333024J, Reactor 2 E-30 and E-XP2 Proportioning System ... › wp-content › uploads › 2014 ›...

Repair-Parts

ReactorReactorReactor 222 E-30E-30E-30 andandand E-XP2E-XP2E-XP2

ProportioningProportioningProportioning SystemSystemSystem 333024JEN

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PROVEN QUALITY. LEADING TECHNOLOGY.

ContentsContentsContentsWarnings ............................................................. 3Important Isocyanate Information........................... 7Models................................................................. 9Approvals........................................................... 11Accessories........................................................ 11Supplied Manuals ............................................... 12Related Manuals ................................................ 12Troubleshooting.................................................. 13

Troubleshoot Errors ..................................... 13Pressure Relief Procedure .................................. 46Shutdown........................................................... 47Flushing ............................................................. 49Repair................................................................ 50

Before Beginning Repair............................... 50Flush Inlet Strainer Screen ........................... 50Change Pump Lubricant ............................... 51Remove Pump............................................. 52Install Pump ................................................ 53Repair Drive Housing ................................... 54Repair Electric Motor.................................... 57Repair Circuit Breaker Module ...................... 58Replace Fluid Inlet Sensor............................ 59

Replace Pressure Transducers ..................... 59Replace Fans .............................................. 60Repair Primary Heater.................................. 62Repair Heated Hose..................................... 66Repair Fluid Temperature Sensor

(FTS) ............................................. 68Replace Power Supply ................................. 71Replace Surge Protector .............................. 71Replace Advanced Display Module

(ADM)............................................ 71Replace Motor Control Module (MCM) ........... 72Software Update Procedure.......................... 72Replace Temperature Control Module

(TCM) ............................................ 72

Parts.................................................................. 73

Electrical Schematics.......................................... 93

Reactor 2 Repair Spare Parts Reference ............. 96

Performance Charts............................................ 97

Technical Specifications.................................... 100

Notes ............................................................. 102

Graco Extended Warranty for Reactor® 2Components ....................................... 103

2 333024J

Warnings

WarningsWarningsWarningsThe following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. Theexclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specificrisks. When these symbols appear in the body of this manual or on warning labels, refer back to theseWarnings. Product-specific hazard symbols and warnings not covered in this section may appear throughoutthe body of this manual where applicable.

WARNINGWARNINGWARNINGELECTRICELECTRICELECTRIC SHOCKSHOCKSHOCK HAZARDHAZARDHAZARD

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

• Turn off and disconnect power at main switch before disconnecting any cables and beforeservicing or installing equipment.

• Connect only to grounded power source.• All electrical wiring must be done by a qualified electrician and comply with all local codesand regulations.

• Do not expose to rain. Store indoors.

TOXICTOXICTOXIC FLUIDFLUIDFLUID OROROR FUMESFUMESFUMESToxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin,inhaled or swallowed.

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

• When spraying, servicing equipment, or when in the work area, always keep work areawell ventilated and always wear appropriate personal protective equipment. See PersonalPersonalPersonalProtectiveProtectiveProtective EquipmentEquipmentEquipment warnings in this manual.

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

PERSONALPERSONALPERSONAL PROTECTIVEPROTECTIVEPROTECTIVE EQUIPMENTEQUIPMENTEQUIPMENT

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

• A properly fitting respirator, which may include a supplied-air respirator, chemicallyimpermeable gloves, protective clothing and foot coverings as recommended by the fluidmanufacturer and local regulatory authority.

• Protective eyewear and hearing protection.

333024J 3

Warnings

WARNINGWARNINGWARNINGSKINSKINSKIN INJECTIONINJECTIONINJECTION HAZARDHAZARDHAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This maylook like just a cut, but it is a serious injury that can result in amputation. GetGetGet immediateimmediateimmediate surgicalsurgicalsurgicaltreatmenttreatmenttreatment.

• Do not spray without tip guard and trigger guard installed.• Engage trigger lock when not spraying.• Do not point gun at anyone or at any part of the body.• Do not put your hand over the spray tip.• Do not stop or deflect leaks with your hand, body, glove, or rag.• Follow the PressurePressurePressure ReliefReliefRelief ProcedureProcedureProcedure when you stop spraying and before cleaning, checking,or servicing equipment.

• Tighten all fluid connections before operating the equipment.• Check hoses and couplings daily. Replace worn or damaged parts immediately.

FIREFIREFIRE ANDANDAND EXPLOSIONEXPLOSIONEXPLOSION HAZARDHAZARDHAZARD

Flammable fumes, such as solvent and paint fumes, in workworkwork areaareaarea can ignite or explode. To helpprevent fire and explosion:

• Use equipment only in well ventilated area.• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, andplastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.• Do not plug or unplug power cords, or turn power or light switches on or off when flammablefumes are present.

• Ground all equipment in the work area. See GroundingGroundingGrounding instructions.• Use only grounded hoses.• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unlessthey are antistatic or conductive.

• StopStopStop operationoperationoperation immediatelyimmediatelyimmediately if static sparking occurs or you feel a shock... Do not useequipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

THERMALTHERMALTHERMAL EXPANSIONEXPANSIONEXPANSION HAZARDHAZARDHAZARD

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

• Open a valve to relieve the fluid expansion during heating.• Replace hoses proactively at regular intervals based on your operating conditions.

4 333024J

Warnings

WARNINGWARNINGWARNINGPRESSURIZEDPRESSURIZEDPRESSURIZED ALUMINUMALUMINUMALUMINUM PARTSPARTSPARTS HAZARDHAZARDHAZARD

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

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

• Many other fluids may contain chemicals that can react with aluminum. Contact your materialsupplier for compatibility.

PLASTICPLASTICPLASTIC PARTSPARTSPARTS CLEANINGCLEANINGCLEANING SOLVENTSOLVENTSOLVENT HAZARDHAZARDHAZARD

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

• Use only compatible water-based solvents to clean plastic structural or pressure-containingparts.

• See TechnicalTechnicalTechnical DataDataData in this and all other equipment instruction manuals. Read fluid andsolvent manufacturer’s MSDSs and recommendations.

EQUIPMENTEQUIPMENTEQUIPMENT MISUSEMISUSEMISUSE HAZARDHAZARDHAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.• Do not exceed the maximum working pressure or temperature rating of the lowest ratedsystem component. See TechnicalTechnicalTechnical DataDataData in all equipment manuals.

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

• Do not leave the work area while equipment is energized or under pressure.• Turn off all equipment and follow the PressurePressurePressure ReliefReliefRelief ProcedureProcedureProcedure when equipment is not in use.• Check equipment daily. Repair or replace worn or damaged parts immediately with genuinemanufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvalsand create safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.• Use equipment only for its intended purpose. Call your distributor for information.• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.• Do not kink or over bend hoses or use hoses to pull equipment.• Keep children and animals away from work area.• Comply with all applicable safety regulations.

MOVINGMOVINGMOVING PARTSPARTSPARTS HAZARDHAZARDHAZARD

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.• Pressurized equipment can start without warning. Before checking, moving, or servicingequipment, follow the PressurePressurePressure ReliefReliefRelief ProcedureProcedureProcedure and disconnect all power sources.

333024J 5

Warnings

WARNINGWARNINGWARNINGBURNBURNBURN HAZARDHAZARDHAZARD

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

• Do not touch hot fluid or equipment.

6 333024J

Important Isocyanate Information

ImportantImportantImportant IsocyanateIsocyanateIsocyanate InformationInformationInformationIsocyanates (ISO) are catalysts used in two component materials.

IsocyanateIsocyanateIsocyanate ConditionsConditionsConditions

Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, andatomized particulates.

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

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

• Use of incorrectly maintained or mis-adjusted equipment may result in improperly cured material, whichcould cause off gassing and offensive odors. Equipment must be carefully maintained and adjustedaccording to instructions in the manual.

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

• Avoid all skin contact with isocyanates. Everyone in the work area must wear chemically impermeablegloves, protective clothing and foot coverings as recommended by the fluid manufacturer and localregulatory authority. Follow all fluid manufacturer recommendations, including those regarding handlingof contaminated clothing. After spraying, wash hands and face before eating or drinking.

• Hazard from exposure to isocyanates continues after spraying. Anyone without appropriate personalprotective equipment must stay out of the work area during application and after application for the timeperiod specified by the fluid manufacturer. Generally this time period is at least 24 hours.

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

333024J 7

Important Isocyanate Information

MaterialMaterialMaterial SelfSelfSelf---IgnitionIgnitionIgnition

Some materials may become self-igniting if appliedtoo thick. Read material manufacturer’s warningsand SDS.

KeepKeepKeep ComponentsComponentsComponents AAA andandand BBB SeparateSeparateSeparate

Cross-contamination can result in curedmaterial in fluid lines which could cause seriousinjury or damage to equipment. To preventcross-contamination:

• NeverNeverNever interchange component A and componentB wetted parts.

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

ChangingChangingChanging MaterialsMaterialsMaterials

NOTICENOTICENOTICEChanging the material types used in yourequipment requires special attention to avoidequipment damage and downtime.

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

• Always clean the fluid inlet strainers afterflushing.

• Check with your material manufacturer forchemical compatibility.

• When changing between epoxies and urethanesor polyureas, disassemble and clean all fluidcomponents and change hoses. Epoxies oftenhave amines on the B (hardener) side. Polyureasoften have amines on the B (resin) side.

MoistureMoistureMoisture SensitivitySensitivitySensitivity ofofof IsocyanatesIsocyanatesIsocyanates

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

NOTICENOTICENOTICEPartially cured ISO will reduce performance andthe life of all wetted parts.

• Always use a sealed container with a desiccantdryer in the vent, or a nitrogen atmosphere.NeverNeverNever store ISO in an open container.

• Keep the ISO pump wet cup or reservoir (ifinstalled) filled with appropriate lubricant. Thelubricant creates a barrier between the ISO andthe atmosphere.

• Use only moisture-proof hoses compatible withISO.

• Never use reclaimed solvents, which maycontain moisture. Always keep solventcontainers closed when not in use.

• Always lubricate threaded parts with anappropriate lubricant when reassembling.

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

FoamFoamFoam ResinsResinsResins withwithwith 245245245 fafafa BlowingBlowingBlowingAgentsAgentsAgents

Some foam blowing agents will froth at temperaturesabove 90°F (33°C) when not under pressure,especially if agitated. To reduce frothing, minimizepreheating in a circulation system.

8 333024J

Models

ModelsModelsModels

ReactorReactorReactor 222 EEE---303030 andandand EEE---303030 EliteEliteElite

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

EEE---303030 ModelModelModel EEE---303030 EliteEliteElite ModelModelModelModelModelModel

101010 kWkWkW 151515 kWkWkW 101010 kWkWkW 15kW15kW15kW

ProportionerProportionerProportioner ★ 272010 272011 272110 272111

MaximumMaximumMaximum FluidFluidFluid WorkingWorkingWorkingPressurePressurePressure psipsipsi (MPa,(MPa,(MPa, bar)bar)bar)

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

ApproximateApproximateApproximate OutputOutputOutput perperper CycleCycleCycle(A+B)(A+B)(A+B) gal.gal.gal. (liter)(liter)(liter)

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

MaxMaxMax FlowFlowFlow RateRateRate lb/minlb/minlb/min (kg/min)(kg/min)(kg/min) 30 (13.5) 30 (13.5) 30 (13.5) 30 (13.5)

TotalTotalTotal SystemSystemSystem LoadLoadLoad ††† � (Watts)(Watts)(Watts) 17,900 23,000 17,900 23,000

ConfigurableConfigurableConfigurable VoltageVoltageVoltage PhasePhasePhase� 200–240VAC1Ø

200–240VAC3Ø∆

350–415VAC3ØY

200–240VAC1Ø

200–240VAC3Ø∆

350–415VAC3ØY

200–240VAC1Ø

200–240VAC3Ø∆

350–415VAC3ØY

200–240VAC1Ø

200–240VAC3Ø∆

350–415VAC3ØY

FullFullFull LoadLoadLoad PeakPeakPeak Current*Current*Current* 78 50 34 100 62 35 78 50 34 100 62 35

FusionFusionFusion APAPAP PackagePackagePackage �(Gun Part No.)

AP2010(246102)

AH2010(246102)

AP2011(246102)

AH2011(246102)

AP2110(246102)

AH2110(246102)

AP2111(246102)

AH2111(246102)

FusionFusionFusion CSCSCS PackagePackagePackage �(Gun Part No.)

CS2010(CS02RD)

CH2010(CS02RD)

CS2011(CS02RD)

CH2011(CS02RD)

CS2110(CS02RD)

CH2110(CS02RD)

CS2111(CS02RD)

CH2111(CS02RD)

ProblerProblerProbler P2P2P2 PackagePackagePackage �(Gun Part No.)

P22010(GCP2R2)

PH2010(GCP2R2)

P22011(GCP2R2)

PH2011(GCP2R2)

P22110(GCP2R2)

PH2110(GCP2R2)

P22111(GCP2R2)

PH2111(GCP2R2)

24K240 24K240 24K240 24K240 24Y240 24Y240 24Y240 24Y240HeatedHeatedHeated HoseHoseHose505050 ftftft (15(15(15 m)m)m)24K240 (scuff guard)24Y240 (Xtreme-Wrap)

Qty:Qty:Qty: 1 Qty:Qty:Qty: 5 Qty:Qty:Qty: 1 Qty:Qty:Qty: 5 Qty:Qty:Qty: 1 Qty:Qty:Qty: 5 Qty:Qty:Qty: 1 Qty:Qty:Qty: 5

HeatedHeatedHeated WhipWhipWhip HoseHoseHose101010 ftftft (3(3(3 m)m)m)

246050 246050 246050 246050

GracoGracoGraco InsiteInsiteInsite™™™ ✓ ✓FluidFluidFluid InletInletInlet SensorsSensorsSensors (2)(2)(2) ✓ ✓

* Full load amps with all devices operating atmaximum capabilities. Fuse requirements atvarious flow rates and mix chamber sizesmay be less.

� Total system watts used by system, based onmaximum heated hose length for each unit.

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

★ See Approvals, page 11.

� Packages include gun, heated hose, andwhip hose. Elite packages also include GracoInSite and fluid inlet sensors.

� Low line input voltage will reduce poweravailable and heaters will not perform at fullcapacity.

VoltageVoltageVoltage ConfigurationsConfigurationsConfigurations KeyKeyKeyØ Phase∆ DELTAY WYE

333024J 9

Models

ReactorReactorReactor 222 EEE---XP2XP2XP2 andandand EEE---XP2XP2XP2 EliteEliteElite

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

E–XP2E–XP2E–XP2 ModelModelModel E–XP2E–XP2E–XP2 EliteEliteElite ModelModelModelModelModelModel

151515 kWkWkW 151515 kWkWkW

ProportionerProportionerProportioner ★ 272012 272112

MaximumMaximumMaximum FluidFluidFluid WorkingWorkingWorkingPressurePressurePressure psipsipsi (MPa,(MPa,(MPa, bar)bar)bar)

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

ApproximateApproximateApproximate OutputOutputOutput perperper CycleCycleCycle(A+B)(A+B)(A+B) gal.gal.gal. (liter)(liter)(liter)

0.0203 (0.0771) 0.0203 (0.0771)

MaxMaxMax FlowFlowFlow RateRateRate gpm/mingpm/mingpm/min (l/min)(l/min)(l/min) 2 (7.6) 2 (7.6)

TotalTotalTotal SystemSystemSystem LoadLoadLoad ††† � (Watts)(Watts)(Watts) 23,000 23,000

ConfigurableConfigurableConfigurable VoltageVoltageVoltage PhasePhasePhase � 200–240 VAC1Ø

200–240 VAC3Ø∆

350–415 VAC3ØY

200–240 VAC1Ø

200–240 VAC3Ø∆

350–415 VAC3ØY

FullFullFull LoadLoadLoad PeakPeakPeak CurrentCurrentCurrent(amps)(amps)(amps)*

100 62 35 100 62 35

FusionFusionFusion APAPAP PackagePackagePackage �(Gun Part No.)

AP2012(246100)

AP2112(246100)

ProblerProblerProbler P2P2P2 PackagePackagePackage �(Gun Part No.)

P22012(GCP2R0)

P22112(GCP2R0)

HeatedHeatedHeated HoseHoseHose505050 ftftft (15(15(15 m)m)m)

24K241(scuff guard)

24Y241(Xtreme-Wrap)

HeatedHeatedHeated WhipWhipWhip HoseHoseHose101010 ftftft (3(3(3 m)m)m)

246055 246055

GracoGracoGraco InSiteInSiteInSite™™™ ✓

FluidFluidFluid InletInletInlet SensorsSensorsSensors (2)(2)(2) ✓

* Full load amps with all devices operating atmaximum capabilities. Fuse requirementsat various flow rates and mix chamber sizesmay be less.

� Total system watts used by system, based onmaximum heated hose length for each unit.

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

★ See Approvals, page 11.

� Packages include gun, heated hose, andwhip hose. Elite packages also includeGraco InSite and fluid inlet sensors.

� Low line input voltage will reduce poweravailable and heaters will not perform at fullcapacity.

VoltageVoltageVoltage ConfigurationsConfigurationsConfigurations KeyKeyKeyØ Phase∆ DELTAY WYE

10 333024J

Approvals

ApprovalsApprovalsApprovalsIntertek approvals apply to proportioners withouthoses.

ProportionerProportionerProportioner Approvals:Approvals:Approvals:

990247199024719902471

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

AccessoriesAccessoriesAccessoriesKitKitKit NumberNumberNumber DescriptionDescriptionDescription

24U315 Air Manifold Kit (4 outlets)

24U314 Wheel and Handle Kit

24T280 Graco InSite Kit

16X521 Graco InSite Extension cable 24.6 ft(7.5 m)

24N449 50 ft (15 m) CAN cable (for remotedisplay module)

24K207 Fluid Temperature Sensor (FTS)with RTD

24U174 Remote Display Module Kit

24K337 Light Tower Kit

15V551 ADM Protective Covers (10 pack)

15M483 Remote Display Module ProtectiveCovers (10 pack)

24M174 Drum Level Sticks

121006 150 ft (45 m) CAN cable (for remotedisplay module)

24N365 RTD Test Cables (to aide resistancemeasurements)

333024J 11

Supplied Manuals

SuppliedSuppliedSupplied ManualsManualsManualsThe following manuals are shipped with the Reactor2. Refer to these manuals for detailed equipmentinformation.

Manuals are also available at www.graco.com.ManualManualManual DescriptionDescriptionDescription333023 Reactor 2 E-30 and E-XP2

Operation333091 Reactor 2 E-30 and E-XP2 Startup

Quick Guide333092 Reactor 2 E-30 and E-XP2

Shutdown Quick Guide

RelatedRelatedRelated ManualsManualsManualsThe following manuals are for accessories used withthe Reactor.

ComponentComponentComponent ManualsManualsManuals ininin English:English:English:

Manuals are available at www.graco.com.SystemSystemSystem ManualsManualsManuals333023 Reactor 2 E-30 and E-XP2 OperationDisplacementDisplacementDisplacement PumpPumpPump ManualManualManual309577 Electric Reactor Displacement Pump,

Repair-PartsFeedFeedFeed SystemSystemSystem ManualsManualsManuals309572 Heated Hose, Instructions-Parts309852 Circulation and Return Tube Kit,

Instructions-Parts309815 Feed Pump Kits, Instructions-Parts309827 Feed Pump Air Supply Kit,

Instructions-PartsSpraySpraySpray GunGunGun ManualsManualsManuals309550 Fusion ™ AP Gun312666 Fusion ™ CS Gun313213 Probler® P2 GunAccessoryAccessoryAccessory ManualsManualsManuals3A1905 Feed Pump Shutdown Kit,

Instructions-Parts3A1906 Light Tower Kit, Instructions-Parts3A1907 Remote Display Module Kit,

Instructions-Parts332735 Air Manifold Kit, Instructions-Parts332736 Handle and Wheel Kit,

Instructions-Parts333276 Graco InSite ™ Kit, Instructions-Parts

12 333024J

Troubleshooting

TroubleshootingTroubleshootingTroubleshooting

TroubleshootTroubleshootTroubleshoot ErrorsErrorsErrors

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

ErrorErrorError DescriptionDescriptionDescription

AlarmsAlarmsAlarms A parameter critical tothe process has reacheda level requiring thesystem to stop. Thealarm needs to beaddressed immediately.

DeviationsDeviationsDeviations A parameter criticalto the process hasreached a level requiringattention, but notsufficient enough tostop the system at thistime.

AdvisoriesAdvisoriesAdvisories A parameter that isnot immediately criticalto the process. Theadvisory needs attentionto prevent more seriousissues in the future.

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

To troubleshoot the error:

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

Note

Press or to return to thepreviously displayed screen.

2. The QR code screen will be displayed. Scanthe QR code with your smartphone to be sentdirectly to online troubleshooting for the activeerror code. Otherwise, manually navigate tohttp://help.graco.com and search for the activeerror.

3. If no internet connection is available, seeError Codes, page 13 for causes and solutionsfor each error code.

ErrorErrorError CodesCodesCodesNote

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

333024J 13

Troubleshooting

ErrorErrorError LocationLocationLocation TypeTypeType DescriptionDescriptionDescription CauseCauseCause SolutionSolutionSolution

Loose/brokenconnection.

Check for loose wireterminations at MCM motorconnector.

A1NM MCM Low Motor Current

Bad Motor. Disconnect motor outputconnector from MCM.Confirm less than 8 ohmsresistance between eachpair of motor power leads(M1 to M2, M1 to M3, M2 toM3). If any readings greaterthan 8 ohms, check motorwiring for damage and/orloose terminations.

Short circuit inheater wiring.

Check wiring for touchingwires.

A4DA Heater A High Current A

Bad Heater. Confirm resistance ofheater. Heater resistanceshould be 18–21 Ω foreach heater element, 9–12Ω combined for 10 kWsystems, and 6-8 Ω for15 kW systems. If out oftolerance, replace heaterelement.

Short circuit inheater wiring.

Check wiring for touchingwires.

A4DB Heater B High Current B

Bad Heater. Confirm resistance ofheater. Heater resistanceshould be 9-12 Ω for 10kW systems and 6-8 Ω for15 kW systems. If out oftolerance, replace heater.

Check continuity oftransformer windings.Normal readings are about0.2Ω on both primary andsecondary. If reading is 0Ωreplace transformer.

A4DH Hose High Current Hose Short circuit inhose wiring.

Check for shorts betweenthe primary winding and thesupport frame or enclosure.

14 333024J

Troubleshooting


Short circuit ofmotor wiring.

Check wiring to the motorto ensure no bare wires aretouching and that no wiresare shorted to ground.

Motor will notrotate.

Remove pump gearhousings from motorand check that motor shaftrotates freely in directionindicated on motor housing.

Damaged geartrain.

Check pump gear trainsfor damage and repair orreplace as necessary.

A4NM MCM High Motor Current

Chemical pump isstuck.

Repair or replace chemicalpump.

A7DA Heater A Unexpected CurrentA

Shorted TCM If error cannot be clearedor regenerates consistently,replace module.

A7DB Heater B Unexpected CurrentB


A7DH Hose Unexpected CurrentHose


333024J 15

Troubleshooting


Tripped circuitbreaker.

Visually check circuitbreaker for a trippedcondition.

A8DA Heater A No Current A


Check heater wiring forloose wires.



A8DB Heater B No Current B





A8DH Hose No Current Hose



Module does nothave software.

Insert a system token intothe ADM module and cyclethe power. Wait until theupload is complete beforeremoving the token.

Dial set to wrongposition.

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

No 24 VDC supplyto module.

Green light on each moduleshould be lit. If green light isnot lit, check to make sureeach CAN cable connectionis tight. Verify the powersupply is outputting 24VDC. If not, check powersupply wiring. If wiring isokay, replace the powersupply.

CACM MCM MCM Communica-tion Error

Loose or brokenCAN cable.

Check the CAN cablesrunning between GCAmodules and tighten ofneeded. If the problemstill persists move eachcable around the connectorand watch the flashingyellow light on the GCAmodules. If the yellow lightstops flashing, replace theCAN cable.

16 333024J

Troubleshooting


Module does nothave software.


No 24 VDC supplyto module.

Green light on each moduleshould be lit. If green light isnot lit, check to make sureeach CAN cable connectionis tight. Verify the powersupply is outputting 24VDC. If not, check powersupply wiring. If wiring isokay, replace the powersupply.

CACT TCM TCM CommunicationError

Loose or brokenCAN cable.

Check the CAN cablesrunning between GCAmodules and tighten ofneeded. If the problemstill persists move eachcable around the connectorand watch the flashingyellow light on the GCAmodules. If the yellow lightstops flashing, replace theCAN cable.

Mix chamber too large forsystem selected. Use mixchamber rated for system.

Ensure the system haschemical and the feedpumps are operatingcorrectly.

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

DADX MCM Pump Runaway Flow rate is toolarge.

Inlet ball valves are closed.Open ball valves.

333024J 17

Troubleshooting


Faulty or missingcycle switch.

Check wiring between cycleswitch and MCM, Port 12.

Switchdisconnected

Measure resistancebetween pin 3 and 4at connector. Normalresistance is 0.10 ohms.

DE0X MCM Cycle Switch Error

Missing or out ofplace cycle switchmagnet.

Check presence andposition of cycle switchmagnet on output crankarm.

18 333024J

Troubleshooting


EVCH ADM Manual Hose ModeEnabled

Manual hose modehas been enabledin System Setupscreen.

Install a functioning fluidtemperature sensor (FTS)on the hose. Manual hosemode will automatically turnoff.

EAUX ADM USB Busy USB drive hasbeen inserted tothe ADM.

Do not remove USB driveuntil download/upload iscomplete.

EVUX ADM USB disabled USBdownload/uploadsare disabled.

Enable USB download/up-loads on the AdvancedSetup screen before insert-ing a USB drive.

F9DX MCM High Pressure/FlowCutback

Mix chamber istoo large for setpressure.

Reference the pressureflow curves and select a tipsize that is the correct sizefor the set pressure.

H2MA Heater A Low Frequency A Line frequency isbelow 45 Hz

Ensure line frequency ofincoming power is between45 and 65 Hz.

H2MB Heater B Low Frequency B Line frequency isbelow 45 Hz


H2MH Hose Low Frequency Hose Line frequency isbelow 45 Hz


H3MA Heater A High Frequency A Line frequency isabove 65 Hz


H3MB Heater B High Frequency B Line frequency isabove 65 Hz


H3MH Hose High FrequencyHose

Line frequency isabove 65 Hz


Motor will notrotate.

Remove pump gearhousings from motorand check that motor shaftrotates freely in directionindicated on motor housing.

Damaged geartrain.

Check motor/pump geartrains for damage and repairor replace as necessary.

K8NM MCM Locked Rotor Motor

Chemical pump isstuck.

Repair or replace chemicalpump.

333024J 19

Troubleshooting


L1AX ADM Low Chemical LevelA

Low material level. Refill material and updatedrum level on ADMMaintenance screen.

Alarm can be disabled onthe System Setup screen.

L1BX ADM Low Chemical LevelB

Low material level. Refill material and updatedrum level on ADMMaintenance screen.

Alarm can be disabled onthe System Setup screen.

MMUX USB Maintenance Due -USB

USB logs havereached a levelwhere data losswill occur if logs arenot downloaded.

Insert a USB drive into theADM and download all logs.

Pressuredifference betweenA and B materialis greater than thedefined value.

Ensure material flow isequally restricted on bothmaterial lines.

Pressureimbalance isdefined too low.

Ensure that the pressureimbalance value, on theSystem Setup screen, is atan acceptable maximumpressure to preventunnecessary alarms andabort dispenses.

Out of material. Fill tanks with material

Fluid leaking fromheater inlet rupturedisk.

Check if heaterand PRESSURERELIEF/SPRAY valve areplugged. Clear. Replacerupture disk. Do not replacewith a pipe plug.

P0AX MCM Pressure ImbalanceA High

Feed systemdefective.

Check feed pump andhoses for blockage. Checkthat feed pumps havecorrect air pressure.

20 333024J

Troubleshooting









P0BX MCM Pressure ImbalanceB High



Inlet pressurelower than definedvalue.

Ensure that inlet pressureto the pump is sufficient.

P1FA MCM Low Inlet Pressure A

Value defined toohigh.

Ensure that the lowpressure alarm leveldefined on the SystemSetup screen is acceptable.



P1FB MCM Low Inlet Pressure B





P2FA MCM Low Inlet Pressure A



333024J 21

Troubleshooting




P2FB MCM Low Inlet Pressure B



Systempressurized beforeallowing heat toreach setpoint.

Pressure in the hose andpumps will increase as thesystem heats up. Turn onheat and allow all zonesto reach the temperaturesetpoint before turning onthe pumps.

Bad pressuretransducer.

Verify the ADM pressurereading and the analoggauges at the manifold.

P4AX MCM High Pressure A

E-XP2 systemconfigured as E-30.

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

Systempressurized beforeallowing heat toreach setpoint.

Pressure in the hose andpumps will increase as thesystem heats up. Turn onheat and allow all zonesto reach the temperaturesetpoint before turning onthe pumps.

Bad pressuretransducer.

Verify the ADM pressurereading and the analogguages at the manifold.

P4BX MCM High Pressure B

E-XP2 systemconfigured as E-30.

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

22 333024J

Troubleshooting


Loose/badconnection.

Check to ensure thepressure transducer isproperly installed andall wires are properlyconnected.

P6AX MCM Pressure SensorError A

Bad sensor. Check if the error followsthe transducer. Disconnecttransducer cables fromthe MCM (connectors 6and 7). Reverse A and Bconnections and check ifthe errors follows. If theerror follows the transducer,replace the pressuretransducer.


Check to ensure thepressure transducer isproperly installed andall wires are properlyconnected.

P6BX MCM Pressure SensorError B

Bad sensor. Check if the error followsthe transducer. Disconnecttransducer cables fromthe MCM (connectors 6and 7). Reverse A and Bconnections and check ifthe errors follows. If theerror follows the transducer,replace the pressuretransducer.

Inlet sensors notinstalled.

If inlet sensors are notinstalled, inlet sensorsshould be disabled on theSystem Setup screen.


Check to ensure inletsensor is properly installedand all wires are properlyconnected.

P6FA MCM Pressure SensorError Inlet A

Bad sensor. Check if the error followsthe inlet sensor. Disconnectinlet sensor cables fromthe MCM (connectors 8and 9). Reverse A and Bconnections and check ifthe errors follows. If theerror follows the sensor,replace the inlet sensor.

333024J 23

Troubleshooting


Inlet sensors notinstalled.

If inlet sensors are notinstalled, inlet sensorsshould be disabled on theSystem Setup screen.


Check to ensure inletsensor is properly installedand all wires are properlyconnected.

P6FB MCM Pressure SensorError Inlet B

Bad sensor. Check if the error followsthe inlet sensor. Disconnectinlet sensor cables fromthe MCM (connectors 8and 9). Reverse A and Bconnections and check ifthe errors follows. If theerror follows the sensor,replace the inlet sensor.








P7AX MCM Pressure ImbalanceA High



24 333024J

Troubleshooting









P7BX MCM Pressure ImbalanceB High



Flow is too high atcurrent setpoint.

Use a smaller mix chamberthat is rated for the unitin use. If recirculating,decrease flow or decreasetemperature setpoint.

Bad RTD or badRTD placementagainst heater.

Swap A and B heater outputcables and RTD cables andsee if issue follows. If so,replace RTD.

T2DA Heater A Low Temperature A

Bad heater rod orloose heater wire.

Confirm resistance ofheater. Heater resistanceshould be 9-12 Ω for 10kW systems and 6-8 Ωfor 15 kW systems. If outof tolerance, check forloose heater rod wire(s).Reconnect wires or replaceheater rod if necessary.

333024J 25

Troubleshooting






T2DB Heater B Low Temperature B





T2DH Hose Low TemperatureHose

Cold chemical inunheated portionof system passedhose FTS atstartup.

Recirculate heatedchemical back to drumin cold conditions beforestartup.

Recirculate fluid throughheaters until inlet fluidtemperature is abovedefined error level.

T2FA MCM Low TemperatureInlet A

Inlet fluidtemperature isbelow the definedlevel.

Increase the lowtemperature deviationlevel on the System Setupscreen.

Recirculate fluid throughheaters until inlet fluidtemperature is abovedefined error level.

T2FB MCM Low TemperatureInlet B

Inlet fluidtemperature isbelow the definedlevel.

Increase the lowtemperature deviationlevel on the System Setupscreen.

26 333024J

Troubleshooting


Hose setpoint higher than Aand B setpoints. Decreasehose setpoint.

T3CH Hose Hose Cutback Hose current hasbeen reducedbecause hosehas been drawingcurrent for anextended period.

Hose FTS is in a colderenvironment than the restof the hose. Expose FTS tothe same environment asthe rest of the hose.

High ambienttemperature.

Ensure ambienttemperature is below120°F(48°C) before usingthe system.

Enclosure fan notoperating.

Ensure fan in electricalenclosure is spinning. If itis not, check fan wiring orreplace fan.

T3CT TCM TCM Cutback

Module fan notoperating.

If a TCM fan error (WMI0)has occurred, fan insidethe module is not workingproperly. Check TCM fanfor debris and clear withforced air if necessary.

Motor is operatingoutside of thepressure flowcurve.

The system is running at alower setpoint to preservemotor life. Run the systemat a lower duty cycle or witha smaller mix chamber.

T3NM MCM Motor TemperatureCutback

High ambienttemperature

Ensure ambienttemperature is below120° F (48° C) before usingthe system.

T3CM MCM MCM TemperatureCutback

Motor controltemperature istoo high.

Ensure ambienttemperature is below120°F(48°C).

Verify that all fans areworking.



T4CM MCM High TemperatureMCM



333024J 27

Troubleshooting






T4CT TCM High TemperatureTCM

Module fan notoperating.

If a TCM fan error (WMI0)has occurred, fan insidethe module is not workingproperly. Check TCM fanfor debris and clear withforced air if necessary.



T4DA Heater A High Temperature A

Flow too highfor temperaturesetpoint, causingtemperatureovershoots whengun is de-triggered.

Use a smaller mix chamberthat is rated for the unit inuse.



T4DB Heater B High Temperature B

Flow too highfor temperaturesetpoint, causingtemperatureovershoots whengun is de-triggered.

Use a smaller mix chamberthat is rated for the unit inuse.

28 333024J

Troubleshooting


Hose portionexposed to anexcessive heatsource, like hotsun or coiledhose, can passfluid more than27°F (15°C) overhose temperaturesetting to the FTS.

Shade exposed hose fromhot sun or expose FTS tosame environment whenat rest. Uncoil entire hosebefore heating to avoidself-heating.

T4DH Hose High TemperatureHose

Setting the A orB setpoint muchhigher than hosesetpoint can causefluid more than27°F (15°C) overhose temperaturesetting to reach theFTS.

Increase hose setpointso it is closer to A and Bsetpoints.

Overtemperatureswitch sensed afluid temperatureabove 230°F(110°C).

Heater was delivered toomuch power, causing theovertemperature switch toopen. RTD is not readingproperly. After the heatercools down, replace RTD.Switch closes and the errorcan be cleared when theheater temperature fallsbelow 190°F (87°C).

Disconnectedor looseovertemperatureswitchcable/connection.

If heater is not actuallyover temperature, checkall wiring and connectionsbetween the TCM and theovertemperature switches.

T4EA Heater A High TemperatureSwitch A

Overtemperatureswitch failed in theopen position.

Replace overtemperatureswitch.

333024J 29

Troubleshooting


Overtemperatureswitch sensed afluid temperatureabove 230°F(110°C).

Heater was delivered toomuch power, causing theovertemperature switch toopen. RTD is not readingproperly. After the heatercools down, replace RTD.Switch closes and the errorcan be cleared when theheater temperature fallsbelow 190°F (87°C).

Disconnectedor looseovertemperatureswitchcable/connection.

If heater is not actuallyover temperature, checkall wiring and connectionsbetween the TCM and theovertemperature switches.

T4EB Heater B High TemperatureSwitch B

Overtemperatureswitch failed in theopen position.

Replace overtemperatureswitch.

Cooling fan is notoperating properly.

Check to see that the motorfan is moving. Measurevoltage to fan. There shouldbe 24 VDC.If no voltage is measured,check fan wiring. If thefan has voltage but is notmoving, replace fan.If necessary use an air hoseto blow out around the fanhousings and remove anybuilt-up debris.



Motor is operatingoutside of thepressure flow curve

Run the system at a lowerduty cycle or with a smallermix chamber.

T4NM MCM High TemperatureMotor

Motor temperaturesensor wires areshorted together

Measure resistancebetween pins 2 and 4on motor temperature cableconnector at MCM, port2. A reading below 75ohms indicates a wire short.Replace motor.

30 333024J

Troubleshooting


Disconnected orloose RTD cable orconnection.

Check all wiring andconnection to RTD.

T6DA Heater A Sensor Error A

Bad RTD. Switch the RTD withanother and see if the errormessage follows the RTD.Replace RTD if the errorfollows the RTD.

333024J 31

Troubleshooting


Disconnected orloose RTD cable orconnection.

Check all wiring andconnection to RTD.

T6DB Heater B Sensor Error B

Bad RTD. Switch the RTD withanother and see if the errormessage follows the RTD.Replace RTD if the errorfollows the RTD.

T6DH Hose Sensor Error Hose Disconnected orshorted RTD cablein hose or bad FTS.

Expose each hose RTDconnection to check andretighten any loose con-nector. Measure hose RTDcable and FTS continuity.See Repair Heated Hose,page 66. Order RTD Testkit 24N365 for measure-ment.

Disconnect hose RTD anduse manual hose mode tofinish job until repair can becompleted.

Shorted RTD cablein hose or FTS.

Expose each hose RTDconnection to check forexposed and shorted RTDwires. Measure hose RTDcable and FTS continuity.See Repair Heated Hose,page 66. Order RTD Testkit 24N365 for measure-ment.

Disconnect hose RTD anduse manual hose mode tofinish job until repair can becompleted.

T6DT TCM Sensor Error TCM

Shorted A or BHeater RTD

If the error still occurs withthe hose FTS unplugged,one of the heater RTDsis bad. Unplug the A orB RTD from the TCM. Ifunplugging an RTD fixesthe T6DT error, replace theRTD.

32 333024J

Troubleshooting


T6NM MCM Sensor Error Motor Disconnectedor loose motortemperature cableconnector

Verify proper cableconnection at MCM, port2. Measure resistancebetween pins 2 and 4 onmotor temperature cableconnector. A correct ohmreading will vary greatlywith temperature. An opencircuit reading indicates awire break. Replace motor.

333024J 33

Troubleshooting






T8DA Heater A No TemperatureRise A

Started sprayingbefore heaterreached operatingtemperature.

Wait until operatingtemperature has beenreached before spraying orrecirculating.





T8DB Heater B No TemperatureRise B



T8DH Hose No TemperatureRise Hose



Loose/badconnection ortripped circuitbreaker.

Check wiring for looseconnection or tripped circuitbreaker.

V1CM MCM Low Voltage MCM

Low incoming linevoltage.

Measure voltage at circuitbreaker and ensure voltageis greater than 195 VAC.

34 333024J

Troubleshooting


V1IT TCM Low Voltage CAN Bad 24 VDC powersupply.

Check voltage of powersupply. Voltage shouldbe 23-25 VDC. If out oftolerance, replace powersupply.

V2IT TCM Low Voltage CAN Bad 24 VDC powersupply.


Loose connectionor tripped circuitbreaker.


V2MA TCM Low Voltage A





V2MB TCM Low Voltage B





V2MH TCM Low Voltage Hose



V3IT TCM High Voltage CAN Bad 24 VDC powersupply.


V3MA TCM High Voltage A Incoming linevoltage is too high.

Ensure incoming systempower is wired properly.Verify voltage at each circuitbreaker is between 195 and264 VAC.

333024J 35

Troubleshooting


V3MB TCM High Voltage B Incoming linevoltage is too high.


V3MH TCM High Voltage Hose Incoming linevoltage is too high.


V4CM MCM High Voltage MCM Incoming linevoltage is too high.


V4IT TCM High Voltage CAN Bad 24 VDC powersupply.


V4MA TCM High Voltage A Incoming linevoltage is too high.


V4MB TCM High Voltage B Incoming linevoltage is too high.


V4MH TCM High Voltage Hose Incoming linevoltage is too high.


36 333024J

Troubleshooting


Incorrect softwareversion.


WBC0 MCM Software VersionError

MCM does nothave line voltage.

If V1CM also exists, seetroubleshooting for V1CM.The software versioncannot be read if the MCMdoes not have line voltage.

WMI0 TCM TCM Fan Error Fan inside TCMis not operatingproperly.

Check for debris in the TCMfan and clear with forced airif necessary.

WSUX USB Configuration ErrorUSB

A validconfiguration filecan't be found forthe USB.

Inset a system token intothe ADM and cycle power.Wait until the lights on theUSB port stop flashingbefore removing token.

WXUD ADM USB Download Error Log downloadfailed.

Backup and reformat theUSB drive. Retry download.

WXUU ADM USB Upload Error Custom languagefile failed to upload.

Perform normal USBdownload and use the newdisptext.txt file to upload thecustom language.

333024J 37

Troubleshooting

SystemSystemSystem

Before performing any troubleshooting procedures:

1. Relieve Pressure. See Pressure Relief Procedure, page 46.

2. Turn main power switch OFF.

3. Allow equipment to cool.

ProblemProblemProblem CauseCauseCause SolutionSolutionSolutionNo power. Turn main power switch ON.Failed 24 V power supply. Replace power supply.

Reactor ADM does not turn on.

Failed surge protector. Replace surge protector.Loose connections. Check MCM connection 13.Tripped circuit breaker (CB02). Reset breaker, see Repair Circuit

Breaker Module, page 58. Check240VAC at output of breaker.

Electric motor does not operate.

Shorted windings. Replace motor, seeRepair Electric Motor, page 57.

Electric motor runs erratically. Failed motor bearing. Replace motor, seeRepair Electric Motor, page 57.

38 333024J

Troubleshooting

ProblemProblemProblem CauseCauseCause SolutionSolutionSolutionLoose wire. Check. See

Electrical Schematics, page 93.Fan blade obstructed. Remove obstruction.

Cooling fans not working.

Defective fan. Replace. SeeReplace Motor Fan, page 60.

Obstructed fluid hose or gun; fluidhose ID too small.

Open, clear; use hose with largerID.

Worn piston valve or intake valvein displacement pump.

See pump manual.

Pump output low.

Pressure setpoint too high. Reduce setpoint and output willincrease.

Fluid leak in pump packing nutarea.

Worn throat seals. Replace. See pump manual.

No pressure on one side. Fluid leaking from heater inletrupture disk (372).

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

333024J 39

Troubleshooting

HoseHoseHose HeatHeatHeat SystemSystemSystem





ProblemProblemProblem CauseCauseCause SolutionSolutionSolution

Ambient temperature is too cold. Relocate hoses to a warmer areaor recirculate heated fluid throughthe hose.

FTS failed or not installed correctly. Check FTS, see Check RTDCables and FTS, page 67.

Hose heats but heats slowerthan usual or it does not reachtemperature.

Low supply voltage. Verify line voltage. Low linevoltage significantly reducespower available to the hose heatsystem, affecting longer hoselengths.

A and B setpoints too low. Increase A and B setpoints.Hose is designed to maintaintemperature, not to increase it.

Ambient temperature is too cold. Increase A and B setpoints toincrease fluid temperature andkeep it steady.

Flow too high. Use smaller mix chamber.Decrease pressure.

Hose was not fully preheated. Wait for hose to heat to correcttemperature before spraying.

Hose does not maintaintemperature while spraying.

Low supply voltage. Verify line voltage. Low linevoltage significantly reducespower available to the hose heatsystem, affecting longer hoselengths.

40 333024J

Troubleshooting


A and/or B heaters are overheatingmaterial.

Check primary heaters for eithera RTD problem or a failedelement attached to RTD, seeElectrical Schematics, page 93.

Faulty FTS connections. Verify that all FTS connections aresnug and that pins of connectorsare clean. Unplug and re-plugRTD wires, cleaning off any debris.

Ambient temperature is too high. Cover hoses or move to a locationwith a lower ambient temperature.

Hose temperature exceedssetpoint.

Missing or damaged insulationaround FTS, causing the hoseheat to be ON constantly.

Make sure the hose bundlehas adequate insulation evenlycovering the entire length andconnection joints.

333024J 41

Troubleshooting


Faulty FTS connections. Verify that all FTS connections aresnug and that pins of connectorsare clean. Unplug and re-plugFTS wires along length of hose,cleaning off any debris.

FTS not installed correctly. FTS should be installed close toend of hose in same environmentas gun. Verify FTS installation,see Repair Fluid TemperatureSensor (FTS), page 68.

Erratic hose temperature.

Missing or damaged insulationaround FTS, causing the hoseheat to be ON constantly.

Make sure the hose bundlehas adequate insulation evenlycovering the entire length andconnection joints.

FTS failed. Check FTS, see Repair FluidTemperature Sensor (FTS), page68.

FTS not installed correctly. FTS should be installed close toend of hose in same environmentas gun. Verify FTS installation,see Repair Fluid TemperatureSensor (FTS), page 68.

Loose hose electrical connections. Check connections. Repair asnecessary.

Circuit breakers tripped. Reset breakers (CB01 ), seeRepair Circuit Breaker Module,page 58.

Hose zone not turned on. Turn on hose heat zone.

Hose does not heat.

A and B temperature setpoints toolow.

Check. Increase if necessary.

42 333024J

Troubleshooting


Hoses near Reactor are warm, buthoses downstream are cold.

Shorted connection or failed hoseheating element.

With power off, check the hoseresistance with and without thewhip hose attached. With thewhip hose attached, the readingshould be less than 3 ohm. With-out the whip hose attached, thereading should be OL (open loop).See Check Hose Heat PowerConnectors, page 66.

A and B temperature setpoints toolow.

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

Hose temperature setpoint toolow.

Check. Increase if necessary tomaintain heat.

Flow too high. Use smaller mix chamber.Decrease pressure.

Low current; FTS not installed. Install FTS, see operation manual.

Hose heat zone not turned on longenough to reach setpoint.

Allow hose to heat up, or preheatfluid.

Loose hose electrical connections. Check connections. Repair asnecessary.

Low hose heat.

Ambient temperature is to low Relocate hoses to a warmer areaor increase A and B setpoints.

333024J 43

Troubleshooting

PrimaryPrimaryPrimary HeaterHeaterHeater





ProblemsProblemsProblems

Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Also,determine that all circuit breakers, switches, and controls are properly set and wiring is correct beforeassuming there is a problem.


Heat turned off. Turn on heat zones.

Temperature control alarm. Check ADM for error codes.

Primary Heater(s) does not heat.

Signal failure from RTD. Signal failure from RTD.

Dirty RTD connections. Examine RTD cables connectedto TCMs. Confirm RTDs arenot plugged into opposite heatzone. Unplug and re-plug RTDconnectors. Unplug and re-plugRTD connectors. Ensure RTD tipcontacts the heater element.

RTD not contacting heaterelement.

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

Failed heater element. SeeReplace Heater Element, page 62.

Control of primary heat isabnormal; high temperatureovershoots (T4DA, T4DB) occursintermittently.

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

44 333024J

Troubleshooting

GracoGracoGraco InSiteInSiteInSiteProblemProblemProblem CauseCauseCause SolutionSolutionSolution

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

No module status LEDs areilluminated.

No power to cellular module.

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

Still identifying location. Wait a few minutes for the unit toidentify the location.Move system to a location with aclear view of the sky.

Has not identified GPS location(green module status LEDflashing). Unable to identify location. In a

location where GPS lock cannotoccur. Buildings and warehousesoften prevent GPS locks.

Use extension cable 16X521 andmove cellular module to a locationwith a clear view of the sky.

Still establishing cellularconnection.

Wait a few minutes for the unit toestablish the connection.Move system to a location withcellular service to establish cellularconnection.

Has not established cellularconnection (orange module statusLED flashing). Unable to establish cellular

connection.

Use extension cable 16X521 andmove cellular module to a locationwith a clear view of the sky.

Cannot view data for my unit(s) onwebsite.

Graco InSite unit has not beenactivated.

Activate unit. See Registeringand Activating the Graco InSitesection.

Temperature data not displayedon website.

Reactor temperaturemeasurement is not working.

See System troubleshootingsection.

Hose zone temperature data notdisplayed on website.

The RTD or thermocouple is notcorrectly installed on the hose oris broken.

See RTD or Thermocouple repairsection.

Pressure data not displayed onwebsite.

Reactor pressure measurement isnot working.

See System troubleshootingsection.

333024J 45

Pressure Relief Procedure

PressurePressurePressure ReliefReliefRelief ProcedureProcedureProcedureFollow the Pressure Relief Procedurewhenever you see this symbol.

This equipment stays pressurized until pressureis manually relieved. To help prevent seriousinjury from pressurized fluid, such as skin injection,splashing fluid and moving parts, follow thePressure Relief Procedure when you stop sprayingand before cleaning, checking, or servicingequipment.

The Fusion AP gun is shown.

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

2. Close gun fluid inlet valves A and B.

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

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

. Ensure gauges drop to 0.

SA SBGA GB

5. Engage gun piston safety lock.

6. Disconnect gun air line and remove gun fluidmanifold.

46 333024J

Shutdown

ShutdownShutdownShutdown

Shutdown system to avoid electric shock. Allelectrical wiring must be done by a qualifiedelectrician and comply with all local codes andregulations. To help prevent serious injury frompressurized fluid, such as skin injection, splashingfluid and moving parts, follow the Pressure ReliefProcedure when you stop spraying and beforecleaning, checking, or servicing equipment.

NOTICENOTICENOTICEProper system setup, startup, and shutdownprocedures are critical to electrical equipmentreliability. The following procedures ensure steadyvoltage. Failure to follow these procedures willcause voltage fluctuations that can damageelectrical equipment and void the warranty.

1. Press to stop the pumps.

2. Turn off all heat zones.

3. Relieve pressure. SeePressure Relief Procedure, page 46.

4. Press to park the Component A Pump. Thepark operation is complete when green dot goesout. Verify the park operation is complete beforemoving to next step.

5. Press to deactivate the system.

6. Turn off the air compressor, air dryer, andbreathing air.


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

333024J 47

Shutdown

8. Close all fluid supply valves. 9. Engage gun piston safety lock then close fluidinlet valves A and B.

FusionFusionFusion ProblerProblerProbler

48 333024J

Flushing

FlushingFlushingFlushing

To avoid fire and explosion:

• Flush equipment only in a well-ventilated area.

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

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

• Use the lowest possible pressure when flushing.

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

To flush feed hoses, pumps, and heatersseparately from heated hoses, set PRESSURERELIEF/SPRAY valves (SA, SB) to PRESSURE

RELIEF/CIRCULATION . Flush through bleedlines (N).

SA SBGA GB

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

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

333024J 49

Repair

RepairRepairRepair

Repairing this equipment requires access to partsthat may cause electric shock or other seriousinjury if work is not performed properly. Be sure toshut off all power to equipment before repairing.

BeforeBeforeBefore BeginningBeginningBeginning RepairRepairRepair

NOTICENOTICENOTICEProper system setup, startup, and shutdownprocedures are critical to electrical equipmentreliability. The following procedures ensure steadyvoltage. Failure to follow these procedures willcause voltage fluctuations that can damageelectrical equipment and void the warranty.

1. Flush if necessary. See Flushing, page 49.

2. See Shutdown, page 47.

FlushFlushFlush InletInletInlet StrainerStrainerStrainer ScreenScreenScreen

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

Isocyanate can crystallize from moisturecontamination or from freezing. If the chemicals usedare clean and proper storage, transfer, and operatingprocedures are followed, there should be minimalcontamination of the A-side screen.

Note

Clean the A-side screen only duringdaily startup. This minimizes moisturecontamination by immediately flushingout any isocyanate residue at the start ofdispensing operations.

1. Close the fluid inlet valve on the y-strainer inletand shut off the appropriate feed pump. Thisprevents material from being pumped whilecleaning the screen.

2. Place a container under the strainer base to catchdrain off when removing the strainer plug (C).

3. Remove the screen (A) from the strainermanifold. Thoroughly flush the screen withcompatible solvent and shake it dry. Inspect thescreen. No more than 25% of the mesh shouldbe restricted. If more than 25% of the mesh isblocked, replace the screen. Inspect the o—ring(B) and replace as required.

4. Ensure the pipe plug (D) is screwed into thestrainer plug (C). Install the strainer plug with thescreen (A) and o—ring (B) in place and tighten.Do not overtighten. Let the gasket make the seal.

5. Open the fluid inlet valve, ensure that there areno leaks, and wipe the equipment clean. Proceedwith operation.

Figure 1

50 333024J

Repair

ChangeChangeChange PumpPumpPump LubricantLubricantLubricant

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

Gel formation is due to moisture absorption by thepump lubricant. The interval between changesdepends on the environment in which the equipmentis operating. The pump lubrication system minimizesexposure to moisture, but some contamination is stillpossible.

Lubricant discoloration is due to continual seepage ofsmall amounts of isocyanate past the pump packingsduring operation. If the packings are operatingproperly, lubricant replacement due to discolorationshould not be necessary more often than every 3 or4 weeks.

To change pump lubricant:

1. Follow Pressure Relief Procedure, page 46.2. Lift the lubricant reservoir (R) out of the bracket

and remove the container from the cap. Holdingthe cap over a suitable container, remove thecheck valve and allow the lubricant to drain.Reattach the check valve to the inlet hose.

3. Drain the reservoir and flush it with cleanlubricant.

4. When the reservoir is flushed clean, fill with freshlubricant.

5. Thread the reservoir onto the cap assembly andplace it in the bracket.

6. Manually prime the ISO pump. Plug the smallvent hole (H) between the tube grommets whilesqueezing the bottle to force the lubricant up thefeed tube. Repeat until the fluid level reaches theISO pump to force the air out.

Pump Lubrication SystemFigure 2

7. Verify that the ISO pump is operating correctlyby feeling the pulsation in the return tube duringnormal proportioner pump operation.

8. Ensure the vent hole stays open.

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Repair

RemoveRemoveRemove PumpPumpPump

Pump rod and connecting rod move duringoperation. Moving parts can cause serious injurysuch as pinching or amputation. Keep hands andfingers away from connecting rod during operation.

Note

See manual 309577 for pump repairinstructions.


2. Turn off heat zones.

3. Flush pump.

4. Press to park the pumps in the down position.


6. Turn main power switch off.

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

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

. Ensure gauges drop to 0.

SA SBGA GB

52 333024J

Repair

Note

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

Note

Steps 9–11 apply to pump A. Todisconnect pump B, go to steps 12 and13.

9. Disconnect fittings at fluid inlet (C) and outlet (D).Also disconnect steel outlet tube from heaterinlet.

10. Disconnect tubes (T). Remove both tube fittings(U) from wet-cup.

11. Loosen locknut (G) by hitting firmly with anon-sparking hammer. Unscrew pump farenough to expose rod retaining pin. Pushretaining wire clip up. Push pin out. Continueunscrewing pump.

Pump AFigure 3

1 Flat side faces up.

2 Lubricate threads with ISO oil or grease.

3Pump top threads must be nearly flush withbearing face (N).

Note

Steps 12 and 13 apply to pump B.12. Disconnect fluid inlet (C) and outlet (D). Also

disconnect steel outlet tube from heater inlet.13. Push retaining wire clip (E) up. Push pin (F)

out. Loosen locknut (G) by hitting firmly with anon-sparking hammer. Unscrew pump.

Pump BFigure 4

1 Flat side faces up.

2 Lubricate threads with ISO oil or grease.

3Pump top threads must be nearly flush withbearing face (N).

InstallInstallInstall PumpPumpPump

Note

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

1. Ensure locknut (G) is screwed on pump withflat side up. Screw pump into bearing housing(M) until pin holes align. Push pin (F) in. Pullretaining wire clip (E) down. See Fig. 4 for viewand assembly notes.

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

3. Tighten locknut (G) by hitting firmly with anon-sparking hammer.

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

5. Go to step 13.

Note

Steps 6–12 apply to pump A only.

6. Ensure star-shaped locknut (G) is screwed onpump with flat side up. Carefully twist and extenddisplacement rod 2 in. (51 mm) above wet-cup.

333024J 53

Repair

Figure 5

7. Start threading pump into bearing housing (M).When pin holes align, insert pin. Pull retainingwire clip down.

8. Continue threading pump into bearing housing(M) until top threads are +/- 1/16 in. (2 mm) ofbearing face (N). Ensure that barbed fittings atwet-cup flush ports are accessible.

9. Connect component A outlet tube loosely atpump and at heater. Line up tube, then tightenfittings securely.

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

11. Apply thin film of TSL to barbed fittings. Usingtwo hands, support tubes (T) while pushingstraight onto barbed fittings. Secure each tubewith a wire tie between two barbs.

Note

Do not let tubes kink or buckle.

12. Reconnect fluid inlet (C).

13. Purge air and prime the system. See Reactoroperation manual.

RepairRepairRepair DriveDriveDrive HousingHousingHousing

RemovalRemovalRemoval


2. Turn off heat zones.

3. Flush pump.

4. Press to park the pumps in the down position.


6. Turn main power switch off.

54 333024J

Repair

7. Perform Pressure Relief Procedure, page 46.

8. Remove the system frame from the floor andL-brackets.

9. Remove two bolts and nuts and fold the electricalenclosure backward.

10. Remove screws (21) and motor shroud (11).Rest the motor shroud behind the motor withoutstraining the fan power cable.

Note

Examine bearing housing (103) andconnecting rod (105). If these parts needreplacing, first remove the pump (106),see Remove Pump, page 52.

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

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

13. Disconnect pump inlet and outlet lines. Removescrews (113), washers (115), and bearinghousing (103).

NOTICENOTICENOTICE

Do not drop gear cluster (104) when removingdrive housing (102). Gear cluster may stayengaged in motor front end bell or drivehousing.

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

Note

The A side drive housing includes cyclecounter switch (121). If replacing thishousing, remove screws (122) andswitch. Reinstall screws and switch onnew drive housing.

Figure 6

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Repair

InstallationInstallationInstallation

1. Apply heavy duty extreme pressure greaseliberally to washers (107, 108, 118), all gears,and inside drive housing (102).

2. Install one bronze washer (108) in drive housing,then install steel washers (107, 118) as shown.

3. Install second bronze washer (108) on gearcluster (104) and insert gear cluster in drivehousing.

Note

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

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

Note

If bearing housing (103), connecting rod(105), or pump (106) were removed,reassemble rod in housing and installpump, see Install Pump, page 53 .

5. Route cycle counter switch cable (121) aroundthe motor fan and reattach to housing (102) withscrews (122).

6. Install bearing housing (103), screws (113), andwashers (114). Pumps must be in phase (both atsame position in stroke).

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

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

Figure 7

56 333024J

Repair

RepairRepairRepair ElectricElectricElectric MotorMotorMotor

RemovalRemovalRemoval

NOTICENOTICENOTICEBe careful not to drop or damage the motor. Themotor is heavy and may require two people to lift.

1. Remove the system frame from the floor andL-brackets.

2. Remove drive housing and pump assemblies.See Repair Drive Housing, page 54.

3. Disconnect electric motor (101) power cable fromport #15 on the MCM. Remove connector byloosening four terminal screws.

4. Remove motor shroud (11). Rest the motorshroud assembly behind the motor withoutstraining the fan power cable.

5. Disconnect over temperature cable from port#2 on MCM. Cut tie wraps around harness toremove cable.

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

InstallationInstallationInstallation

1. Place motor on unit. Thread motorcables into conduit as before. SeeElectrical Schematics, page 93.

2. Fasten motor with screws (25) until screws arefully threaded in frame. Do not tighten screwsuntil drive housing and pumps are connected tothe motor.

3. Install drive housing and pump assemblies, seeInstallation, page 56.

4. Route motor (101) power cord from motorthrough conduit and connect to port #15 onMCM. Route over temperature cable up frommotor and connect to port #2 on MCM. Insertcables in conduit and use tie wraps to secure theconduit together.

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

6. Install drive housing covers and motor cover.

7. Return to service.

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Repair

RepairRepairRepair CircuitCircuitCircuit BreakerBreakerBreaker ModuleModuleModule

1. See Before Beginning Repair, page 50.

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

a. Refer to Electrical Schematics, page 93, andcircuit breaker table.

b. Follow Shutdown instructions. SeeShutdown, page 47.

c. Refer to circuit breaker identification tableand electrical diagrams in Reactor repairmanual.

d. Loosen two screws connecting wires and busbar to circuit breaker that will be replaced.Disconnect wires.

e. Pull locking tab out 1/4 in. (6mm) and pullcircuit breaker away from the din rail. Install

new circuit breaker. Insert wires and tightendown all screws.

Figure 8Circuit Breakers

CircuitCircuitCircuit BreakersBreakersBreakers

Ref.Ref.Ref. SizeSizeSize ComponentComponentComponent

CB01 50 A Heated Hose

CB02 20 A Motor Control Module(MCM)

CB03 40 A ISO Heater

CB04 40 A RES Heater

CB05 40 A Hose Heat Transformer

58 333024J

Repair

ReplaceReplaceReplace FluidFluidFluid InletInletInlet SensorSensorSensor

Note

For Elite models only.

1. Perform Shutdown, page 47.


3. Disconnect inlet sensor cable from the fluid inletassembly. Inspect cable for damage and replaceif necessary. See Electrical Schematics, page 93.

Figure 9 Fluid Inlet Sensor

4. To replace sensor cable:

a. Open wire bundle and remove sensor cable.

b. Cut any wire ties and disconnect from MCM.See Electrical Schematics, page 93.

NOTICENOTICENOTICETo prevent damage to cable, route and securecable in wire bundle with wire ties.

5. Replace sensor (602).

ReplaceReplaceReplace PressurePressurePressure TransducersTransducersTransducers

1. Perform Shutdown, page 47.


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

4. Remove wire ties constraining transducer c

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