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
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