification

Icons

Icon Function

Component A

Component B

Estimated Supply Material

Hose Temperature

Jog Mode Speed

Engine Coolant Temperature

Pressure

Cycle Counter (press and
hold)

Advisory.
See Errors, page 51 for more
information.

Softkeys

Icon Function

Start Proportioner

Start and Stop Proportioner in Jog Mode

Stop Proportioner

Turn on specified heat zone.

Park component A pump

Enter Jog Mode. See Jog Mode, page 60

Reset Cycle Counter
(press and hold)

Select Recipe

Search

Move Cursor Left One Character

Move Cursor Right One Character

Deviation.
See Errors, page 51 for more
information

Alarm.
See Errors, page 51 for more
information

Toggle between upper-case, lower-case, and
numbers and special characters.

Backspace

Cancel

Clear

Troubleshoot Selected Error

Increase value

Decrease value

Next screen

Previous screen

urntofirstscreen

Ret

2

2

3A1705J

Component Ident

ification

Motor Control

MA

MC

Module (MCM)

MB

1A

10

1B

6

7

3

2

9

11

12

Motor Control Module
Figure 10

MA

MB

MC

1A,
1B

2

3

5

6

Token and Rotary Switch Access Cover

Module Status LEDs see Module Status
LEDs (CN) Conditions, page 20

Warning Label

CAN Communication Connections

Heat Exchanger Control Vave Output (to
load center)

Two-way Splitter to A and B Heat
Exchanger Temperature Sensors

ngine Coolant Temperature Sensor

E

ump Cycle Switch

P

13

5

7

8

9

10

11 Not used

12

13

MCM Rotary Switch Positions

=E-30i

0

1=E-XP2i

onal Accessory Connection: Feed

Opti

Shut Down Kit

Pump

ssure Transducer B (Blue) side

Pre

ssure Transducer A (Red) side

Pre

or Brush Wear and Over-Temperature

Mot

sor Connection

Sen

M Power Input Connection

MC

tor Power Connection

Mo

8

3A1705J 23

Component Ident

ification

Engine Contro

l Module

NOTICE

To prevent damage to the softkey buttons, do not
press buttons with sharp objects such as pens,
plastic cards, or fingernails.

For more information about the engine control module,
see Appendix A: Engine Control Module, page 93.

Icon Description Function

On Start Engine

Auto

Off Stop all system

Scroll Scroll through the

Page Sele

Error La

ct

mp

Auto mode (not
used)

processes. Is
not a safety or
emergency stop.

instruments or
recorded events
on the currently
displayed page

Toggle between
the information
page and the error
log page

es error

Indicat
is prese
generat

nt on

or

Figure 1

Engine Control Module

1

4

2

3A1705J

Component Ident

ification

Load Center

F3 Radiator Fan Fuse

F4

K1 Fuel Relay

K2

K3

K4 Radiator Fan Relay

MV

Load Center Power Fuse

Starter Relay

Glow Plug Relay

Manual Valve Switch

LED

D1

D2

D3

D4

D10

D12

D14

D23

Related
Component

Fuel Shutoff
Solenoid (FS)

Starter (ST)

Glow Plugs
(GL)
Radiator F
(RF)

A Coolant Valve

B Coolant Valve

Bypas
Valve

Manual Valve
Switch (MV)

an

s Coolant

Color

Green

Red

Green

Green

Red

Blue

Green

Red

ON-State
Description
Fuel shutoff
solenoid on the
engine is open.
Starter is
cranking.
Glow plugs are
heating.
Radiator fan is
on.
A-side (red)
coolant valve is
open.
B-side
coolan
open.
Bypas
valve
Manu
swit
ON po

(blue)

tvalveis

s coolant

is open.

al valve

ch is in the

sition.

3A1705J 25

Component Ident

ification

Temperature C

Located inside the Electrical Enclosure (DB).

ontrol Modules

High Power Temperature Control Module (HPTCM) Cable Connections

2

1

3

Figure 12

7

8

Low Power Module (LPTCM) Cable Connections

Only used with E-XP2i and E-30i models with booster
heat.

1

2

3

Figure 14

7

6

re 13

Figu

1Notu

2

3

4

5

6

7

8

sed

Fluid Temperature Sensor (FTS)
Connection

put Power Connection

Out

tactor Control Connection

Con

ut Power Connection

Inp

N Communications Connections

CA

tary Switch, Token Access

Ro

dule Status LEDs (see

Mo

vanced Display Module (ADM), page 19,

Ad

CN) for conditions

(

5

4

9

4

Figure 15

1

2

3

4 Not used

5

6

7

8

9Base

Over-Temperature Switch Connection

Booster Heat Temperature Sensor
Connection
Output Power Connection

Input Power Connection

CAN Communications Connections

Rotary Switch, Token Access

Module Status LEDs (see

Advanced Display Module (ADM), page 19,

(CN) for conditions

5

8

6

26 3A1705J

Component Ident

ification

Adjust Rotary Switch

The rotary switch setting indicates which zone the
temperature control module will control in the system.
The HPTCM uses an 8-position rotary switch. The
LPTCM uses a 16-position rotary switch.

Set the rotar
according to

HPTCM Rotary Switch Location
Figure 16

y switch (S) to the specific selection

the settings listed in the following tables.

HPTCM A and B Rotary Switch Settings

Setting

0HeatedHose

1 Not Used

2 Not Used

3 Not Used

4 Not Used

5

6 Not Used

7

LPTCM A and B Rotary Switch Settings

S

Setting

0 Not Used

1 Not Used

2 Not Used

3 Not Used

Zone

Not Used

Not Used

Zone

S

LPTCM Rotary Switch Location
Figure 17

4 Not Used

5

6 Not Used

7

8 Not Used

9 Not Used

A Booster Heat A

B Booster Heat B

C

D Not Used

E Not Used

F Not Used

Not Used

Not Used

Not Used

3A1705J

27

Component Ident

ification

Circuit Break

CB08

CB07

CB06

CB05

CB04

CB03

CB02

CB01

Circuit B
Figure 1

reakers Inside Electrical Enclosure (DB)
8

Note

ers

CT01

Ref. Size Component

CB01

30 A High Power Tem

Control Modu

CB02

20 A

Motor Control Module
(MCM)

CB03

5A

Two Motor Fans, Cabinet
Fan, Power Supply, and
Coolant Circulation Pump

CB04*

30 A

Auxiliary

Power (Air

Compress

CB05*

CB06*

10 A Auxiliary Power

20 A Auxilia

ry Power

E-XP2i and E-30i With
Heat: Low Power

CB07

15 A

Temperature Control
Module (LPTCM) A

E-30i:

Auxiliary

E-XP2i and E-30i With
Heat: Low Power

CB08 15 A

Temperature Control
Module (LPTCM) B

E-30i: Auxiliary

perature

le (HPTCM)

or)

Not all wires are shown.

*SeeCircuit Breaker Configuration Options, page 29.

CB20

Circuit Breakers Inside Proportioner Cabinet
Figure 19

Ref. Size Component

CB20

5

0A

eated Hose

H

28 3A1705J

Component Ident

ification

CB04 be substituted to accommodate larger loads
or a sub-panel. The total auxiliary equipment
loads added to the configuration must be limited
to the system’s available auxiliary current. See

Proportioner Models, page 9, for available auxiliary

current at 240V, 60Hz.

CB10

Circuit Breakers Inside Alternator Assembly
Figure 20

Ref. Size Component

CB10

90 A 120/240V Alternator

Circuit Breaker Configuration Options

Improper configurat
All changes from the
configuration must
and Local safety an
a qualified electri
changes. See page 2
breaker configura

The Electrical Enclosure (DB) circuit breaker
configuration described in the tables on the previous
page is the recommended configuration.

Sub-Panel Options

ion can result in electric shock.

recommended circuit breaker

meet all National, State,

d electrical codes. Consult

cian before attempting any

7 and 28 for correct circuit

tion.

See the React
breakers and
used must mee

or repair manual for optional circuit

their current ratings. Circuit breakers

t UL489 specifications.

Auxiliary Wiring Diagram Options.

The generator supplies power in a 3-wire,
single-phase, mid-point neutral wiring configuration.
For 240 VAC loads, wire the load across the output
terminals of the circuit breaker. For 120 VAC loads,
wire the load between the neutral terminal blocks
next to the three pole main power switch (CT01)
to one pole of the circuit breaker. See electrical
diagrams in Reactor repair manual.

Disable L

PTCMs For Booster Heat

Both LPTCMs for booster heat must be disabled to
allow use of power for additional auxiliary power.

1. Follow Shutdown instructions. See

Shutdown, page 63.

2. Refer to Disable Optional Booster Heater Wiring
Diagram in the Reactor repair manual.

To repl
follow

ace or repair a circuit breaker, use the

ing steps:

1. Follow Shutdown instructions. See

Shutdown, page 63.

2. Refer to circuit breaker identification table and
electrical diagrams in Reactor repair manual.

3. Loosen four screws connecting wires and bus
bar to circuit breaker that will be replaced.
Disconnect wires.

Some customer changes are acceptable to
accommodate larger loads from auxiliary equipment
or a sub-panel. It is suggested that circuit breakers

4. Pull locking tab out 1/4 in. (6mm) and pull circuit
breaker away from the din rail. Install new circuit
breaker. Insert wires and tighten down all screws.

3A1705J 29

Overview

Overview

The system use
released from
component mat
defined on the

The engine coolant loop (gray) circulates heated
coolant from the engine (EE), through the heat

s two coolant loops to use heat

the engine to heat the A and B

erial to the target temperatures

ADM (PD).

exchanger (HE
engine. Coola
(black) captu
inside the he

res heat from the engine coolant loop

at exchanger (HE) near the radiator.

), radiator (ER), and back to the

nt in the proportioner coolant loop

e Coolant Loop and Proportioner Coolant Loop

Engin

re 21

Figu

30 3A1705J

Overview

The proportioner coolant loop circulates coolant
through secondary heat exchangers (HE) located
on the back of the proportioner to heat the A
and B component material before the material is
pressurized in the proportioner pumps (PA, PB). After
the A and B material has been heated in the heat
exchangers, the material enters the fluid manifold
(FM) and heated hose.

FM

For models with a booster heater, the A and B
material enters the booster heater after the material
is pressurized in the proportioning pumps to heat the
material higher than 140°F (60°C).

PA

PB

HE

d B Component Material Flow

Aan

ure 22

Fig

3A1705J 31

Overview

Coolant only flows through the secondary heat
exchangers when the heat exchanger control valves
(VA, VB) are open and the A and B component
temperatures are below the target temperatures set
on the ADM. See Fig. 24.

When the contr
and B materia
Coolant flows
circulation
coolant fill b
in the engin

ol valves (VA, VB) close, the A
l has reached target temperature.
through the bypass control valve (VC),

pump (CP), sight glass (SG), proportioner

ottle (HF), and back to the heat exchanger

e coolant loop. See Fig. 23

CP

SG

VC

CP

SG

VC

HE

HE

Proportioner Coolant Loop — A and B Valves Open
(heating material)
Figure 24

VB

VA

Propor
(not he

e23

Figur

HE

tioner Coolant Loop — A and B Valves Closed

ating material)

VB

HE

VA

32 3A1705J

Setup

Setup

NOTICE

Proper system setup, startup, and shutdown
procedures are critical to electrical 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.

NOTICE

Do not remove or separate the proportioner, engine
assembly, or power distribution box from the pallet.
Failure to leave the component mounting intact will
cause heating efficiency degradation, and potential
unsafe wiring and grounding.

Locate Reactor

If system was not ordered with the air compressor,
go to step 2.

1. Forsystemswithanaircompressor, install the
air tank bracket assembly and connect air lines.
For systems without an air compressor, order air
compressor kit 24K335. See manual 3A1902 for
complete installation instructions.

NOTICE

Only use air compressors with a
continuous run head unloader. Repeated
compressor motor startups will cause
errors and shutdown the system. See

Technical Specifications, page 102 for

recommended air compressors and
requirements. Other models may be used, but
motor must not stop and start during operation.

a. Use at least two people to install the air

tank assembly (AT). Secure to frame with
supplied screws (AS) and nuts (AN). See
illustration on next page.

d. Connect air line (A2) between proportioner

air inlet to air dryer outlet.

e. Connect pilot air lines (A3 and A4) between

the air compressor and air tank.

f. Secure water drain lines (A5 and A6) to the

frame and drain outlets.

2. Install hose rack, if ordered. See manual 3A1903
for detailed instructions.

3. Locate Reactor on a level surface that is
nonporous and diesel resistant, such as diamond
plate. See Dimensions, page 96, for clearance
and mounting hole dimensions.

Note

Leave at least 1 ft. (0.3m) distance from
the engine side of the pallet to any wall
for engine maintenance access. See

Fig. 27, page 37.

4. Do not expose Reactor to rain or below 20°F
(-7°C).

NOTICE

To ensure the heat exchanger control valves
open and close properly, do not store Reactor
below 20°F (-7°C).

5. If a wal
propor
the fue

Traile

6. To mou
by ins
frame
side.

l will be installed between the

tioner and generator, remove

l tank and battery bracket. See

r Setup Guidelines, page 35 for instructions.

nt in a trailer, use forklift to move Reactor
erting the forks through the Reactor pallet
. It is recommended to lift from the engine

Bolt pallet directly to trailer frame.

Note

Use Pallet Support Kit 24L911 (rollers not
included) to relocate pallet to mounting
location when forks are unavailable. See
kit manual for instructions.

NOTICE

b. Remove u-bolt holding desiccant container

and add all desiccant pellets (shipped
separately). Replace u-bolt securely. See
manual 309921.

c. Connect air line (A1) between compressor

and air tank inlet.

p the vent holes in the bottom of the

Kee

portioner cabinet open. Make sure there is

pro

obstructed incoming air for the cooling fan at the

un

p of the proportioner cabinet that blows air up into

to

e electric motor. Failure to provide unobstructed

th

coming air can cause the motor to overheat.

in

3A1705J 33

Setup

A2

A4

A1

A3

A3

AT

A4

AN

AS

A2

A6

A5

34 3A1705J

Setup

Trailer Setup

Route exhaust system away from combustible
materials to prevent materials from igniting or gas
recirculation into a wall, ceiling, or a concealed
space. Provide exhaust system guards to prevent
burns.

Guidelines

NOTICE

Provide recommended size louvers. Failure to do
so can damage the engine and void the engine
warranty.

Exhaust pipes that pass through flammable ceilings
must be guarded by vented metal thimbles that
extend at least 9 in. (228.6 mm) below and above
the roof and are at least 6 in. (152.4 mm) in diameter
larger than the exhaust pipe.

Exhaust pipes that pass through flammable walls
must be guarded by either:

2. Provide radiator exhaust for Reactor. Use a 400

2

in.

(258,064 mm2) minimum louver.

3. Provide air duct to connect radiator exhaust to
louver.

2

4. Provide a 400 in.
air intake louver near the generator.

5. Remove red exhaust cap.

6. Provide a minimum 2 in. (50.8 mm) diameter
engine exhaust outlet with flexible pipe element.
Provide rain cap, or equivalent routing, to prevent
moisture from entering the metal exhaust pipe.

( 258,064 mm2) minimum fresh

• Metal ventilated thimble at least 12 in. (305 mm)
larger than the diameter of the exhaust pipe.

• Metal or other approved fireproofing materials
that provides at least 8 in. (203 mm) of insulation
between the exhaust pipe and flammable material.

Exhaust pipes not covered above must have at least
9 in. (228.6 mm) of clearance from the outside of the
exhaust pipe to adjacent flammable materials.

1. Provide sufficient lighting to safely operate and

maintain system equipment.

Radiator Exhaust and Air Intake Louvers
Figure 25

3A1705J 35

Setup

Install Wall (

Install a wall between the proportioner and generator
to:

• Temperature condition the trailer space where
chemical is stored. Check with chemical
manufacturer for chemical storage temperatures.

• Reduce noise for the operator while the Reactor
is running.

The supplied fuel lines and battery cable may need
to be replaced if a wall is installed between the
proportioner and generator. Purchase the Fuel Line
and Battery Cable Extension Kit 24K333.

1. If necessar

Drain Cool

need to be d

Note

Battery must be connected to starter to
drain coolant from system.

2. Remove screws and battery bracket from the

pallet.

optional)

y drain coolant from system. See

ant, page 69. Coolant lines do not

isconnected to install a wall.

3. Remove fuel tank from the pallet.

a. Remove the mou

spacers.

b. Disconnect in

fuel tank.

c. Use two peopl

and place whe
accessible.

Note

Do not mount fuel tank in front of
the generator air intake or where it
will limit opening and access to the
electrical enclosure (DB).

4. Install wall (IW) where the fuel tank was located.
Ensure there is at least 1.25 in. (31.75 mm)
between the wall, exhaust muffler, and MCM.
See Fig. 27, page 37.

Note

To prevent an air pocket from forming
inside the coolant lines between the
proportioner and generator, ensure
there is a constant rise in elevation if
the coolant lines are adjusted. Failure
tohaveaconstantriseinelevation
will reduce heating efficiency. See

Fig. 28, page 37.

nting screws, supports, and

let and outlet fuel lines from the

e to lift fuel tank off of the pallet

re the fuel fill spout is easily

ve Battery Bracket and Fuel Tank

Remo

re 26

Figu

5. Reconnect inlet and outlet fuel lines.

6. Install spacers, supports, and screws through
the fuel tank and tighten to the floor. Torque to
40 ft-lbs (54 N•m).

7. Place battery bracket over fuel tank or near the
Reactor. Remove existing battery cables from
engine and replace with the cables provided from
the fuel line and battery cable extension kit.

8. Install mounting bolts through battery bracket and
tighten to the floor. Torque to 40 ft-lbs (54 N•m).

Note

s under the battery bracket help

Pad

bilize the fuel tank during operation.

sta

36 3A1705J

Setup

Top View
Figure 2

With Wall

7

Side View With Wall
Figure 28

3A1705J 37

Setup

Connect Batte

Improper battery installation or maintenance
may result in electric shock, chemical burns,
or explosion. Battery maintenance must only
be performed or supervised by personnel
knowledgeable of batteries and the required
precautions. Keep unauthorized personnel away
from batteries.

See Technical Specifications, page 102 for battery
requirements and recommended battery size.

1. Secure battery (not supplied) to bracket with
strap.

ry

PC

3. Cover battery terminals with plastic caps (PC)
attached to supplied battery cables.

4. Verify battery was connected properly by

pressing OFF
(PE) to “wake up” the controller screen. Do not
attempt to start the engine until all Setup steps
are complete. See Repair manual if engine
control module doesn’t light up.

on the engine control module

Add Fuel

1. Remove fuel cap (FS) and fill fuel tank with no
more than 20 gallons (75 liters) of diesel fuel.
Replace cap. See Perkins engine manual for
approved diesel fuels.

2. Squeeze prime bulb (P) to prime engine. Press
the prime bulb repeatedly until fuel begins to
return to the fuel tank.

Figure 29

2. Connect battery cable from the engine starter
(ST) and chassis to the battery. Connect the
black cable to battery negative (-) and the red
cabletobatterypositive(+).

NOTICE

Always connect the red battery cable to battery
positive (+) and the black battery cable to the
battery negative (-). Failure to properly connect
the battery cable to the battery will damage the
fusible link when the engine control module is
turned ON. Do not bypass the fusible link when
damaged. The fusible link prevents damage
to other system components. See the system
repair manual for repair instructions.

FS

P

Figure 31

eral Equipment Guidelines

Gen

Maintain and inspect the generator, air compressor,
and other equipment per the manufacturer
recommendations to avoid an unexpected shutdown.
Unexpected equipment shutdown will cause voltage
fluctuations that can damage electrical equipment.

Figure 30

38 3A1705J

Setup

Electrical Co

Connect air compressor, breathing air, and auxiliary
power electrical connections to the specified circuit
breakers. See Circuit Breakers, page 28.

1. Remove one or more knock-outs on side

of electrical enclosure, as required, and
route wires through for air compressor,
breathing air, and auxiliary equipment. See

Circuit Breaker Configuration Options, page 29,

for more information.

nnections

Connect Feed Pumps

1. Install feed pumps (K) in component

A and B supply drums. See

Typical Installation, with circulation, page 13 and
Typical Installation, without circulation, page 14.

2. Seal component A drum and use desiccant dryer

(M) in vent.

3. Install agitator (L) in component B drum, if

necessary.

4. Connect supply hoses from feed pumps to the

component A and component B material inlets
on the system. Ensure A and B inlet valves are
closed.

PF

PG

PJ

PH

Ref Air Outlet

PF A Pump

PG

PH Agitator

PJ

Note

Agitator air supply (PH) includes a small
internal restriction orifice to limit the air
flow to minimize air compressor load.
Maximum supplied air flow is 2.0 scfm
(0.1 m3/min) at 100 psi (0.7 MPa, 7 bar).
Designed for use with Twistork agitator

224854. Do not use the agitator air outlet
(PH) for any other component.

BPump

Gun

Breathing Air

Note

Supply hoses from feed pumps should
be 3/4 in. (199 mm) ID.

5. Connect air lines to proportioner. Ensure

components are properly connected to correct
location.

3A1705J 39

Breathing the air from the compressed air supply
can cause serious injury if inhaled.

y use an independent and approved

•Onl
athing air system with adequate air flow to

bre

vide clean breathable air.

pro

Setup

Connect Press

Do not operate Reactor without all covers and
shrouds in place.

1. Recommended: Connect high pressure
hose (R) to relief fittings (BA, BB) of both
PRESSURE RELIEF/SPRAY valves. Route
hose back to component A and B drums. See

Typical Installation, with circulation, page 13.

2. Alternately: Secure supplied bleed tubes (N)
in grounded, sealed waste containers (H). See

Typical Installation, without circulation, page 14.

ure Relief Lines

Install Fluid Temperature Sensor

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

coded: red for component A (ISO), blue for
component B (RES). Fittings are sized to prevent
connection errors.

Note

Manifold hose adapters (HA, HB) allow
use of 1/4 in. and 3/8 in. ID fluid hoses.
To use 1/2 in. (13 mm) ID fluid hoses,
remove adapters from fluid manifold and
install as needed to connect whip hose.

FM

HA

A

SC

C

HB

B

V

Connect Heated Hose

See Heated Hose manual for detailed instructions on
connecting heated hoses.

Note

The FTS (C) and whip hose (D) must be used
with heated hose. Hose length, including
whip hose, must be 60 ft (18.3 m) minimum.

NOTICE

Apply grease on all system and hose fluid fittings.
This lubricates the threads and prevents material
from hardening on the threads.

1. Turn main power switch OFF .

2. Assemble heated hose sections, FTS, and whip
hose.

3. Connect A and B hoses to A and B outlets on
Reactor fluid manifold (FM). Hoses are color

Figure 32

4. Connect cables (C). Connect electrical
connectors (V). Be sure cables have slack
when hose bends. Wrap cable and electrical
connections with electrical tape.

5. Connect quick-disconnect pin fitting to 4 ft air
hose, shipped loose. Connect other hose end to
the gun air hose in the heated hose bundle. Push
pin fitting into the lowest air panel outlet (PJ).

Figure 33

40 3A1705J

Setup

Close gun fluid

manifold valves A and

B

Connect Whip Hose to Gun Or Gun Fluid Manifold

See hose manual for proper connections.

Pressure Check Hose

See hose manual. Pressure check for leaks. If
no leaks, wrap hose and electrical connections to
protect from damage.

or vehicle chassis or, if stationary, to true earth
ground. Remove bolt and braided cable from
pallet. Install grounding cable terminated with a
ring terminal (cable and terminal not supplied)
under braided cable. Reinstall bolt and torque
to minimum 25 ft-lbs (34 N∙m). An alternate
grounding location is to the ground bar (CB02) in
the electrical enclosure. Follow all National, State,
and Local safety and fire codes.

Connect Remote Display Module

See Remote Display Module kit manual for
installation instructions.

Grounding

The equipment must be grounded to reduce the
risk of static sparking and electric shock. Electric
or static sparking can cause fumes to ignite or
explode. Improper grounding can cause electric
shock. Grounding provides an escape wire for the
electric current.

•

Reactor System:

an appropriately sized conductor to the trailer

System must be grounded with

•

Spray gun:

See Install Fluid Temperature Sensor, page 40.
Do not disconnect ground wire or spray without
whip hose.

•

Fluid supply containers:

Object being sprayed:

•

Solvent pails used when flushing:

•

code. Use only metal pails, which are conductive,
placed on a grounded surface. Do not place pail
on a nonconductive surface, such as paper or
cardboard, which interrupts grounding continuity.

•

To maintain grounding continuity when flushing or
relieving pressure,

firmly to the side of a grounded
trigger gun.

connect whip hose ground wire to FTS.

follow your local code.

follow your local code.

follow your local

hold a metal part of spray gun

metal

pail, then

3A1705J

41

Setup

Supply Wet Cup

s With Throat Seal

Liquid (TSL)

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 wet-cup during operation.

To prevent the pump from moving, turn the main
power switch OFF.

• Component A (ISO) Pump: Keep reservoir (R) filled
with Graco Throat Seal Liquid (TSL), Part 206995.
Wet-cup piston circulates TSL through wet-cup, to
carry away isocyanate film on displacement rod.

• Component B (Resin) Pump: Check felt washers
in packing nut/wet-cup (S) daily. Keep saturated
with Graco Throat Seal Liquid (TSL), Part No.
206995, to prevent material from hardening on
displacement rod. Replace felt washers when worn
or contaminated with hardened material.

S

Component B Pump
Figure 35

R

Component A Pump
Figure 34

2

4

3A1705J

Advanced Displa

yModule(ADM)Operation

Advanced Disp

When main powe
power switch
screen will b
initializat

Then the power key icon screen will display until the

ADM power on/off button (A)
first time after system power-up.

To begin using the ADM, the machine must be active.
To verify the machine is active, verify that the System
Status Indicator Light (B) is illuminated green, see

Advanced Display Module (ADM), page 19.Ifthe

System Status Indicator Light is not green, press

the ADM Power On/Off (A) button
Status Indicator Light will illuminate yellow if the
machine is disabled.

ion is complete.

r is turned on by turning the main

(MP) to the ON position, the splash

e displayed until communication and

lay Module (ADM) Operation

is pressed for the

. The System

Perform the following tasks to fully setup your system.

1. Select pr
Alarm to a

2. Enter, en

Recipes S

3. Set gene

Advance

4. Set unit

Advance

5. Set USB

Advanc

6. Set tar

Target

7. Set co
level

8. Ensur
home s

essure for the Pressure Imbalance

ctivate. See System Screen , page 47.

able, or disable recipes. See

creen, page 47.

ral system settings. See

d Screen 1 — General, page 46.

sofmeasure. See

d Screen 2 — Units, page 46.

settings. See

ed Screen 3— USB, page 46.

get temperatures and pressure. See

s, page 50.

mponent A and component B supply

s. See Maintenance, page 51.

e engine is at operating temperature on the

creen.

3A1705J 43

Advanced Displa

yModule(ADM)Operation

Setup Mode

The ADM will start in the Run screens at the Home screen. From the Run screens,press to
access the Setup screens. The system defaults with no password, entered as 0000. Enter the

current password then press .Press to navigate through the Setup Mode screens. See

Setup Screens Navigation Diagram, page 45.

Set Passwor

Set a password to allow Setup screen access, see Advanced Screen 1 – General, page 46. Enter any number
from 0001 to 9999. To remove the password, enter the current password in the Advanced Screen – General
screen and change the password to 0000.

From the Setup screens, press to return to the Run screens.

d

4

4

3A1705J

Advanced Displa

yModule(ADM)Operation

Setup Screens Navigation Diagram
Figure 36

3A1705J 45

Advanced Displa

yModule(ADM)Operation

Advanced Setu

Advanced setup screens enable users to set units, adjust values, set formats, and view software information

for each component. Press

Advanced setup screen, press

to exit edit mode.

Note

Users must be out of edit mode to scroll
through the Advanced setup screens.

Advanced Screen 1 — General

Use this screen to set the language, date format,
current date, time, setup screens password (0000 –
for none) or (0001 to 9999), screen saver delay, and
enable or disable silent mode.

p Screens

to scroll through the Advanced setup screens, Once in the desired

to access the fields and make changes. When changes are complete press

Advanced Screen 3 — USB

Use this screen to disable USB downloads/uploads,
disable USB log errors, enter the maximum number
of days to download data, and how frequently USB
logs are recorded. See USB Data, page 89.

Advanced Screen 4— Software

Advanced Screen 2 — Units

This screen displays the software part number and

Use this screen to set the temperature units, pressure
units, volume units, and cycle units (pump cycles or
volume).

46 3A1705J

software version for the Advanced Display Module,
Motor Control Module, High Power Temperature
Control Module, Low Power Temperature Control
Modules, and USB Configuration.

Advanced Displa

yModule(ADM)Operation

System

Use this screen to set the activation pressure for the
Pressure Imbalance Alarm and Advisory, enable or
disable diagnostic screens, enable drum alarms, set
the maximum drum volume, enable drum alarms,
and set low material alarm level.

Recipes

Use this screen to add recipes, view saved recipes,
and enable or disable saved recipes. Enabled
recipes can be selected at the Home Run Screen. 24
recipes can displayed on the three recipe screens.

Add Recipe

1. Press and then use to select a

recipe field.

(maximum 16 characters). Press
old recipe name.

2. Use to hi

number pad to enter a value. Press

Press

ghlight the next field and use the

to enter a recipe name

to clear the

to save.

Enable or Disable Recipes

1. Press

pe that needs to be enabled or disabled.

reci

andthenuse to select the

2. Use

Press

to highlight the enabled check box.

to enable or disable the recipe.

3A1705J

47

Advanced Displa

yModule(ADM)Operation

Run Mode

The ADM will start in the Run screens at the “Home” screen. Press to navigate through the Run Mode
screens. See Run Screens Navigation Diagram, page 44.

From the Run screens, press

to access the Setup screens.

48 3A1705J

Advanced Displa

yModule(ADM)Operation

Run Screens Navigation Diagram
Figure 37

3A1705J 49

Advanced Displa

yModule(ADM)Operation

Home — System Off

This is the home screen when the system is off.
This screen displays actual temperatures, actual
pressures at the fluid manifold, jog speed, coolant
temperature, and number of cycles.

Home — System Active

When the system is active, the home screen displays
actual temperature for heat zones, actual pressures
at the fluid manifold, coolant temperature, jog speed,
the number of cycles, along with all associated
control soft keys.

Use this screen to turn on heat zones, view
coolant temperature, start the proportioner, stop the
proportioner, park the component A pump, enter jog
mode, and clear cycles.

Home — System With Error

Active errors are shown in the status bar. The error
code, alarm bell, and description of the error will
scroll in the status bar.

1. Press

2. See for corrective action.

to acknowledge the error.

Targets

Use this screen to define the setpoints for the
A Component Temperature, B Component
Temperature, heated hose temperature, and
pressure.

Maximum A and B temperature for systems without
booster heat: 140°F (60°C)

Maximum A and B temperature for systems with
booster heat: 180°F (82°C)

Maximum heated hose temperature: 10°F (5°C)
above the highest A or B temperature setpoint or
180°F (82°C).

Note

If the remote display module kit is used,
thesesetpointscanbemodifiedatthegun.

50 3A1705J

Advanced Displa

yModule(ADM)Operation

Maintenance

Use this screen to view daily and lifetime cycles or
gallons that have been pumped and gallons or liters
remaining in the drums.

The lifetime v
gallons sinc

The daily value automatically resets at midnight.

The manual value is the counter that can be manually

reset. Press

alue is the number of pump cycles or

e the first time the ADM was turned on.

and hold to reset manual counter.

Events

This screen shows the date, time, event code, and
description of all events that have occurred on
the system. There are 10 pages, each holding 10
events. The 100 most recent events are shown. See

System Events

for event code descriptions.
See Error Codes and Troubleshooting, page 74 for
error code descriptions.

All events a
downloaded
see Downloa

nd errors listed on this screen can be

on a USB flash drive. To download logs,

d Procedure, page 91.

Cycles

This screen shows daily cycles and gallons that have
been sprayed for the day.

All information listed on this screen can be
downloaded on a USB flash drive.

Errors

This screen shows the date, time, error code, and
description of all errors that have occurred on the
system.

All errors listed on this screen can be downloaded on
a USB flash drive.

3A1705J 51

Advanced Displa

yModule(ADM)Operation

Diagnostic

Use this screen to view information for all system
components.

The follo

Temperature

• Hx A Chem: Heat Exchanger A Chemical

• Hx B Chem: Heat Exchanger B Chemical

• Hose Chemical

• Booster A Chemical

wing information is displayed:

• Booster B Chemical

• Booster A PCB — temperature control module
temperature

• Booster B PCB — temperature control module
temperature

• Hose PCB — temperature control module
temperature

• Coolant Outlet

Amps

• Booster A Current

• Booster B Current

• Hose Current

Volts

•MCMBus

• Incoming Hose Voltage (240V)

Pressure

• Pressure A — chemical

• Pressure B — chemical

Cycles

• CPM — cycles per minute

• Total Cycles

52 3A1705J

Advanced Displa

yModule(ADM)Operation

Troubleshooting

This screen displays the last ten errors that
occurred on the system. Use the up and down

arrows to select an errors and press
troubleshooting information for the selected error.

Press
error code th

Error Codes

informatio

to acce

nonerrorcodes.

ss troubleshooting screen for an

at is not listed on this screen. See

and Troubleshooting, page 74,formore

to view

Recipes

Use this screen to select an enabled recipe. Use the
up and down arrows to highlight a recipe and press

to load. The currently loaded recipe is outlined

by a green box.

Note

This screen w
any enabled
recipes, se

ill not display if there are not

recipes. To enable or disable

e Recipes Setup Screen, page 47.

3A1705J 53

Advanced Displa

yModule(ADM)Operation

System Events

Use the table below to find a description for all system events. All events are logged in the USB log files.

Event Code

EA

EADA

EADB

EADH

EAPX

EARX

EAUX

EB0 X

EBDA

EBDB

EBDH

EBPX

EBRX

EBUX

E

C

E

C

E

C

E

C

E

C

E

C

EL0X

EM0 X

EP0 X

E

Q

E

Q

E

Q

E

Q

E

Q

ER0 X

EVUX

C

0X

DA

DB

DH

DP

DX

U1

U2

U3

U4

U

Description

Recipe Select

X

Heat On A

Heat On B

Heat On Hose
Pump On

Jog On

USB Drive Inserted
ADM Red Stop

Heat Off A

Heat Off B

Heat Off Hose
Pump Off

Jog Off

USB Drive Removed
Setup Value Changed

A Temperature Setpoint Changed

B Temperature Setpoint Changed

Hose Temperature Setpoint Changed

Pressure Setpoint Changed

Recipe Changed

System Power On

System Power Off

Pump Parked

System Settings Downloaded

System Settings Uploaded

Custom Language Downloaded

Custom Language Uploaded

Logs Downloaded

5

User Counter Reset

USB Disabled

ed

Button Pressed

54 3A1705J

Startup

To prevent serious injury, only operate Reactor
with all covers and shrouds in place.

Startup

NOTICE

Proper system setup, startup, and shutdown
procedures are critical to electrical 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. Check generator fuel level.

Running out of fuel will cause voltage fluctuations
that can damage electrical equipment.

2. Check coolant levels.

Inspect the level of coolant inside the engine
coolant expansion bottle (EB) and heat
exchanger coolant expansion bottle (HB).

HOT

COLD

3. Check fluid inlet screens.

HOT

COLD

6. Start the generator.

Press start button

twice on the engine
control module. The controller will automatically
sequence glow plug warming and crank
operations. Allow engine to reach full operating
speed.

Note

Engine will not start if main power switch
is in the on position.

Note

If the engine control module screen
does not light up after the start button is
pressed, see the system repair manual.

7. Turn main power switch ON.

When the system is powered up by turning the
main power switch (MP) to the ON position, the
splash screen will display until communication
and initialization is complete.

Before daily startup, ensure that the
fluid inlet screens are clean. See

Flush Inlet Strainer Screen, page 67

4. Check ISO lubrication reservoir.

Check level and condition of ISO lube daily. See

Pump Lubrication System, page 68.

5. Confirm main power switch is OFF before starting
generator.

3A1705J 55

Startup

8. Check coolant color.

Use a flashlight to inspect the color of th
through sight glass (SG). The mesh filter
be visible inside the sight glass and the
should be green. If there are a lot of air b
then the coolant level may be low. If the c
is a milky color, then that indicates A o
has likely leaked inside a heat exchan

e coolant

should

coolant

ubbles,

oolant

rBmaterial

ger and

that the coolant needs to be drained.

• To add more coolant, see

Refill Proportioner Coolant Loop, page 70 and
Refill Engine Coolant Loop, page 72.

• To drain the coolant system, see

Drain Coolant, page 69.

9. Switch on the air compressor, air dryer, breathing
air, and other accessories.

Complete the following steps for systems with a
supplied air compressor.

a. Before startup, close the main air shutoff

valve (CK), desiccant air dryer inlet valve
(CL), and water drain valve (CM) whenever
the pressure in the air supply tank has been
relieved.

c. Open the desiccant dryer inlet valve (CL),

waterdrainvalve(CM),andthemainair
shutoff valve (CK).

10. During initial startup, ensure all three air
regulators are turned fully counterclockwise.

11. Open the main air shutoff valve.

12. Slowly increase the air pressure regulator
settings.

13. Load fluid with feed pumps.

Main Air Shutoff Valve (CK)

b. Press start on the air compressor power box

(CB). Wait until the pressure gauge (CJ) on
the air supply tank reaches 30 psi.

a. Check that all Setup steps are complete.

See Setup, page 33.

b. If an agitator is used, open the agitator’s air

inlet valve.

c. If you need to circulate fluid through the

system to preheat the drum supply, see

Circulation Through Reactor, page 59If

you need to circulate material through
the heat hose to the gun manifold, see

Circulation Through Gun Manifold, page 60.

d. Turn both PRESSURE RELIEF/SPRAY

valves (SA, SB) to SPRAY

GA

SA

GB

.

SB

e. Adjust A and B feed pump air regulators to

desired air pressure, on front of proportioner,
to start the feed pumps. Do not exceed 130
psi (0.2 MPa, 2 bar) to the A and B feed
pumps.

56 3A1705J

f. Open fluid inlet valves (FV). Check for leaks.

Do not mix components A and B during
startup. Always provide two grounded
waste containers to keep component A
and component B fluids separate.

g. Hold gun fluid manifold over two grounded

waste containers. Open fluid valves A and B
until clean, air-free fluid comes from valves.
Close valves.

Startup

This equipment is used with heated fluid which
can cause equipment surfaces to become very
hot. To avoid severe burns:

• Do not touch hot fluid or equipment.

• Do not turn on hose heat without fluid in
hoses.

• Allow equipment to cool completely before
touching it.

• Wear gloves if fluid temperature exceeds
110°F (43°C).

Thermal expansion can cause
overpressurization, resulting in equipment
rupture and serious injury, including fluid
injection. Do not pressurize system when
preheating hose.

The Fusion AP gun manifold is shown.

14. Setup ADM. Advanced Display Module (ADM)

Operation, page 43.

15. Press

to turn on hose heat zone.

16. Wait for
tempera
tempera
temper
green a
fan wil
reache

17. Wait for the hose to reach set point temperature
or a hose overpressure condition may occur due
to thermal expansion.

18. Pres

the engine to reach operating
ture and the hose to reach setpoint
ture. The engine has reached operating

ature when the black arrow is under the

rea of the temperature bar. The radiator

l turn on when operating temperature is

d.

s

to turn on A and B heat zones.

3A1705J 57

Temporary Manua

l Hose Tempe rature Control

Temporary Manual Hose
Temperature Co

If T6DH error code appears from a break in the
hose RTD cable or FTS sensor, follow the steps for
temporary manual hose temperature control. Repair
or replace the hose RTD cable or FTS as soon as
job is finished.

1. Connect the spare RTD (15V837), shipped with
the system, to the Fluid Temperature Sensor
(FTS) cables (SC) at the Reactor Fluid Manifold
(FM).

A

SC

15V837

ntrol

B

2. Insert the RTD sensor probe between the two
hoses where the scuff guard ends.

3. Lower the hose temperature setpoint on the
system ADM screen by (20°F (-6°C). Push probe
into the hose bundle at least 3 in. (76 mm).

4. Do not leave the RTD tip probe exposed to air or
a hose overtemperature condition may occur.

NOTICE

To prevent ov
the hoses, do
the two hose

5. Repair or replace the hose RTD cable or FTS as
soon as the job is finished.

erheating material and damaging

not leave the spare RTD between

s after the job is complete.

58 3A1705J

Fluid Circulati

on

Fluid Circula

Circulation T

hrough Reactor

tion

NOTICE

Do not circul
without cons
regarding fl

To circulate through gun manifold and preheat hose,
see Circulation Through Gun Manifold, page 60.

1. Follow Sta

To avoid injection injury and splashing, do not
install shutoffs downstream of the PRESSURE
RELIEF/SPRAY valve outlets (BA, BB). The
valves function as overpressure relief valves

when set to SPRAY
open so valves can automatically relieve
pressure when machine is operating.

2. See Typical Installation, with circulation, page 13.
Route circulation lines back to respective
component A or B supply drum. Use
hoses rated at the maximum working
pressure of this equipment. See

Technical Specifications, page 102.

ate fluid containing a blowing agent
ulting with your material supplier

uid temperature limits.

rtup, page 55.

. Lines must be

3. Set PRESSURE R

SB) to PRESSURE RELIEF/CIRCULATION

4. Set temperature targets. See Targets, page 50.

5. Press
A and B temperatures reach targets. See

Jog Mode, page 60 for more information about

jog mode.

6. Press

7. Turn on
fluid in
the min
supply

8. Exit j

9. Set PR

SB) to SPRAY

to circulate fluid in jog mode until

to

the A and B heat zones. Wait until the

let valve temperature gauges (FV) reach

imum chemical temperature from the

drums.

og mode.

ESSURE RELIEF/SPRAY valves (SA,

ELIEF/SPRAY valves (SA,

GB

GA

SA

turn on the hose heat zone.

.

GA

SA

SB

GB

SB

.

3A1705J 59

Jog Mode

Circulation T

hrough Gun Manifold

NOTICE

Do not circula
without cons
regarding flu

Circulating
rapid prehe

1. Install gun fluid manifold (P) on accessory
circulation kit (CK). Connect high pressure
circulation lines (R) to circulation manifold.

te fluid containing a blowing agent
ulting with your material supplier
id temperature limits.

fluid through the gun manifold allows
ating of the hose.

P

CK

3. Follow procedures from Startup, page 55.

4. Turn main power switch on

5. Set temperature targets. See Targets, page 50.

6. Press
A and B temperatures reach targets. See

Jog Mode, page 60 for more information about

jog mode.

to circulate fluid in jog mode until

.

Jog Mode

Jogmodehastwopurposes:

• It can speed fluid heating during circulation.

• It can ease system flushing and priming.

1. Turn main power switch on

.

R

The Fusion AP gun manifold is shown.

CK Gun

2

24636

256566

2. Route circulation lines back to respective
component A or B supply drum. Use
hoses rated at the maximum working
pressure of this equipment. See

Technical Specifications, page 102.

nAP

Fusio

Fusion CS

Manual

30981

313058

2. Press c

3. Press up or down
(J1 through J20).

8

4. Press

5. To s

or .

irculate

Note

Jog speeds correlate to 3-30% of motor
power, but will not operate over 700 psi
(4.9 MPa, 49 bar) for either A or B.

to start motor.

top the motor and exit jog mode press

to enter jog mode.

to change jog speed

60 3A1705J

Spraying

Spraying

4. Adjust the gun air regulator on the proportioner

control panel to desired gun air pressure. Do not
exceed 130 psi (0.2 MPa, 2 bar).

The Fusion AP

gun is shown.

1. Engage gun piston safety lock.

2. Close gun fluid inlet valves A and B.

3. Attach gun fluid manifold. Connect gun air line.
Open air line valve.

5. Set PRESSURE RELIEF/SPRAY valves (SA,

SB) to SPRAY

SA

GA

.

GB

SB

6. Check that heat zones are on and temperatures
are on target, see Home screen, page 50

7. Verify that the engine temperature is at least up
to the minimum operation temperature range.
The fan will start running when the engine has
reached maximum temperature.

8. Press

to start motor and pumps.

9. Check fluid pressure and adjust as necessary.

10. Check fluid pressure gauges (GA, GB) to
ensure proper pressure balance. If imbalanced,
reduce pressure of higher component by
slightly turning PRESSURE RELIEF/SPRAY
valve for that component toward PRESSURE

RELIEF/CIRCULATION

until gauges show

balanced pressures.

SA

SB

GB

GA

11. Instructions continue on next page.

3A1705J 61

Spraying

12. Open gun fluid inlet valves A and B.

Note

On impingement guns, never open
fluid manifold valves or trigger gun if
pressures are imbalanced.

13. Disengage gun piston safety lock.

14. Test spr
tempera

ay onto cardboard. Adjust pressure and
ture to get desired results.

15. Equipment is ready to spray.

Spray Adjustm

Flow rate, atomization, and amount of overspray are
affected by four variables.

• Fluid pressu
in an uneven p
flow, and poo
in excessiv
control, an

• Fluid tempe
setting. T
help balan

• Mix chambe
on desired

• Clean-of
results i
nozzle, a
overspra
air-ass

e overspray, high flow rates, difficult

d excessive wear.

he A and B temperatures can be offset to

cethefluidpressure.

flow rate and fluid viscosity.

f air adjustment. Too little clean-off air

n droplets building up on the front of the

nd no pattern containment to control

y. Too much clean-off air results in

isted atomization and excessive overspray.

ents

re setting. Toolittlepressureresults

attern, coarse droplet size, low

r mixing. Too much pressure results

rature. Similareffectstofluidpressure

rsize. Choice of mix chamber is based

62 3A1705J

Shutdown

Shutdown

NOTICE

Proper system
procedures ar
reliability
voltage. Fai
cause voltag
electrical e

1. Press to stop the pumps.

2. Turn off heat zones.

3. Relieve pressure. See

Pressure Relief Procedure, page 64.

4. Press

5. Press

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

7. Close the main air shutoff valve.

setup, startup, and shutdown

e critical to electrical equipment

. The following procedures ensure steady

lure to follow these procedures will

e fluctuations that can damage

quipment and void the warranty.

to park the Component A Pump.

to deactivate the system.

8. Turn main power switch OFF.

To prevent electric shock do not remove any
shrouds or open the electrical enclosure door.
240 V is still present in the system until the
engine has stopped.

9. Allow engi

ne dwell time.

NOTICE

Allow engine dwell time, per manufacturer
recommendations, prior to shutdown. Dwell
time will help engine cool down after running at
operating temperature for any period of time.

10. Press on the engine control module.

11. Open air compressor bleed valve to relieve
pressure and remove water from tank.

12. Close all fluid supply valves.

3A1705J 63

Pressure Relief

Procedure

Pressure Relief Procedure

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

This equipme
is manually r
injury from p
splashing flu
Pressure Rel
and before c

nt stays pressurized until pressure

elieved. To help prevent serious

ressurized fluid, such as skin injection,

id and moving parts, follow the

ief Procedure when you stop spraying

leaning, checking, or servicing

equipment.

TheFusionA

P gun is shown.

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

2. Close gun fluid inlet valves A and B.

3. Shut of

f feed pumps and agitator, if used.

. Ensure gauges drop to 0.

SA

SB

GB

GA

5. Engage gun piston safety lock.

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

64 3A1705J

Flushing

Flushing

To prevent fire and explosion, flush equipment only
in a well-ventilated area. Do not spray flammable
fluids. Do not turn on heaters while flushing with
flammable solvents.

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

• Use the lowest possible pressure when flushing.

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

• Toflushfeedho
separately fr
RELIEF/SPRAY

RELIEF/CIRC

ses, pumps, and heaters

om heated hoses, set PRESSURE

valves (SA, SB) to PRESSURE

ULATION

. Flush through bleed

lines (N).

SA

SB

GB

GA

• 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 Two-

Component Material Information, page 7.

3A1705J 65

Maintenance

Maintenance

Prior to perfo
follow Pressu

rming any maintenance procedures,

re Relief Procedure, page 64.

Preventative Maintenance Schedule

The operati
determine h
Establish a
recording w
needed, an
checking y

ng conditions of your particular system

ow often maintenance is required.
preventive maintenance schedule by
hen and what kind of maintenance is

d then determine a regular schedule for

our system.

Proportioner Maintenance

Wet Cup

Check th
Throat S
not over

ewetcupdaily. Keepit2/3fullwithGraco

eal Liquid (TSL

tighten packing nut/wet cup.

®

) or compatible solvent. Do

ISO Lubricant

Inspect ISO lu
daily. Refill o

Pump Lubrica

bricant level and condition

r replace as needed. See

tion System, page 68.

Wiring Conne

Tighten all
Electrical
compressor

Compresso

Open the ma
valve loca
pressure

Dust Prot

Use clea
dust bui
fans, an

screw-type wiring connections in the

Enclosure (DB), Reactor cabinet, and air

control box (if supplied) monthly.

r Tank Water Drain

nual water drain valve weekly. See

tion on page 34. Open only when air

is less than 25 psi.

ection

n, dry, oil-free compressed air to prevent
ldup on control modules, control boards,
d motor (under shield).

Level

ctions

Fluid I

Inspec

Flush I

Coola

Inspe
as a ba
See R

Grea

Gre
gre

nlet Strainer Screens

t fluid inlet strainer screens daily, see

nlet Strainer Screen, page 67.

nt Filter

ct filter in coolant sight glass with a flashlight,

ck light, weekly. Replace filter semi-annually.

epair manual.

se Circulation Valves

ase circulation valves (SA, SB) with Fusion

ase (117773) weekly.

Coolan

Check c

Flush and refill the coolant on both the engine and
heat exchanger coolant loop once a year. See

Refill Proportioner Coolant Loop, page 70.See
Refill Engine Coolant Loop, page 72.

tLevels

oolant level inside both overflow tanks daily.

66 3A1705J

Maintenance

Engine Maintenance

The engine ins
unit detail sp
the engine. Fo
recommendati

Daily

• Cooling System Coolant Level — Check

• Engine Air Cleaner Service Indicator — Inspect

• Engine Oil Level — Check

Every 500 Se

• Engine Air Cleaner Element (Dual Element) —
Clean/Replace

• Engine Oil and Filter — Change

• Fuel System Filter — Replace

• Battery Voltage — Check. See

Appendix A: Engine Control Module, page 93.

Contact an Authorized Perkins Dealer or Distributor
for replacement filter elements. Refer to Perkins
engine part number GN66141N for compatible parts.

tructions that accompany your

ecific procedures for maintenance of

llowing the engine manufacturer’s

ons will extend engine work life.

rvice Hours or 1 Year

Note

Clean the A-si
daily startup
contaminatio
out any isocya
dispensing op

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

2. Place a container under the strainer base 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. No more than 25% of the mesh should
be restricted. If more than 25% of the mesh is
blocked, replace the screen. Inspect the gasket
(B) and replace as required.

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

de screen only during

. This minimizes moisture

n by immediately flushing

nate residue at the start of

erations.

Fuel Tan

Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel tank
can cause excessive wear to the fuel system. See
the supplied Perkins engine manual for fuel tank
maintenance recommendations.

Flush

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 used
are clean and proper storage, transfer, and operating
procedures are followed, there should be minimal
contamination of the A-side screen.

k

Inlet Strainer Screen

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

A

B

C

D

Figure 38

3A1705J 67

Maintenance

Pump Lubricat

Check the condition of the ISO pump lubricant daily.
Change the lubricant if it becomes a gel, its color
darkens, or it becomes diluted with isocyanate.

Gel formatio
pump lubrica
depends on th
is operatin
exposure to
possible.

Lubricant discoloration is due to continual seepage of
small amounts of isocyanate past the pump packings
during operation. If the packings are operating
properly, lubricant replacement due to discoloration
should not be necessary more often than every 3 or
4weeks.

To change pump lubricant:

1. Follow Pr

2. Lift the
and remo
the cap o
check va
Reattac

3. Drain t
lubric

n is due to moisture absorption by the

nt. The interval between changes

g. The pump lubrication system minimizes

moisture, but some contamination is still

essure Relief Procedure, page 64.

lubricant reservoir (R) out of the bracket

lve and allow the lubricant to drain.

h the check valve to the inlet hose.

he reservoir and flush it with clean

ant.

ion System

e environment in which the equipment

ve the container from the cap. Holding
ver a suitable container, remove the

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

5. Thread the reservoir onto the cap assembly and
place it in the bracket.

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

R

Pump Lubrication System
Figure 39

68 3A1705J

Maintenance

Drain Coolant

To avoid burns, do not perform maintenance on
the coolant system until the coolant system has
reached ambient temperature.

Drain coolant from the engine and proportioner
coolant loops once a year or if the coolant lines need
to be disconnected, in order to install a wall between
the generator and proportioner.

1. Perform Shutdown, page 63.

2. Remove the cabinet door from the front of the
proportioner.

3. Turn on manual valve switch (MV), located on
the load center (LC), to manually open the A
and B heat exchanger control valves and bypass
control valve.

Note

b. Place the other end of the drain tube in a

waste container. Open the drain valve. Drain
coolant until coolant is no longer visible in
the sight glass.

Proportioner Coolant Loop Drain Valve
Figure 41

c. To refill coolant loop, see

Refill Proportioner Coolant Loop, page 70.

5. To drain proportioner coolant loop from filter
housing. Only available on Series B systems.

a. Remove the proportioner coolant loop fill

bottle cap (HF).

The battery must be connected to
operate valves. The load center (LC)
LEDs will stay on when the manual valve
switch (MV) is in the ON position.

LC

Figure 40

LED Component LED Color

Manualvalveswitch(MV)

A Side Control Valve

B Side Control Valve

Bypass Valve

Red

Red

Blue

Green

HF

MV

H

T

D

Filter Housing Drain Valve (D)
Figure 42

b. Place the other end of the filter housing drain

tube (T) in a waste container. Open the drain
valve (D).

4. To drain proportioner coolant loop:

a. Remove the proportioner coolant loop fill

bottle (HF) cap.

c. To refill coolant loop, see

Refill Engine Coolant Loop, page 72.

3A1705J 69

Maintenance

6. To drain engine coolant loop:

a. Remove the eng

b. Remove engine

guards rest on
valve.

Engine Coolant Loop Drain Valve
Figure 43

c. Place a waste container under the drain

valve. Open the drain valve and drain
coolant.

d. To refill coolant loop, see

Refill Engine Coolant Loop, page 72.

e. Replace engine shrouds. Torque screws to

25 ft-lbs (33.8 N∙m)

ine coolant loop (RC) cap.

guards as shown. Let the

theenginetoaccessthedrain

Only use coolant solutions that are compatible with
the system. See Coolant Specifications, page 72.

1. Before refilli
from Drain Coo
if necessary.

ng coolant loop, perform steps 1–3

lant, page 69. Drain coolant loop

NOTICE

Do not refill with drained coolant. Use only
fresh, new coolant to avoid contaminants.

NOTICE

Do not use any “stop leak” additives to prevent
plugged filters and small orifices.

NOTICE

Do not inte
the radiat
have diff
overflow.

2. Remove the caps from the metal proportioner
coolant loop fill bottle (HF) and expansion
bottle (HB). Fill the proportioner coolant loop fill
bottle (HF) to the top and add more coolant to
expansion bottle (HB) until the coolant is at the
cold fill line. See Coolant Specifications, page 72.

HB

rchange the two caps between

or and coolant bottle. The caps

erent pressure ratings that affect the

RC

HF

EB

Refill Proportioner Coolant Loop

Note

Air needs to be purged from the proportioner
coolant loop when it is filled with new coolant
or when air enters the coolant system. It
takes about one full warm-up and cool-down
cycle to purge air from coolant.

avoid burns, do not perform maintenance on

To

e coolant system until the coolant system has

th

ached ambient temperature.

re

70 3A1705J

Coolant System Bottles
Figure 44

Maintenance

3. Replace cap. Tighten past the “safety” latch
position.

4. Press start bu
control modul

5. Turn main pow

6. Inspect coolant flow in sight glass (SG) for
bubbles and to verify that the coolant is flowing.

7. Inspect coolant loops for leaking fittings or valves.

8. The coolant has reached operating temperature
when the radiator fan turns on. When the fan
turns on, turn the main power switch OFF.

tton

e.

er switch on.

twice on the engine

9. Press to stop the generator.

10. After the coolant system temperature lowers to
ambient temperature, refill or add coolant to the
expansion bottle (HB) cold level indicator line.

11. Turnoffmanualvalveswitch(MV)toclosetheA
and B heat exchanger control valves (VA, VB)
and bypass control valve (VC).

Note

When the man
is in the OFF
(LC) LEDs on
opens the v

12. If necessa
bottle (HB

ry, refill or add coolant to the expansion

) cold level indicator line. See Fig. 42.

ual valve switch (MV)
position, the load center
ly turn on when the system

alves.

3A1705J

71

Maintenance

Refill Engine C

Refill the engine coolant loop when the coolant is
below the cold level line at ambient temperature.

To avoid burns, do not perform maintenance on
the coolant system until the coolant system has
reached ambient temperature.

Only use coolant solutions that are compatible with
the system. See Coolant Specifications, page 72.

oolant Loop

NOTICE

Do not refill with drained coolant. Use only fresh,
new coolant to avoid contaminants.

NOTICE

Do not use any “stop leak” additives to prevent
plugged filters and small orifices.

6. Inspect coolant loops for leaking fittings or valves.

7. The coolant has reached operating temperature
when the radiator fan turns on. When the fan
turns on, turn the main power switch OFF.

8. Press to stop the generator.

9. Add more coolant to expansion bottle (EB)
after the coolant system temperature lowers to
ambient temperature. Repeat until coolant level
stays at cold level when at ambient temperature.
It may take a few cycles to remove all air out of
coolant system.

Coolant Specifications

NOTICE

Do not interchange the two caps between the
radiator and coolant bottle. The caps have different
pressure ratings that affect the overflow.

1. Perform Shutdown, page 63.

2. Remove the engine radiator coolant cap
(RC) and fill until the coolant reaches the
bottom of the neck. Replace cap. See

Coolant Specifications, page 72.

3. Remove the cap from the engine coolant loop
bottle (EB) and fill until the coolant is at the hot
level. Replace cap.

4. Press start button
control module.

5. Turn main power switch ON.

twice on the engine

NOTICE

Do not refill with straightwaterortapwater.
Changing the 50% mix ratio use of tap water will
allow fittings to rust.

Only refill the coolant loops with a solution of 50%
distilled or soft water and 50% green ethylene glycol
antifreeze with a corrosion inhibitor. Do not use
common tap water; it contains chlorides and minerals
which form scale on the coolant system walls. Do not
use any stop leak products. The additives in these
products will clog the heat exchanger and fluid valves,
decreasing system performance. Use only antifreeze
that meets specification ASTM D3306–89, BS658, or
AS 2108. A pre-diluted mix is recommended, such
as PEAK Ready Use 50/50 Pre-Diluted.

2

7

3A1705J

Errors

Errors

View Errors

When an error
screen displ
description

Troublesho

The error code, alarm bell, and active errors will scroll
in the status bar. For a list of the ten most recent
errors see Troubleshooting, page 74.

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

Alarms a
aparame
level re
to be add

quiring the system to stop. The alarm needs

occurs the error information

ays the active error code and

. To diagnose the active error, see

ot Errors, page 73.

re indicated by

ter critical to the process has reached a

ressed immediately.

. This condition indicates

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

Note

Press
previously displayed screen.

2. Press
that are

to diagnose the error. Press
previous screen.

present in the system until you are able

or to return to the

elect one of following conditions

to s

to return to the

Deviations are indicated by
indicates a parameter critical to the process has
reached a level requiring attention, but not sufficient
enough to stop the system at this time.

Advisories are indicated by
indicates a parameter that is not immediately critical
to the process. The advisory needs attention to
prevent more serious issues in the future.

. This condition

. This condition

Troubleshoot Errors

See Error Codes and Troubleshooting, page 74 for
causes and solutions to each error code.

To troubleshoot the error:

3. Select conditions that are present in the system

until a cause has been identified. Press
go the troubleshooting screen that displays the
ten most recent errors.

to

3A1705J 73

Troubleshootin

g

Troubleshooting

See Errors, page 73 for information about errors that
can occur on the system.

See Troubleshooting, page 53 for the ten most
recent errors that have occurred on the system. See

Troubleshoot Errors, page 73 to diagnose errors on

the ADM that have occurred on the system.

Error Codes and Troubleshooting

See Reactor repair manual for non-error based
troubleshooting.

Error

Code
A1NM

Error

Location
MCM

Type Name

ALARM No Motor

Current

See Error Code
codes, possib

Note

Error codes are stored in the error log and
displayed on the Error and Troubleshooting
screens on the ADM.

Cause Solution

Loose or bad motor or
wire connection.

Motor brushes
completely worn down.

Bad MCM. Replace MCM. See

s and Troubleshooting for error

le causes, and solutions.

Check for tight motor
wireterminationingreen
connector. If loose,
contact Graco distributor
for rework instructions.
Check for tight motor
brush wire terminal screw.
See system repair manual.

Check motor brushes and
replace if needed.

system repair manual.

4

7

3A1705J

Troubleshootin

g

Error

Code
A4CH

A4CM MCM

A4DA

A4DB

A4DH Hose ALARM High Heater

Error

Location
Hose ALARM High Relay

Boost A

Boost B

Type Name

Current Hose

ALARM

ALARM High Heater

High MCM
Current

Current

Current

Cause Solution

Wiring problem.

Shorted contactor.

MCM is drawing too
much current from the
system.

Short circuit in booster
heater wiring.

Bad heater.

Short c
wirin

ircuit in hose

g.

Check wiring b
HPTCM and cont
Look for short
between HPTCM
contactor te
and A2.

Measure resi
between A1 a
terminals.
should be ab
If contacto
less than 1
contactor
should be r

If problem continues
replace MCM. See system
repair manual.

Check wiring for touching
wires.

Measure resistance of
heater(s), replace if
needed. See system
repair manual.

Check c

former windings,

trans

l reading are about

norma

0.2Ω o
dary. If reading is

secon
0Ω rep

Check for shorts between
the primary winding and
the support frame of the
transformer.

etween

actor.

ed wire

and

rminals A1

stance

nd A2

The resistance

out 289Ω.

r is measuring

00Ω, then the

is shorted and

eplaced.

ontinuity of

nbothprimaryand

lace transformer.

3A1705J 75

Troubleshootin

g

Error

Code
A4NM

A7CH

A7DA Boost A

A7DB Boost B

A7DH Hose ALARM Unexpected

A8DA

A8DB

A8DH

Error

Location
MCM

Hose ALARM Unexpected

Boost A

tB

Boos

Hose

Type Name

ALARM High Motor

Current

Relay Current

ALARM Unexpected

Heater Current

Heater Current

ALARM No Heater

Current

Cause Solution

Short circuit
wiring.

Motor will no

Chemical pump is stuck

Shorted HPTCM. Replace Module. See

Shorted L

Turned of
switch wi
motor ON

Turned o
breaker
on.

Failed to power off after
loading software.

Shorted HPTCM. Replace Module. See

Tripped circuit breaker. Visually check circuit

Loose/broken
connection.

of motor

t rotate.

PTCM.

f main power

th heaters and

.

n hose circuit

with hose heat

Check wiring t
to ensure no ba
are touching a
no wires are sh
ground.

Replace motor. See
system repair manual.

Repair or replace chemical
pump. See system repair
manual.

system repair manual.
Replace M

System Re

Turn off h
power at A
turning
switch.

Turn on c
with hos

Power off after software
downloaded.

system repair manual.

breaker for a tripped
condition.

k heater wiring for

Chec

se wires.

loo

othemotor

re wires

nd that

orted to

odule. See

pair manual.

eat and motor

DM before

off the main power

ircuit breaker

e heat off.

76 3A1705J

Troubleshootin

g

Error

Code
CACA

CACB

CACH

CACM

CACP

Error

Location
Boost A

Boost B

Hose

MCM

Remote
Display
Module

Type Name

ALARM

Communicatio
Error

Cause Solution

Module does not have

n

software or dial is set
to wrong position.

No 24 VDC supply to
module.

Loose or broken CAN
cable.

Bad module

Insert a system token
into the missing GCA
module and cycle the
power. Wait until the red
light on the module stops
flashing before removing
the token. Verify the dial
on the module is in the
correct position: 0 for
hose, A for boost A, B for
boost B

MCM switch:
1forE-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, replace power supply.
See system repair manual.

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

A or CACB) Replace

(CAC

M.

LPTC

0forE-30i,

i

3A1705J

(CACH) Replace HPTCM.

(CACM) Replace MCM.

system repair manual

See

instructions to replace

for

ules.

mod

(CACP) Replace Remote
Display Module. See
Remote Display Module
manual for instructions.

77

Troubleshootin

g

Error

Code
DADX

DE0X

F9DX

H1MH Hose ALARM Low Line

H4MH Hose ALARM High L

K8NM

AX

L1

L1BX

Error

Location
MCM

MCM

MCM

MCM

M

AD

Type Name

ALARM Pump Runaway Flow rate is too large

ALARM

ALARM Pressure Flow

ALARM Locked Rotor

ARM

AL

Pump Cycle
Switch Fault

Cutback

Frequency

ine

uency

Freq

Low Chemical
Level A

Low Chemical
Level B

Cause Solution

Mix chamber to
system select
chamber rated

Ensure the sy
chemical and
pumps are ope
correctly.

No material
Verify pump
supplying c
necessary,
drums.

Inlet ball
Open ball v

Faulty or m
switch.

Mix chamber is too
large for the set
pressure.

Line fr
55 Hz.

Line frequency is above
65 Hz.

Locked rotor.

emical pump is

Ch

uck.

st

nks low on material.

Ta

issing cycle

equency is below

Check wiring between
cycle switch and MCM
port 6.

Reference the pressure
flow curves and select a
tipsizethatisthecorrect
size for the set pressure.
See Performance Charts,

page 99.

Check f
out of

ied 120/240V

suppl

nator manual for

alter

r instructions.

repai
Check frequency. If

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

Replace motor. See
system repair manual.

Repair or replace pump.
See system repair manual.

ll tanks with material.

Fi

o large for

ed. Use mix

for system.

stem has

the feed

rating

in pumps.

sare
hemical. If
replace or refill

valves are closed.

alves.

requency. If

tolerance, see

78 3A1705J

Troubleshootin

g

Error

Code
MBN0

MMUX

P4AX

P4BX

P6AX

P6BX

Error

Location
MCM

USB

MCM

MCM

Type Name

ADVI­SORY

ADVI­SORY

ALARM

ALARM Pressure

Motor Brush
Wear

USB Log Full USB logs have

Over Pressure A

Over Pressure B

Transducer
Fault A

Pressure
Transducer
Fault B

Cause Solution

Brushes have worn
down and need
replacing.

reached
a level were d
will occur if
downloaded.

System pressurized
before allowing heat to
reach setpoint.

Bad pressu
transduce

E-XP2i system
configured as E-30i.

Loose/bad connection.

Bad sensor.

ata loss

logs are not

re

r.

Replace Brush
system repair

Use a USB driv
download all

Turn on the h
thehosetor
setpoint be
the pumps.

Verify the ADM pressure
reading the analog gauges
at the manifold. Replace
transducers if they do not
match. See system repair
manual.

Ensure rotary switch on
MCM is set to position 0
for E-30i.

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

Check

ws the transducer.

follo

nnect transducer

Disco

from #8 and #9

cable

ectors on MCM.

conn

rseAandB

Reve

ections and check

conn

e error follows. If

if th

rror follows the

the e

sducer, replace the

tran

ssure transducer. See

pre

tem repair manual. If

sys

error does not follow,

the

lace MCM. See system

rep

air manual.

rep

es. See

manual.

eand

logs.

eat and allow

each the

fore turning on

if the error

3A1705J 79

Troubleshootin

g

Error

Code
P7AX

P7BX

P0AX

P0BX

T1DE Engine

Error

Position
MCM

MCM ADVISO

MCM ADVIS

Heat
Exchanger

Type Name

ALARM Pressure

Imbalance A High
(P7AX)

Pressure
Imbalance B H
(P7BX)

Pressure

RY

Imbalance A High

ORY

ALARM Low Temperature

Pressure
Imbalance B High

Coolant Outlet

igh

Cause Solution

Pressure diff
between A and B
is greater tha
defined value.

Pressure imb
defined too lo

Out of material.

Fluid leaking from heater
inlet rupture disk.

Feed system defective. Check feed pump and hoses

See P7A

See P7

tor fan will not stop.

Radia

ne thermostat is

Engi

kclosed.

stuc

erence

material

nthe

alance is

w.

X.

BX.

Ensure the mat
equally restr
material line

Ensure that t
imbalance va
System Setup
an acceptab
pressure to
unnecessar
abort dispe

Fill tanks

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

for blockage. Check that the
feed pumps have the correct
air pressure.

ce fan relay. See

Repla

m repair manual.

syste
Replace thermostat. See

Perkins dealer.

erial flow is

ictedonboth

s.

he pressure

lue, on the

screen, is at

le maximum

prevent

yalarmsand

nses.

with material.

80 3A1705J

Troubleshootin

g

Error

Code
T2AE

T2BE

Error

Position
Heat

Exchanger

Type Name

DEVIATION

Low Temperature
Hx A

Low Temperatu
Hx B

Cause Solution

Recirculating material
to heat with drum feed
pumps only.

re

Coolant circ
not working.

Air lock in c
pump.

Loose or incorrect wiring
connections.

No volta
valve.

ulation pump

irculation

ge to coil of

Recirculate material
using Jog mode for heat
exchanger heating.

Check for 240
pump. If ther
voltage, rep
pump. See sys
manual.

Check for coolant flow in
sight glass.

See wiring schematics, in
the system repair manual,
and verify coolant valve
connections. Check coolant
valve harness and verify
voltage is 11–13 volts at
coolant valve connectors.

Turn on the manual valve
switch (MV), on the load
center (PE), to manually turn
on the solenoids and see if
the temperature rises. If not,
check voltage output on J6
connector on the load center
and ensure the LEDS are
on. See load center wiring
in system repair manual.

VAC on

eisthecorrect

lace circulation

tem repair

wLoadCenter

Follo

ostics instructions

Diagn

tem repair manual. If

in sys

ssary, replace the load

nece

er board.

cent

If voltage is present,
measure the resistance
of the coil, it should be
approximately 12.5 Ω, if coil
is open replace coil.

If voltage is present, test
the coil with screwdriver.
The screwdriver should
magnetically stick inside
the coil. If screwdriver
sticks, then the coil is
good. Replace the plunger
on valve or replace the
complete valve assembly.
See system repair manual.

3A1705J 81

Troubleshootin

g

Error

Code
T2DA

T2DB

T2DH Hose ALARM

T2DE Heat

T3NM

T4AE

T4BE

Error

Position
Boost A

Boost B

Exchanger

MCM ADVISORY

Heat
Exchan

Type Name

ALARM

ADVISORY

ALARM

ger

Low Chemical
Temperature

Low Chemical
Temperature

Low Temperature
Coolant Outlet

High Mot
Tempera

High Chemical
Temperature Hx A
(T4AE)

High Chemical
Temperature Hx B
(T4BE)

or

ture

Cause Solution

Flow is too high at current
setpoint.

Bad heater(s

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

Radiator fan will not stop. Replace fan relay. See

Engine thermostat is
stuck open.

Motor is
outside
flow curv
is runni
setpoin
motor l

Manual valve switch (MV)
on load center board is in
the ON position.

A or B side control valve
solenoid is stuck in the
open position. Debris
in valve diaphragm
or plunger preventing
spring-loaded closed
function.

Shortonloadcenter
board. If the blue and red
LEDsareonwhilethe
heat is off, then the load
center board is bad.

4BE only) J6 connector

(T

load center “Heat

on

lves” location is not

Va

ntered.

ce

and B heat

A

xchanger RTD cables

e

ross-connected to

c

plitter cable.

s

)

operating

of pressure

e. The system

ng at a lower

ttopreserve

ife.

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

Confirm resis
is 23–26.5 oh
OL/open loop

Recirculate
back to drum
conditions

system repair manual.
Replace t

Perkins d
replace.

Run the s
lower du
smaller

Perform

99.

Open cabinet cover and turn
switch to the OFF position.

Disconnect connector
from valve solenoid coil.
If temperature does not
decrease, rebuild solenoid.

See Load Center
Diagnostics in the system
repair manual.

Reconnect J6 connector
on load center in centered
location.

See System Repair Manual
for correct connection.

tance of heater

ms. Replace if

.

heated chemical

in cold

before startup.

hermostat. See
istributor to

ystem at a

ty cycle or with a
mix chamber. See

ance Charts, page

82 3A1705J

Troubleshootin

g

Error

Code
T4CA

T4CB

T4CH

T4CM MCM

T4DA

T4DB

T4DE Heat

Error

Position
Boost A

Boost B

Hose

Boost A

Boost B

Exchanger

Type Name

ALARM

ALARM

ALARM

ALARM High Temperature

(T4CA or T4CB)
LPTCM Over
Temperature

(T4CH) HPTCM
Over Temperature

High MCM
Temperature

High Che
Tempera

Coolant Outlet

mical

ture

Cause Solution

Cooling fan no

Overheated module. Turn controller off. Wait

High ambient
temperature.

Overheated control
module.

Bad RTD or bad RTD
placement against heater
rod.

Bad Low
Temper
Module

Broken Fan.

Plugged radiator.

High ambient
temperature.

t operating.

Power

ature Control

.

If fan is not wo
wiring betwee
fan. If wiring
fan.

a few minutes. If the
condition does not clear or
regenerates consistently,
replace module.

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

Stop the pumps. Wait
a few minutes. If the
condition does not clear or
regenerates consistently,
replace MCM. See System
Repair manual.

Swap A an
cables a
see if is
replac

Swap the A and B LPTCMs
and see if the issue follows
the module. If so replace
LPTCM. See system repair
manual.

Check fan relay (K4) and
fuse (30 Amp ATO “F3”) on
load center board. Replace
if needed.

Rep

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

sue follows. If so,

eRTD.

lace if needed.

rking check

nCB03and

is good, replace

d B heater volex

nd RTD cables and

3A1705J 83

Troubleshootin

g

Error

Code
T4DH Hose ALARM

T4NM

Error

Position

MCM

Type Name

ALARM High Motor

High Chemical
Temperature

Temperature

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 temperature
settingtotheFTS.

BadHighPower
Temperature Control
Module.

Cooling fan
operating

sarenot

properly.

Shade exposed
hot sun or expo
same environm
at rest. Uncoi
before heati
self-heatin

Replace HPT
system repa

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

Check to se
are moving
voltage to
shouldbe2
voltage i
wiring be
circuit b

If the fans have voltage but
are not moving, replace fan.

hose from

se FTS to

ent when

l entire hose

ng to avoid

g.

CM. See

ir manual.

e that the fans

. Measure

fans. There

40 VAC. If no

s measured, check

tween fan and

reaker CB03.

Bad electric motor.

Use an air hose to blow out
around the fan housings and
remove any built-up debris.

Replac
System

e electric motor. See

Repair manual.

84 3A1705J

Troubleshootin

g

Error

Code
T6AE Heat

T6BE Heat

T6DA Boost A

T6DB Boost B

T6DE Engine

T6DH Hose ALARM

Error

Position

Exchanger
A

Exchanger
B

Heat
Exchanger

Type Name

ALARM RTD Fault

RTD Cable o
Fault

Cause Solution

Broken or loose RTD
cable or connection.

Bad RTD.

Broken RTD cable in

rFTS

hose or bad FTS.

Check all wiri
connection to

Switch the RT
and see if the
follows the R
RTD if the err
RTD. See sys
manual for i

Expose each hose RTD
connection to check
and retighten any loose
connector. Measure
hose RTD cable and
FTS continuity. See system
repair manual. Order
RTD Test Kit 24N365 for
measurement.

See Temp

Hose Tem
page 58,to

repair c

ng and

RTD.

D with another
error message

TD. Replace

or follows the

tem repair

nstructions.

orary Manual

perature Control,

finish job until

an be completed.

3A1705J 85

Troubleshootin

g

Error

Code

T8AE

T8BE

Error

Position

Heat
Exchanger

Type Name

ALARM Temperature Not

Rising Hx A (T8AE)

Temperature N
Rising Hx B (T8

Cause Solution

Low chemical supply
temperature.

ot

BE)

System stored below
20°F(-7°C) causing slow
control valve operation.

Plugged filter in sight glass.
Indicated by consistent
low A and B temperature
alarms.

Coolant debris stuck in
valve pilot hole or passages.

No coolant flow Check coolant level. Check for

(T8AE onl
load cent
location

Bad valve

Valve so
12 VDC e

Bad load center. Red, blue, and green LEDs

A and B heat
exchanger RTD cables
cross-connected to splitter
cable.

y) J6 connector on

er “Heat Valves”

is not centered.

solenoid coil.

lenoid not getting

lectrical signal.

Recirculate heated chemical
back to drum in cold conditions
before spraying. Chemical
below 32°F(0°C) at startup.

Ensure ambient temperature is
above 20°F(-7°C).

Clean or replace filter. See
system repair manual.

Inspect and clean control valve.
Repair or replace if necessary.
See system repair manual.

coolant flow in sight glass.

Ensure that the circulation
pump has 240 VAC. If not,
replace the circulation pump.
See system repair manual.

Reconnect J6 connector on
load center in centered location.

Turn on th
switch (
and see i
shifts.
identifi
manual.
shift, r
system r

Verify 12 VDC signal is at the
valve solenoid coil connector.
All three valves are normally
closed with power removed.
See system repair manual
for valve wiring harness
identification diagram.

should light up on load center
board. If not, replace load
center. See system repair
manual.

See Sy
corre

e manual valve

MV), on the load center,

f the valve solenoid

For coolant valve LED

cation, see system repair

If solenoid does not

eplace solenoid coil. See

epair manual.

stem Repair Manual for

ct connection.

86 3A1705J

Troubleshootin

g

Error

Code
T8DA

T8DB

T8DH Hose ALARM Temperature Not

V1CM MCM

V1MH Hose ALARM Low Line Voltage

V4CM MCM

V4MH Hose ALARM High Line Voltage

WBNM

Error

Position
Boost A

Boost B

M

MC

Type Name

ALARM Temperature Not

Rising

Rising

ALARM Bus Under

Voltage

ALARM

ALARM

Bus O

tor Sensor

Mo

ult

Fa

vervoltage

Cause Solution

Bad heater rod

Low chemical supply
temperature.

Bad heated hose. Measure hose resistance,

Started sp
engine and
operating

Low chemical supply
temperature.

Tripped
breaker

Loose or bad connection.

Low generator line
voltage

High auxiliary inrush
current.

Incoming line voltage is
too high.

Bad connection between
MCM (Port 10) and brush
wear/over temperature
board.

Bad brush wear/over
temperature board.

MCM circuit

(CB02).

(boost).

raying before

hose reached

temperature.

Measure resistance, 23 – 26
Ω, of heater rod, replace if
reading open.

Recirculate heated chemical
back to drum in cold
conditions before spraying
chemical below 32°F(0°C)
at startup. Use Jog Mode for
heat exchanger heating.

replace if reading open.
Wait until operating

temperatures have been
reached on engine and hose
before spraying.

Recirculate heated chemical
back to drum in cold
conditions before spraying.
Chemical below 32°F(0°C)
at startup.

Visually check circuit
breaker for a tripped
condition. If Diagnostic
screen is enabled, MCM
Bus14Vindicatesnormal
voltage and 1 V indicates
failed MCM.

Check w

Measure voltage across
main power switch (CT01).
Voltage should measure
between 190 and 264 VAC.

Ensure compressor or
air dryer are setup to be
continuous run and sized
according to manual.

Measure voltage across
main power switch (CT01).
Voltage should measure
between 190 and 264 VAC.
If voltage is too high, see
supplied alternator manual
for generator specifications
and repair.

Ch
ca

eplace Motor. See system

R

epair manual.

r

iring for loose wires.

eck connection and

bles.

3A1705J 87

Troubleshootin

g

Error

Code
WMCE MCM

WSCX

WSUX USB ADVISORY USB Invali

WXUD ADM

WXUU ADM

WX00

Error

Position

ADM

MCM

Type Name

ALARM

ADVISORY Invalid CAN

ADVISORY USB Download

ADVISORY USB Upload Error Custom language file

ALARM External Input The alarm external input

Load Center Fa

Configuration

Configurat

Error

d

ion

Cause Solution

ult

Bad Connectio
MCM (Port 2) an
center board.

Bad load cent

Duplicate node on CAN
network.

A valid con
can't be fo
USB.

Bad ADM.

Log download failed. Backup and reformat the

failedtoupload

hasbeendrivenlow.

n between

dload

er.

figuration file

und for the

Check connect
cables.

Replace load center. See
System Repair manual.

Verify LPTCM are set to A
and B.

Insert a system token into
theADMandcyclethe
power. Wait until the lights
on USB port stop flashing
before removing the token.

Replace A
Repair ma

USB drive. Retry download.
Perform normal USB

download and use the new
disptext.txt file to upload the
custom language.

An active alarm is being
generated by the external
trigger. If the external alarm
is not configured check for a
short in the wiring going to
MCM port 7, pins 1 and 3.

ion and

DM. See System
nual.

88 3A1705J

USB Data

USB Data

USB Logs

Note

TheADMcanread/writetoFAT(File
Allocation Table) storage devices. NTFS,
used by 32 GB or greater storage devices,
is not supported.

During operation, the ADM stores system and
performance related information to memory in the
form of log files. The ADM maintains four log files:

• Event Log

• Job Log

• Daily Log

• System Software Log

• Blackbox Log

Follow Download Procedure, page 91,toretrieve
log files.

Each time a USB flash drive is inserted into the ADM
USB port, a new folder named DATAxxxx is created.
The number at the end of the folder name increases
each time a USB flash drive is inserted and data is
downloaded or uploaded.

Event codes in
deviations,

Actions Taken includes setting and clearing event
conditions by the system, and acknowledging error
conditions by the user.

clude both error codes (alarms,

and advisories) and record only events.

Job Log

The job log file name is 2–JOB.CSV and is stored
in the DATAxxxx folder.

The job log maintains a record of data points
based on the USB Log Frequency defined
in the Setup screens. The ADM stores the
last 415,413 data points for download. See

Setup - Advanced Screen 3 — USB, page 46,for

information on setting the Download Depth and USB
Log Frequency.

• Data poi

• Data poi

•Asidehe

•Asideb

•Bsideh

nt date

nt time

at exchanger temperature

oost heater temperature

eat exchanger temperature

Event Log

The event log file name is 1–EVENT.CSV and is
stored in the DATAxxxx folder.

The event log maintains a record of the last 49,182
events and errors. Each event record contains:

• Date of event code

• Time of event code

• Event code

•Eventtype

• Action taken

vent Description

•E

•Bsideb

•Hoset

•Engin

•Aside

•Bside

•Hose

•Asid

•Bsid

•Pre

•Sys

•Pre

oost heater temperature

emperature

e coolant temperature

temperature setpoint

temperature setpoint

temperature setpoint

epressure

epressure

ssure setpoint

tem lifetime pump cycle counts

ssure, volume, and temperature units

3A1705J 89

USB Data

Daily Log

The daily log file name is 3–DAILY.CSV and is stored
in the DATAxxxx folder.

The daily log m
and volume spr
powered up. T
that were use

The following data is stored in this file:

• Date that material was sprayed

• Time — unused column

• Total pump cycle count for day

• Total volume sprayed for day

aintains a record of the total cycle
ayed on any day that the system is

he volume units will be the same units

d in the Job Log.

System Software Log

The system software file name is 4–SYSTEM.CSV
andisstoredintheDATAxxxxfolder.

The syste

• Date log was created

m software log lists the following:

Blackbox Log File

The black box file name is 5–BLACKB.CSV and is
stored in the DATAxxxx folder.

The Blackbox l
system runs an
will help Gra

og maintains a record of how the

d the features that are used. This log

co troubleshoot system errors.

System Configuration Settings

The system c
SETTINGS.T
folder.

A system configuration settings file automatically
downloads each time a USB flash drive is inserted
intotheADM.Usethisfiletobackupsystem
settings for future recovery or to easily replicate
settings across multiple systems. Refer to the

Upload Procedure, page 92 for instructions on how

to use this file.

onfiguration settings file name is

XTandisstoredintheDOWNLOAD

• Time log was created

• Component name

• Software version loaded on the above component

90 3A1705J

USB Data

Download Procedure

Note

System configuration setting files and custom
language files can be modified if the files
are in the UPLOAD folder of the USB flash
drive. See System Configuration Settings
File, Custom Language File, and Upload
Procedure sections.

Note

If needed, s
download on
3–USB in the
only be cha

1. Insert USB flash drive into USB port.

2. The menu bar and USB indicator lights “USB
Busy” to indicate that the USB is downloading
files. USB activity is complete when the “USB
Busy” screen prompt disappears or the flash
drive LED stops flashing.

Note

Normal s
while do

3. Remove U

4. Insert

5. The USB
If it do
Window

6. Open G

7. Open t
from m
than o

sponding serial number of the ADM (The

corre

al number is on the back of the ADM.)

seri

et the number of days to

the Advanced Setup Screen

ADM. USB log frequency can

nged before logging occurs.

ystem spraying can continue

wnload is in progress.

SB flash drive from USB port.

USB flash drive into USB port of computer.

flash drive window automatically opens.

es not, open USB flash drive from within

s® Explorer.

RACO folder.

he system folder. If downloading data

ore than one system, there will be more

ne folder. Each folder is labeled with the

9. Open DATAxxxx folder.

10. Open DATAxxxx folder labeled with the highest
number. The highest number indicates the most
recent data download.

11. Open log file. Log files open in Microsoft® Excel
by default as long as the program is installed.
However,theycanalsobeopenedinanytext
editor or Microsoft® Word.

Note

All USB logs are saved in Unicode
(UTF-16) format. If opening the log
file in Microsoft Word, select Unicode
encoding.

Custom Language File

The custom language file name is DISPTEXT.TXT
and is stored in the DOWNLOAD folder.

A custom language file automatically downloads
each time a USB flash drive is inserted into the ADM.
If desired, use this file to create a user-defined set of
custom language strings to be displayed within the
ADM.

The syst
charac
the sys
charac
inside

• U+0020 - U+007E (Basic Latin)

• U+00A1 - U+00FF (Latin-1 Supplement)

• U+0100 - U+017F (Latin Extended-A)

• U+0386 - U+03CE (Greek)

• U+0400 - U+045F (Cyrillic)

em is able to display the following Unicode

ters. For characters outside of this set,

tem will display the Unicode replacement

ter, which appears as a white question mark

of a black diamond.

8. Open

DOWNLOAD folder.

3A1705J 91

USB Data

Create Custom Language Strings

The custom language file is a tab-delimited text file
that contains two columns. The first column consists
of a list of strings in the language selected at the
time of download. The second column can be used
to enter the custom language strings. If a custom
language was previously installed, this column
contains the custom strings. Otherwise the second
column is blank.

Modify the s
as needed an
to install t

The format of the custom language file is critical.
The following rules must be followed in order for the
installation process to succeed.

• Define a custom string for each row in the second
column.

• The file name must be DISPTEXT.TXT.

• The file format must be a tab-delimited text file
using Unicode (UTF-16) character representation.

• The file must contain only two columns, with
columns separated by a single tab character.

• Do not add or remove rows to the file.

• Do not change the order of the rows.

econd column of the custom language file

d the follow Upload Procedure, page 92 ,

he file.

Note

If the custom language file is used, you
must define a custom string for each
entry in the DISPTEXT.TXT file. Blank
second-column fields will be displayed
blank on the ADM.

1. If necessary, follow the Download Procedure to
automatically generate the proper folder structure
on the USB flash drive.

2. Insert USB flash drive into USB port of computer.

3. The USB flash drive window automatically opens.
If it does not, open USB flash drive from within
Windows Explorer.

4. Open GRACO folder.

5. Open the system folder. If working with more
than one system, there will be more than one
folder within the GRACO folder. Each folder is
labeled with the corresponding serial number of
the ADM. (The serial number is on the back of
the module.)

6. If installing the system configuration settings
file, place SETTINGS.TXT file into the UPLOAD
folder.

7. If installing the custom language file, place
DISPTEXT.TXT file into the UPLOAD folder.

8. Remove USB flash drive from the computer.

9. Install USB flash drive into the ADM USB port.

10. The menu bar and USB indicator lights indicate
that the USB is downloading files. Wait for USB
activity to complete.

11. Remove USB flash drive from USB port.

Note

If the custom language file was installed,
users can now select the new language
from the Language drop-down menu in

Advanced Screen 1 — General, page 46.

Upload Procedure

Use this procedure to install a system configuration
file and/or a custom language file.

92 3A1705J

Appendix A: Engi

ne Control Module

Appendix A: En

gine Control Module

Run Screens

There are seven run screens on the engine control module:

• Line-to-ne

• Line-to-li

• Frequency

•EngineSpe

• Engine lif

•Batteryvo

Press

Run Screen Layout

Inst

Icon

utral voltage

ne voltage

ed

etime counter

ltage

to scroll through the run screens. Press to enter the Information screens.

Alarm

Icon

Instrumentation Units

Mode

Icon

Information Screens

From the Run Screen, press to enter the information screens. Press to scroll through the last five
generator events.

s

Pres

Information Screen Layout

Event

#

3A1705J 93

to return to the Run Screens.

Time of Event (Engine

Run Hours)

Units

Alarm

Icon

Mode

Icon

Appendix A: Engi

ne Control Module

Mode Icons

An icon is displayed in the mode icon area of the display to indicate what mode the unit is currently in.

Icon Description Details

Stopped

Auto Engine is at r

Manual Engine is at rest and the unit is in manual run mode.

Timer animation Engine is starting up.

Running animation Engine is running.

Engine is at re

st and the unit is in stop mode.

est and the unit is in auto mode.

Instrumentation Icons

A small icon is displayed in the instrumentation icon area to indicate what value is currently being displayed.

Icon Description Details

Generat

or

Generat

or voltage and frequency screen

Engine Speed

Engine Lifetime
Counter

Event Log Event is being displayed.

ime

Unit T

Engine speed screen

Hours run

Unused feature

94 3A1705J

Appendix A: Engi

ne Control Module

Alarms

There are two types of alarms that can occur on the system. Alarms are indicatedbyanicontheRunand
Information screens.

Warning

When present on system, a warning alarm will not stop the generator.

Icon Description Details

Battery Hig

Battery Low Voltage

Fail To Stop

Flexible Sensor The flexible sensor warning alarm has been triggered.

Shutdown

When pre
Then pre

Icon Descri

sent on system, a shutdown alarm will stop the generator. Clear the alarm and remove the fault.

ss the stop button to reset the module. See the information screen to see the latest alarm.

Fail To Start The engine has not fired after the preset number of start attempts.

Generator High Voltage
Shutdown

ption

h Voltage

The DC Supply has risen above the high volts setting level for the
duration of the high battery volts timer.

The DC Supply has fallen below the low volts setting level for the
duration of the low battery volts timer.

The module
running wh

s

Detail

The gen

detected a condition that indicates that the engine is

en it has been instructed to stop.

erator output voltage has risen above the preset level.

Generator Low Voltage
Shutdown

High Coolant Temperature
Shutdown

il Pressure Shutdown

Low O

Over Frequency Shutdown The generator output frequency has risen above the preset level.

Under Frequency Shutdown The generator output frequency has fallen below the preset level.

The generator output voltage has fallen below the preset level.

The module detects that the engine coolant temperature has
exceeded the high engine temperature shutdown setting after the
Safety On timer has expired.

ngine oil pressure has fallen below the low oil pressure trip

The e

ing level after the Safety On timer has expired.

sett

3A1705J 95

Dimensions

Dimensions

Top View
Figure 45

Side View
Figure 46

96 3A1705J

Dimensions

Top View: System with Compressor and Hose Rack
Accessories
Figure 47

Front View
Figure 48

Side View: System with Compressor and Hose Rack
Accessories
Figure 49

3A1705J 97

Dimensions

Mounting Dimensions

Pallet
Figure

50

98 3A1705J

Performance Charts

Performance Cha

rts

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

Proportioners For Foam

2000

(138)

AR4242

(01)

15

(6.8)

AR5252

(02)

20

(9.1)

AR6060

(03)

AR7070

(04)

25

(11.3)

E-30i

30

(13.6)

35

(15.9)

PRESSURE

psi (bar)

1500

(103)

1000

(69)

500

(34)

05

(2.3)

10

(4.5)

FLOW lbs/min (kg/min)

h mix chamber. Flow

40

(18.1)

Proportioners For Coatings

Table 1 Fusion Air Purge, Round Pattern

3500

(241)

3000

(207)

2500

(172)

PRESSURE

psi (bar)

2000

(138)

1500

(103)

1000

(69)

500

(34)

0 0.5

(1.9)

AR2020

(000)

AR2929

(00)

AR4242

(01)

1.0

(3.8)

FLOW gal./min (kg/min)

E-XP2i

1.5

(5.7)

2.0

(7.6)

3A1705J 99

Performance Cha

rts

Table 2 Fusion Air Purge, Flat Pattern

3500

(241, 24.1)

3000

(207, 20.7)

2500

PRESSURE

(174, 17.4)

2000

(138, 13.8)

AF2020

(FTXX24 TIP)

psi (bar)

1500

(103, 10.3)

1000

(69, 6.9)

500

(35, 3.5)

0 0.5

(1.9)

FLOW gal./min (kg/min)

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)

(RTM040)

XR3535

(RTM055)

1.0

(3.8)

E-XP2i

XR2929

AF2929

(FTXX38 TIP)

AF4242

(FTXX38 TIP)

AF5252

(FTXX48 TIP)

MR3535

(RTM040)

XR4747

(RTM055)

1.5

(5.7)

MR4747

(RTM055)

E-XP2i

2.0

(7.6)

500

(35, 3.5)

0 0.5

(1.9)

(3.8)

1

1.5

(5.7)

2.0

(7.6)

FLOW gal./min (kg/min)

100 3A1705J