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Graco 312066Z User's Manual

1. The inlet strainer at each proportioning pump filters out solid matter that can plug the inlet check valves Inspect the screens daily as part of the startup routine and clean as required Isocyanate can crystallize from moisture contamination or from freezing If the chemicals used are clean and proper storage transfer and operating procedures are followed there should be minimal contamination of the A side screen Clean the A side screen only during daily startup This minimizes moisture contamination by immedi ately flushing out any isocyanate residue at the start of dispensing operations 1 Close the material supply valve at the pump inlet to prevent material from being pumped while the strainer plug C is removed 2 Place a container under the strainer base to catch drain off when removing the strainer plug 3 Remove the screen A from the strainer manifold Thoroughly flush the screen with gun cleaner and shake it dry Inspect the screen for blockage No more than 25 of the mesh should be restricted If more than 25 is blocked replace the screen Inspect the strainer gasket B and replace as required 4 Ensure the pipe plug D is securely screwed into the strainer plug C Install the strainer plug with the screen A and gasket B in place and tighten Do not overtighten Let the gasket make the seal 5 Open the material supply valve ensure that there are no leaks and wipe the equipment clean 6
2. 10 Electric Motor 2 0 esee 33 E06 Communication cable unplugged 10 Motor Control Board 00 0 eee 34 Motor Control Diagnostic Codes 11 EE A ee ei 36 AMS iria pon rd a 11 Electric Fan o oooooooooooooooooo 36 WaIMINGS ssp a Men ari uua ica a se Ag 11 Temperature Control Module 37 E21 No component A transducer 12 Primary Heaters 0 essen 40 E22 No component B transducer 12 Heated Hose 0 cee eee 43 E23 High fluid pressure 12 Fluid Temperature Sensor FTS 44 E24 Pressure Imbalance 12 Display Module sse ne 46 E25 High line voltage 14 Inlet Fluid Strainer Screen 48 E26 Low line voltage 14 Pump Lubrication System 48 E27 High Motor Temperature a Pals eisereen rota VR Baa lutea ae 50 E28 High current in motor 14 Reactor Assembly Model E XP1 Shown 50 E29 Brush Wear llle 14 Parts Used on All Models 53 E31 Motor Control Failure Parts that Vary by Model 54 E 30 and E XP2 only 66 6 15 Sub Assemblies 0 0 cece ee eeeee 58 E32 Motor Control Overtemperature 16 Proportioner Module 0 eee eee 58 Communication Diagnostic Codes 16 Fluid Heaters eared eirian a na An
3. LABEL warning CABLE harness filter 5 IKIT fluid inlet 5a ELBOW swivel 3 4 npt m x 1 160327 npt f SCREW machine 20 BRACKET heater BRACKET heater ASHER lock CAPACITOR BRACKET CABLE over temperature 15H187 15H187 15H187 jumper 5 BOLT hex hd 3 8 16 BOLT hex hd O 1 EK N 247523 247523 247523 47523 247523 247523 247523 247523 247523 UN 247523 247523 247523 1 1 m ka 3 6 103181 103181 aralara e N 15H187 15H187 15H187 UN 15H187 15H187 15H187 1 co 100469 ves ess sen n nen eu n v e ens fs o on n o os E ELS js Er M NE IM TES ilg DES Eea KER DM p mE 100469 100469 100469 LOCKWASHER 3 lE uid 100133 EE 100133 mE 100133 97 NUT channel 418446 118446 118446 118446 118446 118446 118446 118446 118446 mE A NUT channel 118446 118446 118446 102 STRAP motor NO mb E Co gt E Due ITI E 15M504 m ES iu ES sare sarao prejara EE mpm Tuo Tous E EN 1107 1107 tasas pavos 15B107 15B107 15B108 15B108 15B107 15B107 15B108 15B108 15B107 15B107 15B108 15B108 15M500 15M499 15M501 15M504 15M500 15M499 15M501 15M504 15M500 15M499 167002 167002 167002 167002 167002 167002 167002 167002 167002 167002 167002 mb 22 NSULATOR 167002 312066Z 55 Parts Parts that Vary by Model continued Reactor Models Qt 259058 259059 E 30 Description w 15 3kW w 15 3kW w 15 3k
4. 2 Run the unit to build up some pressure 1000 1200 psi Shut down the unit clear the alarm and power back up Do not depressurize the unit 3 Check the analog gauges to see which pressure is higher Check if the display pressure matches indi cating that the motor control board sees that trans ducer If not the motor control board does not see that transducer Check the wire connections and or replace the transducer 4 With the pump zone off use the pressure relief valves to slowly relieve the high side pressure while watching the digital display and the analog gauges Once the higher analog gauge drops below the lower analog pressure the motor control board should start reading the new high side pressure because it is now the higher of the two Continue dropping the original high side pressure the digi tal display should stop dropping Repeat the pro cess to check the other pressure transducer The last test determines if the pressure transducer has failed or if the socket on the pressure control board has gone bad 3120662 Motor Control Diagnostic Codes 1 Swap the transducer plug ins on the motor control board J3 and J8 for the E 20 and E XP1 J3 and J5 for the E30 and E XP1 2 Repeat above test 3 Ifthe problem stays with the same side as before then the pressure transducer is bad 4 Ifthe problem switches to the other transducer then the problem is in the motor contr
5. 59035 F 5 17 900 0 200 30 13 5 0272 0 1034 2000 14 140 59057 F 30V 1 23 000 5 300 30 13 5 0272 0 1034 2000 14 140 59058 F 30V 3 23 000 5 300 30 13 5 0272 0 1034 2000 14 140 V 13 5 0272 0 1034 000 14 140 59059 F 3 400 23 000 5 300 0 E XP1 SERIES Approximate Primary Max Flow Output per Cycle Maximum Fluid Full Load Peak Voltage System Heater Rates A B Working Pressure Part Series Amps Wattst Watts gpm Ipm gal liter psi MPa bar 259024 E 69 230V 1 15 800 10 200 1 0 3 8 0 0104 0 04 2500 17 2 172 259029 E 400V 3 15 800 10 200 1 0 3 8 0 0104 0 04 2500 17 2 172 259033 E 230V 3 15 800 10 200 1 0 3 8 0 0104 0 04 2500 17 2 172 E XP2 SERIES Approximate Primary Max Flow Output per Cycle Maximum Fluid Part Full Load Peak Voltage System Heater Rates A B Working Pressure Series Wattst Watts gpm Ipm gal liter psi MPa bar 0 0203 0 0771 200 22 220 259028 F 100 230V 1 23 000 15 300 2 0 7 6 0203 3200 22 220 259032 F 35 400V 3 23 000 15 300 2 0 7 6 0 0203 0 0771 3200 22 220 230V 3 15 2 0 7 6 0203 35 259036 F 23 000 5 300 0 0203 0 0771 3200 22 220 Full load amps with all devices operating at maximum capabilities Fuse requirements at various flow rates and mix chamber sizes may be less T Total system watts based on maximum hose length for each unit e E 20 and E XP1 seri
6. No hose heat Loose hose electrical connections Check connections Repair as necessary Circuit breakers tripped Reset breakers CB1 or CB2 page 32 Hose zone not turned on Press zone O key A and B temperature setpoints too Check Increase if necessary low Failed temperature control board Open cabinet Check if board LED is blinking If not check power wiring con nections to ensure board has power If board has power and LED is not blinking replace board page 37 A and B temperature setpoints too Increase A and B setpoints Hose low designed to maintain temperature not increase temperature Hose temperature setpoint too low Check Increase if necessary to maintain heat Flow too high Use smaller mix chamber Decrease pres sure Low current FTS not installed Install FTS see operation manual Hose heat zone not turned on long Allow hose to heat up or preheat fluid enough Loose hose electrical connections Check connections Repair as necessary Low hose heat 22 31206672 Repair Repairing this equipment requires access to parts that may cause electric shock or other serious injury if work is not performed properly Have a qualified elec trician connect power and ground to main power switch terminals see operation manual Be sure to shut off all power to the equipment before repairing Before Beginning Repair 1 Flush if necessary see Flushing 2
7. TOA Heater Module To Hose Heater Module 603 TI9843a 603 Ref Part Description Qty 601 247772 PANEL module mounting 1 602 247827 HOUSING control module 1 603 247828 HOUSING heater module 3 604 115942 NUT hex 4 605 247801 CABLE communication 1 606 247825 KIT cover connector with screws 1 64 312066Z Parts Motor Control 24G879 Motor Control for E 20 and EXP 1 AM Apply 110009 thermal heatsink compound to mating surfaces A Motor harness 609 plugs in here 701 TI3153a 24G881 Motor Control for E 30 and EXP 2 701 e 704 707 TI2576a 24G879 Motor Control for E 20 and EXP 1 24G881 Motor Control for E 30 and EXP 2 Ref Part Description Qty Ref Part Description Qty 701 15B297 HEAT SINK 1 701 16F745 HEAT SINK 1 702 24G878 BOARD motor control 1 702 BOARD motor control 1 703 107156 SCREW machine 6 32 7 703 SCREW machine 6 6 32 x 3 8 in 10 mm 704 117526 SPACER 3 705 117683 SCREW 6 32 x 1 1 2 in 38 mm 2 707 15C007 INDUCTOR 1 709 15B408 CABLE harness motor 1 Not for sale 3120662 65 Parts Fluid Manifold A Torque to 355 395 in Ib 40 1 44 6 Nem A Apply sealant 113500 to threads A Valve must be closed with handle position as shown on drawing Apply PTFE tape or thread sealant to tapered threads Ref 801 802T 814 Part 247837 247824 802aT 158674 802bT 247779 803 102814 804 162453 805 24K999 806 247788 807 247789 8081
8. Thread the reservoir onto the cap assembly and place it into the bracket 6 The lubrication system is ready for operation No priming is required 3120662 Repair RT RB ae S T110970a RT Je ST LR ns nn i d A 7 A VM TI10969a FIG 13 Pump Lubrication System 49 Parts Parts Reactor Assembly Model E XP1 Shown 3 e 120 40 57 45 2 C 48 a 59 17 RANT A 16 MARES 58 r T110953a 16 41 102 CO C LL Strut Channel Style Support Rail 110 113 119 109 111 112 41 SlotiedU Channel gt Style Support Rail 115 a X 65f ag Lo 65e O a T118608a sd 122 65d TI10961a 65b 65c L_____________ J 50 3120662 Parts Left Side of Cabinet 42 28 5 61 62 123 8 TI9835a 33 31 42 36 400V models only 27 6 39 52 71 73 29 42 TI10968a 312066Z 3 Parts Detail Fluid Manifold Area 7 see page 66 e 16 78 12 817 Ref 90 106 107 127 O T110962a Detail Cabinet Area T 41 mounting base from motor T110978a 92 312066Z Parts Used on All Models See pages 54 through 56 for parts that vary by model O TA OOMONOOAWNY y 65cT 65d Part 245974 247823 246976 261669 15B456 115834 247787 15B380 15B383 116773 C38163 15B361 15B510 15B360 255047 116149 117666 123969 123967 117723 115492 117623 1
9. constantly connection joints 3120662 21 Troubleshooting PROBLEM CAUSE SOLUTION Faulty thermocouple connections Verify that all FTS connections are snug and that pins of connectors are clean Examine connection of thermocouples to long green plug on heater control board Unplug and re plug thermocouple wires Erratic hose temperature cleaning off any debris Unplug and re plug long green connector FTS not installed correctly FTS should be installed close to end of hose in same environment as gun Verify FTS installation page 44 Missing damaged insulation around Ensure hose bundle has adequate insula FTS causing the hose heat to be ON tion evenly covering the entire length and constantly connection joints FTS failed or is not contacting Check FTS page 44 correctly FTS not installed correctly FTS should be installed close to end of hose in same environment as gun Verify Hose does not heat FTS installation page 44 Temperature control alarm Check temperature display or diagnostic code page 44 Shorted connection or failed hose With hose heat on and temperature set heating element point above displayed hose zone tem perature verify voltage between connectors at each section of hose Hoses near Reactor are warm but hoses downstream are cold Voltage should drop incrementally for each section of hose further from Reactor Use safety precautions when hose heat is turned on
10. m x f LABEL warning LABEL pages 54 56 INSULATOR heat pages 54 56 SPACER COVER connector module SCREW machine 6 32 x 0 375 in 9 5 mm N NN PY no PO NO ox oko NO AA E GA A Replacement Danger and Warning labels tags and cards are avallable at no cost See quantity on referenced pages Required for all A D series models Included in Not shown Knob Repair Kit 258920 purchase separately Not required for slotted U Channel style heater sup port rails 53 Parts Parts that Vary by Model Use the following tables on this and the next two pages to find parts that vary by model Find the reference number and of part in left column and Reactor model in top row Intersection is correct part number See page 53 for parts common to all models Reactor Models Qt 259026 259028 259029 259030 Description E 30 E XP2 E XP1 E 20 247509 247509 HEATER pages 247509 60 and 61 247507 247506 247507 aty 2 247507 aty 2 aty 2 MODULE pro portioner page 245956 245956 245957 245959 245956 245956 245957 245959 245956 245956 245957 245959 58 olor pao 65 24G879 24G879 24G881 24G881 24G879 24G879 24G881 24G881 24G879 24G879 24G881 259032 259033 259034 E XP2 E XP1 E 20 259036 E XP2 259024 m gt lt U uh 247506 247507 247507 247506 247507 24G881 TE ad 247840 247840 247812 247812 247840 247840
11. will occur This default value is adjustable see the operation manual E24 can be an alarm or a warning as desired Set DIP switch on motor control board ON for alarm OFF for warning See page 34 Fast E24 Errors Fast E24 errors occur e within 10 seconds of turning the pumps on or e as soon as you trigger the gun Causes of Fast E24 Errors one side of the gun is plugged a pressure transducer has failed damaged pump seals or check valve no feed pressure or empty material drum plugged heater plugged hose plugged manifold one PRESSURE RELIEF SPRAY valve is leaking or X is set to PRESSURE RELIEF CIRCULATION OY 3120662 Checks for Fast E24 Errors If a fast E24 error occurs first check the readings of the analog gauges If gauge pressures are very close 1 Clear the error and run the unit 2 Check plug J10 E20 E XP1 or J7 E30 E XP2 or the jumpers 7 to 8 or 9 to 10 on the motor control board 3 Check pressure transducer performance The digital display on a Reactor always shows the higher of the two pressures As soon as the higher ana log pressure drops below the lower analog pressure the digital display will switch to the new highest reading Determine which transducer is performing poorly 1 For testing purposes only find the dip switches labeled SW2 on the motor control board page 35 Set dips witch 3 to OFF This will allow the Reactor to run with a pressure imbalance alarm
12. 112309 812 117556 813 117557 66 N808 802 pp 802b 801 Description MANIFOLD fluid VALVE drain cartridge O RING SEAL seat valve GAUGE pressure fluid FITTING 1 4 npsm x 1 4 npt TRANSDUCER pressure control HANDLE red HANDLE blue NUT hex jam NIPPLE 8 JIC x 1 2 npt NIPPLE 10 JIC x 1 2 npt 2 lt gt NH 3 NH P wo eae NY o Ref Part 814 121312 815 100840 816 111457 817A 189285 818T 150829 805 Description ELBOW 90 degrees ELBOW street 1 4 npsm x 1 4 npt O RING PTFE LABEL caution SPHING compression T110959a Qty N m nm rnm A Replacement Warning labels signs tags and cards are available at no cost 1 Included in the following complete valve kits ISO Valve Kit left red handle 255149 Resin Valve Kit right blue handle 255150 Valve Set Kit both handles and grease gun 255148 Purchase kits separately Complete valve kits also include thread sealant 312066Z Parts Circuit Breaker Modules A 230V 3 Phase Circuit Breaker Modules E 20 EXP 1 910 For wiring and cable connections refer to electrical 929 905 906 914 917 diagrams manual 312067 supplied See page 70 911 for parts p 903 904 S N 91 LH f s EAL o 908 i f 168BR s02 DINFSI oof a JUN CCTC TIE IC TE IE TE T quill HH lose beds yy ls leales lea 1 SSSR 916 aa I T
13. 245956 or 244265 245957 245959 Parts included in Connecting Rod Kit 241008 245956 or 241279 245957 245959 59 Parts Fluid Heaters 247506 6 0 kW Fluid Heaters 247507 10 2 kW Fluid Heaters Ref 301 303 304 305 306 307 308 309 60 310 p 303 SONUS p lt A UNO CEA ow RO ETN ON NA ANN SOHO RHO CU A r 247507 312408 307 za Apply 110009 thermal heatsink compound Ref Part Description 310 117484 SENSOR Part Description Qty l HOUSING heater 4 311 100518 SCREW machine pan hd 121309 ADAPTER A 313 15H3805 PLUG hollow 15H304 PLUG o 314 247520 DISC rupture 15H306 ADAPTER thermocouple D br Ceres ee 120336 O RING fluoroelastomer 2 HEATER immersion 4 16A110 2550W 10 2kW heater only 16A112 1500 W 6 0 kW heater only 15B137 SWITCH overtemperature 1 15B135 MIXER immersion heater 4 Qty A NAD 312066Z 7 65 kW Single Zone Fluid Heater Two Per Machine Part 247509 304 Ref 301 303 304 305 306 307 308 309 313 Part 121309 15H304 15H306 120336 164110 15B137 15B135 3120662 6 ES 315 Description HOUSING heater ADAPTER PLUG ADAPTER thermocouple O RING fluoroelastomer HEATER immersion 2550 W SWITCH overtemperature MIXER immersion heater 309 r_247813_312066 AM Apply 110009 thermal heatsink compound 2 lt W U UNH Ref 310 311
14. 2550 18 21 10 200 2550 18 21 6 Toremove heater element first remove thermocou ple 310 to avoid damage see step 7 page 42 7 Remove heater element 307 from housing 301 Be careful not to spill any fluid left in housing 8 Inspect element It should be relatively smooth and shiny If there is a crusted burnt ash like material adhered to element or sheath shows pitting marks replace element 9 Install new heater element 307 holding mixer 309 so it does not block thermocouple port P 10 Reinstall thermocouple page 42 11 Reconnect heater element leadwires to heater wire connector 12 Replace heater shroud 40 312066Z Repair B 3 304 31 r 247813 312066 AN Apply 110009 thermal heatsink compound Fic 6 Heater 7 5 kW Single Zone Heater Shown 3120662 41 Repair Thermocouple 8 1 Turn main power OFF Disconnect power supply 2 Relieve pressure page 23 747 3 Wait for heaters to cool 4 Remove heater shroud 5 Disconnect thermocouple wires from B on tempera adapter must be removed ensure that mixer 309 is out of the way when replacing the adapter Replace thermocouple FIG 7 a Remove protective tape from thermocouple tip T b Apply PTFE tape and thread sealant to male threads and tighten thermocouple housing H into adapter 305 c Push in thermocouple 310 so tip T contacts heater element
15. 307 d Holding thermocouple T against heater ele ment tighten ferrule nut N 1 4 turn past tight ture control module See TABLE 5 page 37 and Fic 9 Route wires S into cabinet and thread into bundle 5 page 37 as before Reconnect wires to board 6 Feed thermocouple wires out of cabinet Note path 10 Replace heater shroud ee MANN A OA 11 Turn on heaters A and B simultaneously to test 7 See Fic 7 Loosen ferrule nut N Remove thermo tempera iieS cion pe clea tate One couple 310 from heater housing 301 then heater is low loosen ferrule nut N and tighten ther remove thermocouple housing H Do not remove mocouple housing H to ensure thermocouple tip the thermocouple adapter 305 unless necessary If T contacts element 307 A Apply PTFE tape and thread sealant S 310 N A Apply 110009 thermal heatsink compound N L H 301 307 A 308 q Y 309 FIG 7 Thermocouple 42 ti7924a 3120662 Overtemperature Switch 1 Turn main power OFF Disconnect power supply 2 Relieve pressure page 23 7 4 3 Wait for heaters to cool 4 Remove heater shroud 5 Disconnect one leadwire from overtemperature switch 308 FiG 7 Test across switch with ohm meter Resistance must be approximately O ohms 6 If switch fails test remove wires and screws Dis card failed switch Apply thermal compound 1100089 install new switch in same location on housing 301 and secu
16. Disconnect ribbon cable s R from back of display see FIG 11 Remove nuts 508 and plate 505 Disassemble display see detail in FiG 11 Replace board 501a or 502a or membrane switch 501b or 502b as necessary Reassemble in reverse order see FiG 11 Apply medium strength thread sealant where shown Be sure display cable ground wire G is secured between cable bushing and cover 504 with screws 512 Red Stop Button CAUTION Before handling board put on a static conductive wrist strap to protect against static discharge which can damage board Follow instructions provided with wrist strap 1 Turn main power OFF Disconnect power supply 2 Relieve pressure page 23 3 Refer to electrical diagrams 4 Puton static conductive wrist strap 5 Remove screws 509 510 and cover 504 FIG 11 6 Disconnect button cable connectors 506 from back of temperature display 501 and pressure display 502 7 Remove red stop button 506 8 Reassemble in reverse order Be sure display cable ground wire G is secured between cable bushing and cover 504 with screws 512 3120662 Repair AM Apply medium strength thread sealant 504 510 N ti2574a Detail of Membrane Switches and Display Boards Temperature Display N 502c Pressure Display 502a 502b ti3172a FiG 11 Display Module 312066Z 27 Repair Inlet Fluid Strainer Screen
17. English Description 312416 Instruction Parts Manual English Electric Reactor Installation Part Description 310815 Instruction Manual English 3120662 Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion point symbol alerts you to a general warning and the hazard symbol refers to procedure specific risk Refer back to these warnings Additional product specific warnings may be found throughout the body of this manual where applicable ELECTRIC SHOCK HAZARD Improper grounding setup or usage of the system can cause electric shock e Turn off and disconnect power cord before servicing equipment Use only grounded electrical outlets Use only 3 wire extension cords Ensure ground prongs are intact on sprayer and extension cords Do not expose to rain Store indoors TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed e Read MSDS s to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines e Always wear impervious gloves when spraying or cleaning equipment PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you from serious inj
18. PUMP displacement component B 245957 see 309577 WASHER thrust steel WASHER thrust bronze SCREW self tapping 8 32 x 1 in 25 mm 245956 SCREW self tapping 8 32 x 1 1 4 in 31 mm 245957 245959 CLIP wire 245956 CLIP wire 245957 245959 PIN 245956 PIN 245957 245959 SCREW cap socket hd 1 4 20 x 2 3 4 in 70 mm 245956 SCREW cap socket hd 5 16 18 x 3 1 4 in 83 mm 245957 245959 SCREW cap socket hd 3 8 16 x 1 1 2 in 88 mm 245956 SCREW cap socket hd 3 8 16 x 2 1 4 in 57 mm 245957 245959 WASHER lock 1 4 245956 WASHER lock 5 16 245957 245959 WASHER lock 3 8 size NUT retaining 245956 NUT retaining 245959 NUT retaining 245957 COVER 245956 COVER 245957 245959 WASHER thrust 245956 WASHER thrust 245957 245959 SCREW cap socket hd 1 4 20 x 3 4 in 19 mm 245956 SCREW cap socket hd 5 16 18 x 1 in 25 mm 245957 245959 MAGNET lt NO NO NO MMMNMNN h KR BNNNMNMNNNANMPDY o oco A ADDIEN oco OAN Ref 221 223 224 225 226 Part 117770 100643 102962 104765 15C587 15C588 15M507 15M508 Parts Description SWITCH cycle counter SCREW cap socket hd 1 4 20 x 1 in 4 25 mm 245956 SCREW cap socket hd 5 16 18 x 4 1 1 4 in 31 mm 245957 245959 PLUG 2 GUARD finger 245956 1 GUARD finger 245959 1 LABEL 245956 1 LABEL 245957 245959 1 Parts included in Gear Kit 244264
19. Proceed with operation 48 T110974a Fic 12 Y Strainer Components Fluid filter screen 59g replacements Part Description 180199 20 mesh standard 1 pack 255082 80 mesh optional 2 pack 255083 80 mesh optional 10 pack Pump Lubrication System 754 Check the condition of the ISO pump lubricant daily Change the lubricant if it becomes a gel its color dark ens or it becomes diluted with isocyanate Gel formation is due to moisture absorption by the pump lubricant The interval between changes depends on the environment in which the equipment is operating The pump lubrication system minimizes exposure to mois ture but some contamination is still possible Lubricant discoloration is due to continual seepage of small amounts of isocyanate past the pump packings during operation If the packings are operating properly lubricant replacement due to discoloration should not be necessary more often than every 3 or 4 weeks To change pump lubricant 1 Relieve pressure page 23 2 Liftthe lubricant reservoir LR out of the bracket RB and remove the container from the cap Hold ing the cap over a suitable container remove the inlet check valve and allow the lubricant to drain Reattach the inlet check valve to the inlet hose See FiG 13 312066Z 3 Drain the reservoir and flush it with clean lubricant 4 When the reservoir is flushed clean fill with fresh lubricant 5
20. and E XP2 models only 2 Relieve pressure page 23 3 Perform the following inspections a Motor failure Inspect the motor commutator by removing the top brush see Brush Removal page 30 Rotate the motor inspecting the whole commutator for burns pocking or shorts between poles Continue rotating the motor for a complete pump cycle up and down to ensure that there is no mechanical interference or restriction in the pump lower or gear drive sys tem b Capacitor failure Inspect and test the motor start capacitor following the Capacitor Test instructions on page 32 c Shorted or frayed wiring Inspect all wiring connected to the motor control board and the motor for shorts or frayed insulation Replace any compromised wires with wire of the same gauge color and temperature rating d Inadequate power supply Verify that the power source is of the correct voltage and cur rent rating for the system and that all phases are properly connected Ensure that the power does not dip or surge during operation Prior to shutting down the generator ensure that the motor has stopped and the main dis connect is opened If the generator is stopped during operation even due to running out of fuel the drop in supply voltage may cause a motor drive failure 15 Communication Diagnostic Codes E32 Motor Control Overtemperature The E32 error code indicates a high temperature condi tion within the motor control
21. and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limi
22. buss 3 phase 117678 117678 AR power buss 1 phase 247802 247802 247802 247802 247802 247802 co O ABLE harness lower 247805 247806 247804 247805 247806 247804 co 17 CABLE harness upper 255027 255027 255027 255027 255027 255027 co 18 CONNECTOR 2 pin large 247522 247522 247522 247567 247567 247567 co 19 CONNECTOR 3 pin 255031 255031 255031 255031 255031 255031 co 20 CONNECTOR 4 pin 247791 247791 247791 247791 247791 247791 Oo O gt UJ E TI 22 D D o o O L l l O Ca sy y H D b 70 312066Z 248669 Conversion Kit 248669 Conversion Kit Convert and phase E XP2 to and E 30 with 15 3 kW of heat by changing displacement pumps bearings and Ref Part Description Qty changing the Motor Control DIP settings to that of an 65 118463 ELBOW swivel 3 4 npt m x 1 in D E 30 For removal and installation of displacement npt f pumps and bearings see Pump Removal page 24 303 245927 HOUSING bearing 2 and Pump Installation page 26 For changing Motor 306A 246832 Po ec eene component 1 DIP settings see Motor Control Board page 306B 245972 PUMP displacement component 1 i B see 309577 316 193394 NUT retaining 2 303 316 306A 24G881 Motor Control Board DIP Switch SW2 need to be set for an E 30 1 2 3 ON 4 OFF See page 34 T110966a 312066Z 71 Dimensions Dimensions Dimension 72 in mm 46 0 1168
23. check continuity of overtemperature switches A and B thermocouples A and B or FTS by measuring resistance across the pins on the plug end see TABLE 1 Before doing the following checks note which zone A B FTS or all has high fluid temperature Table 1 Sensor Connector Continuity Checks Description Reading approximately 35 ohms per 50 ft 15 2 m of hose plus approximately 10 ohms for FTS i 10 amp 12 5 Verify fluid temperature using an external tempera ture sensing device e If temperature is too high sensor reading is 229 F 109 C or above 6 Check if thermocouples A and B are damaged or not contacting the heater element page 42 7 Totest that temperature control module turns off when equipment reaches temperature setpoint a Set temperature setpoints far below displayed temperature b Turn zone on If temperature rises steadily power board is failing c Verify by swapping with another power module See Replacing Temperature Control Assem bly Modules page 38 d Ifthe swapped module does not fix the problem the power module is not the cause 8 Verify continuity of heater elements with an ohmme ter see page 40 312066Z Temperature Control Diagnostic Codes E02 High zone current 1 Turn main power OFF 2 Relieve pressure page 23 EN Disconnect whip hose 3 Disconnect hose connector D at Reactor 4 Using an ohmmeter check between the two term
24. fluid pressure 1 Relieve pressure Verify low pressure with analog gauges Turn main power OFF then ON 1 If error persists do checks below 1 Checkthe jumpers and the wiring Check jumper on motor control board J10 for E20 and E XP1 or J7 for E30 and E XP2 pins 7 10 page 34 2 Remove clean and re install the pressure trans ducer leads If the jumpers and the wiring are in good working condi tion and you still have the error then you will need to replace the A and B pressure transducers 3 Todetermine if it s the A or the B transducer you will need a known good Reactor pressure trans ducer to use as a test transducer The test is done without removing the existing pressure transducers from the fluid manifold a Unplug the A transducer from the Motor con trol board socket page 36 and replace with test transducer 12 b Turn on the Reactor master power e fthe error is gone turn off the Reactor main power remove test transducer and replace A transducer e Ifthe error persists unplug the test transducer from the A socket and reinstall the A pres sure transducer back into the A socket Hepeat this test procedure on the B side 4 fthe error persists and no root cause is found through the above testing replace the motor control board page 34 E24 Pressure Imbalance If the pressure difference between components A and B exceeds 500 psi 3 5 MPa 35 bar an E24
25. no 10 KIT fluid inlet FITTING swivel elbow Y STRAINER ELEMENT 20 mesh NIPPLE 3 4 npt 9 lt eo l o O A A acna O y Ol OA MMMNHNOD AtHM 00 950 960 979 102 106 107 109 110 111 112 113 115 117 119 120A 121 122 123 124 125 Part 109077 118459 101078 180199 109077 C20487 157785 15B807 186494 205447 15M338 117502 117677 246928 054826 118433 118432 116746 15C568 206995 191892 171001 247782 247854 114331 Parts Description VALVE ball 3 4 npt fbe FITTING union swivel 3 4 14 npt m x 3 4 14 npt f Y STRAINER includes 66a ELEMENT 20 mesh VALVE ball 3 4 npt fbe NIPPLE 3 4 npt UNION swivel 3 4 npt m x 3 4 npsm f SCREW machine pages 54 56 BRACKET heater pages 54 56 WASHER lock pages 54 56 CAPACITOR pages 54 56 BRACKET pages 54 56 CABLE overtemperature jumper pages 54 56 SHIELD fan CLIP spring COUPLING hose TUBE low pressure 1 4 in 6 mm ID 3 8 in 16 mm OD 4 ft 1 2 m PTFE BOLT hex hd pages 54 56 LOCKWASHER 3 8 pages 54 56 NUT channel pages 54 56 STRAP motor pages 54 56 REDUCER 5 x 8 JIC REDUCER 6 x 10 JIC RESERVOIR includes 110 119 see 309911 TUBE PTFE 1 4 in 6 mm ID 2 ft 0 6 m VALVE check VALVE check FITTING barbed BRACKET reservoir THROAT SEAL LIQUID 1 at 1 liter ELBOW 1 8 npt
26. on plug J13 for each board Step 2 measures line voltage and should be done by a qualified electrician If work is not performed properly it may cause electric shock or other serious injury 2 Measure the incoming voltage to the board it should be 230Vac 3 Ifitwas only receiving 1 leg of the 230Vac the board may light up and still not function properly Correct the incoming voltage problem 312066Z Troubleshooting Troubleshooting PROBLEM CAUSE SOLUTION Reactor does not operate No power Plug in power cord Turn main power ON Turn circuit breakers ON page 32 Red stop button circuit open Check button connections See page 46 and electrical diagrams Motor does not operate Loose connections Check connections at motor control board Circuit breaker tripped Reset breaker CB5 page 32 Check 230Vac at output of breaker Worn brushes Check both sides Length must be 0 7 in 17 mm minimum To replace page 30 Broken or misaligned brush springs Realign or replace page 30 Brushes or springs binding in brush Clean brush holder and align brush holder leads for free movement Shorted armature Replace motor page 33 Check motor commutator for burn Hemove motor Have motor shop spots or other damage resurface commutator if possible Damaged motor control board Replace board See page 34 Defective fan Replace page 36 Pump output low Obstructed fluid hose or
27. on the tem perature control board is bad Replace the tem perature control assembly CAUTION Before handling assembly put on a static conductive wrist strap to protect against static discharge which can damage assembly Follow instructions provided with wrist strap 1 Turn main power OFF Disconnect power supply 2 Relieve pressure page 23 3 Refer to electrical diagrams see Electrical Dia grams manual 312067 Temperature control assem bly is on left side inside cabinet 4 Remove bolts that secure transformer assembly and slide assembly to side in cabinet 5 Put on static conductive wrist strap 6 Disconnect all cables and connectors from assem bly see Parts Temperature Control page 64 7 Remove nuts and take entire temperature control assembly to workbench 8 Replace defective module 9 Install assembly in reverse order 3120662 Repair 312066Z 39 Repair Primary Heaters Line Voltage The primary heaters output their rated wattage at 230 Heater Element Vac Low line voltage will reduce power available and the heaters will not perform at full capability 7 4 1 Turn main power OFF Disconnect power supply 2 Relieve pressure page 23 3 Wait for heaters to cool 4 Remove heater shroud 5 See FIG 6 Disconnect heater element wires from heater wire connector Test with ohmmeter Total Heater Wattage 6 000 7 650
28. prob lem with the motor control board Replace board page 34 Check motor 1 Check to see if the motor rotates freely 2 Checkto see if the brushes are damaged 3 Check that the voltage going to the motor is good 4 Checkthe three wire yellow yellow orange motor connector to the motor board A gentle tug on each wire individually at the connector should identify the loose wire If a wire pulls out bend the locking tab on the crimp end insert the wire until it seats and repeat gentle tug 5 Ifthe above does not resolve the problem replace the motor page 33 E29 Brush Wear Prolonged operation of motor after a brush wear warning may result in failure of motor and motor con trol board 1 Check for normal brush wear which causes the brush sensor to come in contact with the motor commutator Replace the brushes page 30 2 Check spade plug The spade plug inside the motor housing may be twisted and contacting the commu tator side of the brush sensor assembly causing a false alarm Follow the orange wire coming from J7 E 20 E XP1 or J6 E 30 E XP2 up to the spade connector on the motor Using a flashlight ensure the spade plug assembly is not making contact with the metal housing of the brush assembly 312066Z 3 Check wiring The orange brush sensor wire coming out of the brush may be routed online with the com mutator wiring thick red wire causing a false alarm Reroute the orange wire com
29. 13796 115942 15K817 189930 189285 15B593 15B775 247524 256732 15G280 113505 112776 101078 180199 C20487 312066Z Description FRAME page 62 HEATER pages 60 and 61 MODULE proportioner page 58 DISPLAY page 63 CONTROL temperature page 64 CONTROL motor page 65 MANIFOLD fluid page 66 TRANSFORMER pages 54 56 SHIELD page pages 54 56 DOOR cabinet SENSOR fluid temperature GASKET manifold FAN TUBE heater component A pages 54 56 TUBE pump component A pages 54 56 TUBE heater component B pages 54 56 TUBE pump component B pages 54 56 CABLE overtemperature see electrical diagrams CABLE hose control see electrical diagrams CABLE display CONNECTOR tube pages 54 56 CONNECTOR plug WASHER lock external tooth BOOT wire feed through PLATE cover wire GASKET fan STRAIN RELIEF MODULE breaker pages 54 56 SPACER TERMINAL ground SWITCH disconnect SWITCH main power SCREW machine 6 32 x 2 in 51 mm SWITCH added pole 380V page 54 SCREW machine 8 32 x 0 345 in 9 mm FILTER 230V page 54 NUT cap 3 8 16 SCREW flanged hex hd 1 4 20 x 3 4 in 19 mm NUT hex flange 1 4 20 LABEL diagnostic codes LABEL caution LABEL caution LABEL warning pages 54 56 CABLE harness filter pages 54 56 SHIELD membrane switch pack of 10 COVER wire access COVER heater back COVER heater front LABEL warning NUT hex keps 10 24 WASHER plain
30. 247812 247812 247840 247840 247812 247812 SHIELD 276878 276878 276879 276879 276878 276878 276879 276879 276878 276878 276879 276879 i A EM 247920 247920 247920 247915 247920 247920 247920 247915 247920 247920 247920 247915 dal E ERA 247912 247912 247919 247914 247912 247912 247919 247914 247912 247912 247919 247914 STE 247918 247918 247918 247917 247918 247918 247918 247917 247918 247918 247918 247917 N E 247913 247913 247921 247916 247913 247913 247921 247916 247913 247913 247921 247916 bic 121310 121310 121311 121311 121310 121310 1121311 121311121310 121310 121311 MODULE C breaker page 67 SWITCH added pole 380V 9 FILTER 230V 121311 00 O 123968 123968 123968 123968 117667 117667 117667 117667 117667 117667 JEBEPPPN io ORENPEN HEEE E RENBRR HOE Bi iiiiiiii Pid gi iiiiiiii Pi adis 2 992 0 8 098 CODAE RAE Hy iiiiiiii i gg iiiiiiii Pb ag iiiiiiii ir ag iisiiiiild i E B 54 312066Z Parts Reactor Models Qt 259026 259028 259029 259030 259032 259033 259034 259036 E 30 E XP2 E XP1 E 20 E XP2 E XP1 E 20 E XP2 198278 198278 198278 198278 198278 198278 15B385 15B385 NE 5B38515B385 5B38515B385 234366 234366 234367 234366 234366 234366 234367 234366 234366 234366 234367 234366 160327 118463 160327 160327 160327 118463 160327 160327 160327 118463 160327 259024 m gt lt U bh Description 1A 2
31. 3 Remove tape and protective covering from FTS 8 Remove FTS probe H from component A 150 21 Fig 8 Disconnect hose cable F Test with side of hose ohmmeter between pins of cable connector Installation Pins Rest The Fluid Temperature Sensor FTS is supplied Install FTS between main hose and whip hose See Heated approximately 10 ohms Hose manual 309572 for instructions 1 to FTS component A infinity fitting ISO ti17092b ti17029b FIG 9 Fluid Temperature Sensor and Heated Hoses 44 312066Z Repair Transformer Primary Check 3 To verify transformer voltage turn on hose zone Measure voltage from 18CB 2 to POD HOSE P15 2 see Reactor Electrical Dia 1 Turn main power OFF grams manual 312067 2 Locate the two smaller 10 AWG wires coming out Model Secondary Voltage of transformer Trace these wires back to contactor 310 tt and circuit breaker 911 Use an ohmmeter to test i for continuity between two wires there should be 210 ft continuity For 230 Vac line voltage Transformer Secondary Check Replace Transformer 1 Turn main power OFF Ny Use this procedure to replace transformer 2 Locate the two larger 6 AWG wires coming out of transformer Trace these wires back to large green connector under hose control module and circuit breaker 909 Use an ohmmeter to test for continu 1 Turn main power OFF ity between two wires there should be continu
32. 31 0 787 33 0 838 T110953a 3120662 Technical Data Technical Data Category Dat Maximum Fluid Working Pressure Models E 20 and E 30 2000 psi 14 MPa 140 bar Model E XP1 2500 psi 17 2 MPa 172 bar Model E XP2 3500 psi 24 1 MPa 241 bar Maximum Fluid Temperature 190 F 88 C Maximum Output Model E 20 20 Ib min 9 kg min Model E 30 30 Ib min 13 5 kg min Model E XP1 1 gpm 3 8 liter min Model E XP2 2 gpm 7 6 liter min Output per Cycle A and B Model E 20 and E XP1 0 0104 gal 0 0395 liter Model E 30 0 0272 gal 0 1034 liter Model E XP2 0 0203 gal 0771 liter Line Voltage Requirement Parts 259024 259025 259026 259028 259057 195 264 Vac 50 60 Hz Parts 259029 259030 259031 259032 259059 338 457 Vac 50 60 Hz Parts 259033 259034 259035 259036 259058 195 264 Vac 50 60 Hz Amperage Requirement See Table 1 page 9 Heater Power Model E 20 6000 Watts Model E 30 and E XP1 10200 Watts Models E XP2 and E 30 with 15 3kW of heat 15300 Watts Sound Power per ISO 9614 2 Model E 20 80 dB A at 2000 psi 14 MPa 140 bar 0 5 gpm 1 9 Ipm Model E 30 93 5 dB A at 1000 psi 7 MPa 70 bar 3 0 gom 11 4 lpm Model E XP1 80 dB A at 2000 psi 14 MPa 140 bar 0 5 gom 1 9 lpm Model E XP2 83 5 dB A at 3000 psi 21 MPa 210 bar 1 0 gpm 3 8 Ipm Sound Pressure 1 m from equipment Model E 20 70 2 dB A at 2000 psi 14 MPa 140 bar 0 5 gpm 1 9 Ipm Model E 30 83 6 dB
33. 313 314 315 Part 117484 100518 15H305 247520 124132 Description SENSOR SCREW machine pan hd PLUG hollow DISC rupture not shown O RING Parts Qty O 0 N 61 Parts Reactor Frame Ref 401 402 403 404 405 406 407 62 Part 116478 101242 116477 112125 116411 154636 Description FRAME WHEEL RING retaining WASHER flat nylon PLUG SPRING WASHER flat KRMYONMNANND 407 401 406 404 402 a 404 AX 403 TI2513a 312066Z Display Ref 501 501a 501b 501c 502 502a 502b 502c 503 504 507 506 502a mf D 9 Jo ISA ere Part 24G884 24G882 246479 112324 24G883 24G882 246479 112324 15B293 15B292 3120662 508 Description DISPLAY pressure includes 501a 501c BOARD circuit SWITCH membrane SCREW DISPLAY temperature includes 502a 502c BOARD circuit SWITCH membrane SCREW GASKET COVER bh A bh oL oL Ref Part 505 15B291 506 246287 507 117499 508 117523 510 511 15B386 512 195853 Not for sale 502c 501b Description PLATE HARNESS wire red stop button HANDLE NUT cap 10 24 SCREW machine pan hd M5 x 0 8 16 mm CABLE display SCREW machine M2 5 x 6 Parts ti2574a ti3172a ON h 63 Parts Temperature Control 605 ToB Heater 606 Module
34. 66Z yor 6 12 apply to pump A only 6 Ensure star shaped locknut G is screwed on pump with flat side up Carefully twist and extend displace ment rod 2 in 51 mm above wet cup 7 Start threading pump into bearing housing M Place finger guard P over rod when it is accessible through window of bearing housing When pin holes align insert pin Pull retaining wire clip down ye guard is not used on Model E 30 8 Seat finger guard P on wet cup Continue thread ing pump into bearing housing M until top threads are 1 16 in 2 mm of bearing face N Ensure A Flat side faces up A Lubricate threads with ISO oil or grease A Pump top threads must be nearly flush with bearing face N A Finger guard P not used on Model E 30 AD 3120662 12 13 Repair that barbed fittings at wet cup flush ports are acces sible Connect component A outlet tube loosely at pump and at heater Line up tube then tighten fittings securely Tighten star shaped locknut G by hitting firmly with a non sparking hammer Apply thin film of TSL to barbed fittings Using two hands support tubes T while pushing straight onto barbed fittings Do not let tubes kink or buckle Secure each tube with a wire tie between two barbs Heconnect fluid inlet C Purge air and prime the system See Reactor opera tion manual PA NA GAA C A TI3765a 2 27 Repair Drive Housing Removal 1
35. A at 1000 psi 7 MPa 70 bar 3 0 gom 11 4 lpm Model E XP1 70 2 dB A at 2000 psi 14 MPa 140 bar 0 5 gpm 1 9 Ipm Model E XP2 73 6 dB A at 3000 psi 21 MPa 210 bar 1 0 gpm 3 8 Ipm Component A ISO 8 1 2 in JIC with 5 5 16 in JIC adapter Component B RES 10 5 8 in JIC with 6 3 8 in JIC adapter Weight Model E 20 and E XP1 342 Ib 155 kg Model E 30 400 Ib 181kg Models E XP2 and E 30 with 15 3kW of heat 438 Ib 198 kg Wetted Parts Aluminum stainless steel zinc plated carbon steel brass carbide chrome chemically resistant o rings PTFE ultra high molecular weight polyethylene All other brand names or marks are used for identification purposes and are trademarks of their respective owners 312066Z 73 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear
36. Inspect brush and commutator contact area for excessive arcing Arcs should not trail or circle around com mutator surface Run motor for 20 30 min at J 6 to seat brushes 31 Repair Capacitor Test Circuit Breaker Module Ts EUA POWer Ore DISCORDBCLDONSE 1 Turn main power OFF Disconnect power supply supply Turn circuit breakers on to test 2 Relieve pressure page 23 3 Locate the large blue capacitor in the upper right corner of the lower cabinet 4 With a DC voltmeter measure the voltage across the capacitor terminals to verify that the voltage has discharged to below 10 volts 2 Relieve pressure page 23 5 With an insulated handle screw driver short across 3 Using an ohmmeter check for continuity across cir the two contacts on the end of the capacitor to com cuit breaker top to bottom If no continuity trip plete discharging it Hold for two seconds breaker reset and retest If still no continuity replace breaker as follows NOTE A small spark may issue from the contact point j a Refer to electrical diagrams and to TABLE 2 Dis 6 Inspect the capacitor for irregularities such as connect wires and remove bad breaker cracks leakage burn marks or irregular shape b Install new breaker and reconnect wires 7 Setan Ohmmeter to a range of at least 1KQ and connect the meter leads to the capacitor with the Table 2 Circuit Breakers see Fic 1 red le
37. Park component A pump A a Press o b Trigger gun until pump A stops After fluid pres sure drops below 700 psi 7 9 MPa 79 bar motor will run until component A pump is at bot tom of its stroke then shut off c Check ISO reservoir for component A pump Fill wet cup on component B pump Refer to Reac tor Operation manual 312065 3 Turn main power OFF 4 Relieve pressure Pressure Relief Procedure 1 Relieve pressure in gun and perform gun shutdown procedure See gun manual 3120662 Repair 2 Engage gun piston safety lock ti2409a ti2421a Shut off feed pumps and agitator if used Turn PRESSURE RELIEF SPRAY valves SA SB to PRESSURE RELIEF CIRCULATION Y Route fluid to waste containers or supply tanks Ensure gauges drop to 0 m ad SB t110955a Disconnect gun air line and remove gun fluid mani fold ti2554a 23 Repair Flushing mw Flush equipment only in a well ventilated area Do not spray flammable fluids Do not turn on heaters while flushing with flammable solvents i manual 309577 for pump repair instructions Shut off 3 and heat zones Flush pump Flush out old fluid with new fluid or flush out old fluid with a compatible solvent before introducing new fluid Use the lowest possible pressure when flushing All fluid components are compatible with common solvents Use only moistur
38. Repair Parts gt y Reacts Electric Heated Plural Component Proportioner For spraying polyurethane foam and polyurea coatings For professional use only Not approved for use in European explosive atmosphere locations Important Safety Instructions Read all warnings and instructions in this manual Save these instructions see page 3 for model information including Model E XP1 Shown maximum working pressure and approvals T110953a cE EM ISTE 9902471 Conforms to ANSI UL Std 499 Certified to PROVEN QUALITY LEADING TECHNOLOGY o Contents MOGBIS 5 3 race do o ACE ii 3 Nepal lana o Medo deer aera s 23 Supplied Manuals 4 Before Beginning Repair 23 Related Manuals 4 Pressure Relief Procedure 23 Ward 4 5 25 5 4 pao ua ee eee ee os 5 misc Tcr ETT 24 Temperature Control Diagnostic Codes 8 Pump Removal o oooooo 24 E01 High fluid temperature 8 Pump Installation 26 E02 High zone current 9 Drive Housing 2 00 cee eee eee 28 E03 No zone current 0005 10 Motor Brushes 2 00000 e eee eee 30 E04 Fluid Temperature Sensor FTS or Capacitor TesSt oooooooooomomoo 32 thermocouple disconnected 10 Circuit Breaker Module 32 E05 Circuit board overheated
39. See E04 Fluid Temperature Sen sor FTS or thermocouple discon nected page 10 Examine connection of thermocou ples to long green plug on heater control board Unplug and re plug thermocouple wires cleaning off any debris Unplug and re plug long green connector Loosen ferrule nut N push in ther mocouple 310 so tip T contacts heater element 307 Holding themo couple tip T against heater element tighten ferrule nut N 1 4 turn past tight See page 42 for illustration See Primary Heaters page 20 See E04 Fluid Temperature Sen sor FTS or thermocouple discon nected page 10 See E04 Fluid Temperature Sen sor FTS or thermocouple discon nected page 10 Power up zones one at a time and verify that tempera ture for each zone rises 3120662 Troubleshooting Hose Heat System 3 Allow equipment to cool Problems df Try the recommended solutions in the order given for A LA each problem to avoid unnecessary repairs Also determine that all circuit breakers switches and con trols are properly set and wiring is correct before assum Before performing any troubleshooting procedures ing there is a problem 1 Relieve pressure page 23 2 Turn main power OFF PROBLEM CAUSE SOLUTION Ambient temperature is too cold Use auxiliary hose heat system FTS failed or not installed correctly Check FTS page 10 Low supply voltage Verify line voltage Low line
40. Turn main power OFF Disconnect power supply 2 Relieve pressure page 23 3 Remove screws 38 and motor shield 9 page 50 4 Remove screws 209 and front cover 217 Examine bearing housing 203 and connecting rod 205 If these parts need replacing first remove the pump 206 page 28 5 Disconnect pump inlet and outlet lines Remove screws 213 washers 215 and bearing housing 203 CAUTION Do not drop gear cluster 204 when removing drive housing 202 Gear cluster may stay engaged in motor front end bell R or drive housing 6 Remove screws 212 219 and washers 214 and pull drive housing 202 off motor 201 The A side drive housing includes cycle counter switch 221 If replacing this housing remove pins P and switch Reinstall pins and switch on new drive housing Switch wires connect to J10 pins 5 and 6 on motor control board page 34 TI3250 28 Installation 1 Apply grease liberally to washers 207 208 218 all gears and inside drive housing 202 2 Install one bronze washer 208 in drive housing then install steel washers 207 218 as shown 3 Install second bronze washer 208 on gear cluster 204 and insert gear cluster in drive housing Drive housing crankshaft S must be in line with crankshaft at other end of motor 4 Push drive housing 202 onto motor 201 Install screws 212 219 and washers 214 If bearing housing 203 connect
41. W HEATER pages 60 and 61 247509 247509 MODULE pro portioner page 245957 245957 58 CONTROL motor page 65 24G881 24G881 RANSFORMER 247812 247812 HIELD 276879 276879 TUBE heater TUBE pump TUBE heater TUBE pump 1 CONNECTOR e OR atan 121311 8 MODULE F breaker page 67 6 SWITCH added pole 380V FILTER 230V 117667 117667 1A LABEL warning 198278 198278 2 poses harness 15B385 15B385 5 KIT fluid inlet 234367 234367 5a ELBOW swivel 3 4 npt m x 1 118463 118463 npt f CREW machine RACKET heater 247523 247523 ASHER lock 103181 103181 APACITOR 244733 244733 7 RACKET 197999 197999 59 BOLT hex hd rie 100469 400469 LOCKWASHER 3 8 PE 100133 100133 247509 245957 24G881 247812 2 6879 247915 dal O Co NO NO Co NO N O A 247914 247917 247916 121311 123968 co 117667 198278 dl 15B385 234367 O 118463 be CD UJ 247523 103181 244733 197999 N 2 ev UJ Oo O co 100469 100133 56 Reactor Models Qt 259058 259059 E 30 Description w 15 3kW w 15 3kW w 15 3kW re NOT cama opp NUT channel Neue neus eue 3 y A Heplacement Danger and Warning labels tags and cards are available at no cost Not required for slotted U Channel style heater sup port rails Not for sale 312066Z 3120662 Parts 57 Parts Sub Assemblies Propo
42. ad to the positive terminal and the black lead to the negative terminal Size 50A Hose Transformer 8 Observe the meter reading It should start near 00 Secondary Side and climb up to 10KCO 20KO etc as the meter Transformer 20A battery charges the capacitor This indicates a good Primary 9 A reading of OQ shorted or O L open indicates a 25A 40A bad capacitor In this case replace the capacitor 20 Motor Pumps with the exact replacement part item 76 on pages 55 and 56 NOTE To reference cables and con nectors see the electrical diagrams and the parts drawings on pages 67 68 913 ti9884a Fic 1 Circuit Breaker Module 32 3120667 Electric Motor Removal 1 Turn main power OFF Disconnect power supply 2 Relieve pressure page 23 3 Remove drive housing pump assemblies page 28 4 Disconnect motor cables as follows a Refer to electrical diagrams Motor control board is on right side inside cabinet see page 34 b Unplug motor power harness from connector J4 on board See FIG 2 page 35 c Unplug 3 pin connector J7 from board d Thread cables through top of cabinet to free motor CAUTION Motor is heavy Two people may be required to lift 5 Remove screws holding motor to bracket Lift motor off unit 3120662 Repair Installation 1 Place motor on unit Thread motor cables into cabi net and into bundles as before See el
43. aea Rae oi 60 E30 Momentary loss of communication 16 7 65 kW Single Zone Fluid Heater 61 E99 Loss of communication 16 Reactor Frame LLL L LLL 62 Troubleshooting 0 0 0ooooooooomomoo 17 Display 63 Reactor Electronics o oo 18 Temperature Control sss esses 64 Primary Heaters A and B sese 20 Motor SONO creas padre bi teorie 65 Hose Heat System 21 Fluid Manifold 0 0 cece eee 66 Circuit Breaker Modules 67 248669 Conversion Kit 71 DIMENSIONS ii aia 72 Technical Data x92 iaa 73 Graco Standard Warranty 74 Graco Information 74 2 3120667 Models Models E 20 SERIES Approximate Primary Output per Cycle Maximum Fluid Full Load Peak Voltage System Heater A B Working Pressure Part Series Amps Wattst Watts gal liter psi MPa bar 259025 E 230V 1 10 200 6 000 20 9 0 0104 0 04 2000 14 140 259030 E 400V 3 10 200 6 000 20 9 0 0104 0 04 2000 14 140 259034 E 230V 3 10 200 6 000 20 9 0 0104 0 04 2000 14 140 E 30 SERIES Approximate Primary Output per Cycle Maximum Fluid Part Full Load Peak Voltage System Heater A B Working Pressure Series Watts gal liter psi MPa bar 59026 F 78 0 13 5 0272 0 1034 2000 14 140 59031 F 34 0 200 30 13 5 0272 0 1034 2000 14 140 0 2 5 1 O
44. amaged or corroded Clean connections replace cable if is Display does not respond properly to damaged button pushes Ribbon cable on display circuit board Connect cable page 46 or replace disconnected or broken Broken display button Replace page 46 Red stop button does not work Broken button fused contact Replace page 46 Blown fuse Verify with ciar Es if nec essary page 46 Defective fan Replace page 46 3120662 Troubleshooting Primary Heaters A and B 77 Before performing any troubleshooting procedures 1 Relieve pressure page 23 PROBLEM Primary heater s does not heat Control of primary heat is abnormal high temperature overshoots or E01 error occurs intermittently 20 2 Turn main power OFF 3 Allow equipment to cool Try the recommended solutions in the order given for each problem to avoid unnecessary repairs Also determine that all circuit breakers switches and con trols are properly set and wiring is correct before assum ing there is a problem CAUSE Heat turned off SOLUTION Press Or 3 zone O keys Temperature control alarm Check temperature display for diag nostic code page 8 Signal failure from thermocouple Dirty thermocouple connections Thermocouple not contacting heater element Failed heater element Signal failure from thermocouple Thermocouple wired incorrectly
45. board 701 This could be caused by an abnormally high ambient temperature in the work location blockage of cooling vents in the cabi net or the failure of the cooling fan inside the cabinet 1 Relieve pressure page 23 Verify low pressure with analog gauges 2 Turn main power OFF then ON If error still remains identify cause of the overtempera ture condition and remedy Communication Diagnostic Codes E30 Momentary loss of communication Communications between the display and the motor control board or the temperature control board have been momentarily lost Normally when communication is lost the corresponding display will show E99 The corresponding control board will register E30 The red LED will flash 30 times If communications are recon nected the display can show the E30 for a short time no more than about two seconds It should not be pos sible for E30 to be shown continuously unless there is a loose connection causing the display and the board to continuously lose and regain communication Check all wiring between the display and the corre sponding control board 16 E99 Loss of communication Communications between the display and the motor control board or the temperature control board has been lost When communication is lost the corresponding display will show E99 1 Check all wiring between the display and the corre sponding control board Pay close attention to the wire crimping
46. damaged Defective circuit board Swap display connection to motor control board with connection to heater control board If temperature Temperature display does not illuminate display illuminates heater control board is causing problem Otherwise display cable or display is failing Display disconnected Check cable connections page 46 Display cable damaged or corroded Clean connections replace cable if is damaged Defective circuit board Swap display connection to motor control board with connection to heater control board If pressure dis play illuminates motor control board is causing problem Otherwise dis play cable or display is failing Low voltage Ensure input voltage is within specifi cations page 46 Poor display connection Check cable connections page 46 Erratic display display turns on and Replace damaged cable off Display cable damaged or corroded Clean connections replace cable if is damaged Display cable not grounded Ground cable page 46 Display extension cable too long Must not exceed 100 ft 30 5 m Hose display reads OA at startup FTS disconnected or not installed Verify proper installation of FTS see Pressure display does not illuminate Operation manual 312065 or adjust FTS to desired current setting 18 31206672 Troubleshooting PROBLEM CAUSE SOLUTION Poor display connection Check cable connections page 46 Replace damaged cable Display cable d
47. dels only Jumper wire on J1 connector between module 3 and dis play 4 is loose or incorrectly wired Code Code Name Alarm Corrective Zone Action page High fluid temperature Individual EE NE C High zone current Individual 9 03 No zone current with a E hose heater on 104 FTSnotconnected not connected Individual HM Board overtemperature Individual 10 NEL cable EN NM CTE from module Loss of communication ALL 16 For hose zone only if FTS is disconnected at startup display will show hose current OA Checks AM Troubleshooting this equipment requires access to parts that may cause electric shock or other serious injury if work is not performed properly Have a quali fied electrician perform all electrical troubleshooting Be sure to shut off all power to the equipment before repairing Check which zone is displaying the E01 error 1 Check that connector B is firmly plugged into tem perature control board see FIG 5 page 37 2 Clean and re plug connections 3 Check connections between the temperature con trol board and overtemperature switches A and B 308 and between temperature control board and thermocouples A and B 310 or FTS 21 depend ing on which zone is displaying E01 See Table 5 page 37 Ensure that all wires are securely con nected to connector B 3120662 4 Remove connector B from temperature control mod ule and
48. display There are two types of motor control codes alarms and warnings Alarms take priority over warnings Alarms Alarms turn off Reactor Turn main power OFF then ON to clear SR can also be cleared except for code 23 by pressing O 312066Z Warnings Reactor will continue to run Press O to clear A warning will not recur for a predetermined amount of time varies for different warnings or until main power is turned OFF then ON 1 Code Code Name Alarm A or Corrective Warning W Action No transducer compo A nent A No transducer compo nent B 23 Low line voltage High motor temperature High current Momentary loss of communication Motor control overtemperature Loss of communication 25 High line voltage A m m m 11 Motor Control Diagnostic Codes E21 No component A transducer 1 Check transducer A connection at J3 on motor con trol board page 34 and clean contacts 2 Reverse A and B transducer connections If error moves to transducer B E22 replace transducer A page 36 If error does not move replace motor con trol board page 34 E22 No component B transducer 1 Check transducer B connection at J8 on motor con trol board page 35 and clean contacts 2 Reverse A and B transducer connections If error moves to transducer A E21 replace transducer B page 36 If error does not move replace motor con trol board page 34 E23 High
49. e free solvents To flush feed hoses pumps and heaters separately from heated hoses set PRESSURE HELIEF SPRAY valves SA SB to PRESSURE RELIEF CIRCULATION C25 Flush through bleed lines N SA SB N N TI10954a To flush entire system circulate through gun fluid manifold with manifold removed from gun To prevent moisture from reacting with isocyanate always leave the system dry or filled with a mois ture free plasticizer or oil Do not use water 3 If pumps are not parked press T Trigger gun until pumps stop 4 Turn main power off Disconnect power supply 5 Shut off both feed pumps Close both fluid inlet ball valves B A cU YS ti4147a 6 Turn both PRESSURE RELIEF SPRAY valves SA SB to PRESSURE RELIEF Route fluid to waste containers or supply tanks Ensure gauges drop to O SA SB Pump Removal ZN Ya Pump rod and connecting rod move during operation Moving parts can cause serious injury such as pinch ing or amputation Keep hands and fingers away from connecting rod during operation 24 T110956a 3120662 Use drop cloth or rags to protect Reactor and sur rounding areas from spills Steps 7 9 apply to pump A To disconnect pump B go to steps 10 and 11 7 Disconnect fittings at fluid inlet C and outlet D out of view Also disconnect steel outlet tube from heater inlet 8 Disconnect tubes T Remov
50. e tube fittings U from wet cup 9 Loosen locknut G by hitting firmly with a non sparking hammer Unscrew pump far enough to separate and push up finger guard P to expose rod retaining pin Push retaining wire clip up Push pin out Continue unscrewing pump EN y ma ma YA N gt im E Ww a s M TI3765a 2 3120662 Repair xe 10 and 11 apply to pump B 10 Disconnect fluid inlet C and outlet D Also discon nect steel outlet tube from heater inlet 11 Push retaining wire clip E up Push pin F out Loosen locknut G by hitting firmly with a non sparking hammer Unscrew pump E F G D C TI3765a 1 25 Repair Pump Installation 2 Continue screwing pump into housing until fluid out let D is aligned with steel tube and top threads are 1 16 in 2 mm of bearing face N Steps 1 5 supply to pump B To reconnect pump A proceed to step 6 3 Tighten locknut G by hitting firmly with a non sparking hammer 1 Ensure locknut G is screwed on pump with flat 4 Reconnect fluid inlet C and outlet D side up Screw pump into bearing housing M until pin holes align Push pin F in Pull retaining wire 9 Go to step 13 clip E down AAG DA AM Flat side faces up A Lubricate threads with ISO oil or grease A Pump top threads must be nearly flush with bearing face N T13765a 1 26 3120
51. eactor to a cooler location Allow one hour for cooling 2 Check fan operation 3 Ensure there is no obstruction around the fan area that would cause lack of airflow ensure the motor fan shroud is installed 4 Ensure the unit is being operated with the front cover on 5 Ensure the brush wear over temp switch wire assembly is plugged into J7 E 20 E XP1 or J6 E 30 E XP2 of the motor control board 6 With the main power off unplug the wire harness from J7 E 20 E XP1 or J6 E 30 E XP2 on the motor control board and install a jumper wire on pins 1 and 2 Turn the main power back on If E27 is gone If the E27 error is gone and the motor is truly not over heated then the problem can be in the motor motor wire harness assembly Measure the resistance between the two yellow wires that go to pins 1 and 2 of the motor connector If there is an open connection the thermal overload switch is open or there is a broken wire inside the motor or a broken wire in the motor harness If the E27 error code is still there double check if pins 1 and 2 are jumpered properly If jumpered properly then it would appear that the problem is with in the motor control board 14 E28 High current in motor Check motor control board 1 Turn the master power off 2 Disconnect socket J4 E 20 E XP1 J1 E 30 E XP2 on the motor control board 3 Turn the master power back on 4 Ifthe E28 error did not go away then there is a
52. ectrical dia grams Fasten motor with screws Plug 3 pin connector J7 to board Plug motor power harness to connector J4 on board Install drive housing pump assemblies page 28 Return to service 33 Repair Motor Control Board 8 Set DIP switch SW2 on new board See TABLE 3 for factory settings See FIG 2 for location on board Motor control board has one red LED D11 Power must be on to check See FIG 2 for location Func Table 3 DIP Switch SW2 Settings tion is e Startup 1 blink for 60 Hz 2 blinks for 50 Hz EA Switch Position e Motor running LED on e Motor not running LED off Switch 1 e Diagnostic code motor not running LED blinks diagnostic code pauses then repeats E 30 models E XP2 for example E21 21 blinks pause 21 blinks Switch 3 ON to enable pres OFF to enable sure imbalance pressure imbalance warning alarm Switch 4 CAUTION Before handling board put on a static conductive wrist 9 Install new board in reverse order Apply thermal heatsink compound to mating surfaces of board and heatsink strap to protect against static discharge which can damage board Follow instructions provided with wrist strap dl Part 110009 Thermal Compound 1 Turn main power OFF Disconnect power supply Table 4 Motor Control Board Connectors Description Wait 5 minutes for stored voltage to discharge E 30 n a and E XP2 models only n a Transducer B 3 Refer to elec
53. energized or under pressure Turn off all equipment and follow Pressure Relief Procedure in this manual when the equipment is not in use e Do not operate the unit when fatigued or under the influence of drugs or alcohol e Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals e Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equip ment manuals Read fluid and solvent manufacturer s warnings For complete information about your mate rial request MSDS forms from distributor or retailer e Check equipment daily Repair or replace worn or damaged parts immediately with genuine manufacturer s replacement parts only e Do not alter or modify equipment e Use equipment only for its intended purpose Call your distributor for information e Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces e Do not kink or over bend hoses or use hoses to pull equipment e Keep children and animals away from work area e Comply with all applicable safety regulations 6 3120662 74 312066Z Warnings MOVING PARTS HAZARD Moving parts can pinch 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 servicing equipment
54. er module FIG 4 Replace if blown If good continue with step 4 36 4 Disconnect transducer cables at board see FIG 2 page 35 Reverse A and B connections and check if diagnostic code follows see E21 No component A transducer page 12 5 If transducer fails test thread cable through top of cabinet Note path as cable must be replaced in same way 6 Install o ring 820 on new transducer 806 FIG 3 7 Install transducer in manifold Mark end of cable with tape red transducer A blue transducer B 8 Route cable into cabinet and thread into bundle as before 9 Connect transducer cable at board see FIG 2 page 35 806 B Side 820 T110957a 4 Refer to electrical diagrams Disconnect fan wires from fuses F 5 Remove fan 6 Install fan in reverse order F Viii ae JE H Q Q EH plot T E AL ti9884a 1 Fic 4 Fan Fuses 3120662 Repair Temperature Control Module Table 5 Temperature Control Module Connections DATA A Data reporting PIN 12 11 HOSE T C P FTS purple HOSE T C R FTS red 10 HOSE T C S FTS silver unshielded bare wire HEATER T C B Y hermocouple yellow HEATER T C B R hermocouple red 7 Not used HEATER T C A Y hermocouple yellow 5 HEATER T C A R hermocouple red Overtemperature switch B Overtemperature switch A 3 1 COMMUNICATION D Communicati
55. es 210 ft 64 m maximum heated hose length including whip hose e E 30 and E XP2 series 310 ft 94 5 m maximum heated hose length including whip hose Maximum flow rate given for 60 Hz operation For 50 Hz operation maximum flow rate is 5 6 of 60 Hz maximum flow 312066Z 3 Supplied Manuals Supplied Manuals The following manuals are shipped with the Reactor Proportioner Refer to these manuals for detailed equip ment information Order Part 15M334 for a compact disk of Reactor manu als translated in several languages Manuals are also available at www graco com Reactor Electric Proportioner Description 312065 Reactor Electric Proportioner Operation Manual English Reactor Electrical Diagrams Description 312067 Reactor Electric Proportioner Electrical Diagrams English Displacement Pump Description 309577 Electric Reactor Displacement Pump Repair Parts Manual English Related Manuals The following manuals are for accessories used with the Reactor Order Part 15M334 for a compact disk of Reactor manu als translated in several languages Reactor Data Reporting Kit Description 309867 Fusion Spray Gun Instruction Parts Manual English Description 309550 Instruction Parts Manual English Heated Hose Description 309572 Instruction Parts Manual English Circulation and Return Tube Kit Description 309852 Rupture Disk Assembly Kit Instruction Parts Manual
56. follow the Pressure Relief Procedure in this manual Disconnect power or air supply BURN HAZARD Equipment surfaces and fluid that s heated can become very hot during operation To avoid severe burns do not touch hot fluid or equipment Wait until equipment fluid has cooled completely Temperature Control Diagnostic Codes Temperature Control Diagnostic Codes Temperature control diagnostic codes appear on tem perature display These alarms turn off heat E99 clears automatically when communication is regained Codes E03 through E06 can be cleared by pressing O For other codes turn main power OFF then ON to clear E01 High fluid temperature Causes of E01 Errors Thermocouple A or B 310 senses a fluid tempera ture above 230 F 110 C Fluid temperature sensor FTS senses a fluid tem perature above 230 F 110 C Overtemperature switch A or B 308 senses a fluid temperature above 230 F 110 C and opens At 190 F 87 C the switch closes again Thermocouple A or B 310 fails is damaged is not touching the heater element 307 or has a poor connection to the temperature control board Overtemperature switch A or B 308 fails in the open position The temperature control board fails to turn off any heat zone Zone power wires or thermocouples are switched from one zone to another Failed heater element where thermocouple is installed Loose wire On 6 0 and 10 2 kW heater mo
57. gun fluid Open clear use hose with larger ID hose ID too small Worn piston valve or intake valve in See pump manual displacement pump Pressure setpoint too high Reduce setpoint and output will increase Fluid leak in pump packing nut area Worn throat seals Replace See pump manual No pressure on one side Fluid leaking from heater inlet rupture Check if heater 2 and PRESSURE disk 314 HELIEF SPRAY valve SA or SB are plugged Clear Replace rupture disk 314 with a new one do not replace with a pipe plug 3120662 17 Troubleshooting Reactor Electronics 2 Turn main power OFF 7 Try the recommended solutions in the order given for each problem to avoid unnecessary repairs Also Before performing any troubleshooting procedures determine that all circuit breakers switches and con trols are properly set and wiring is correct before assum 1 Relieve pressure page 23 ing there is a problem PROBLEM CAUSE SOLUTION Plug in power cord No power Turn disconnect ON l Both sides of display do not 1 illuminate Low voltage Ensure input voltage is within specifi cations page 46 Loose wire Loose wire Check connections page 46 Display disconnected Check cable connections page 46 Display disconnected Display disconnected Check cable connections page 46 Display cable damaged or corroded Clean connections replace cable if is
58. i nals of the connector D There should be no conti nuity 5 Exchange zone module with another one Turn zone on and check for error If error disappears replace faulty module For hose zone If error still occurs perform Trans former Primary Check and Transformer Secondary Check starting on page 45 When there is a a high current error the LED on that zone s module will turn red while the error is displayed Temperature Control Diagnostic Codes E03 No zone current 1 Check for tripped circuit breaker inside electrical cabinet or at power source for that zone Replace circuit breaker if it trips habitually 2 Check for loose or broken connection at that zone 3 Exchange zone module with another one Turn zone on and check for error See page 38 If error disappears replace faulty module 4 f E03 occurs for all zones the contactor may not be closing Verify wiring from heater control to contac tor coil a Hose zone test hose continuity page 43 b Perform Transformer Primary Check and Transformer Secondary Check starting on page 45 When ano current error occurs the LED on the specific zone s module turns red when the error is displayed E04 Fluid Temperature Sensor FTS or thermocouple disconnected 1 Check temperature sensor connections to long green connector B on temperature control module page 37 Unplug and re plug sensor wires 2 Test fluid temperature sensor continuity w
59. ing out of the brush away from the commutator wiring 4 Check motor control board e Remove the plug in J7 E 20 E XP1 or J6 E 30 E XP2 This will cause an E27 alarm e To remove the E27 alarm use a jumper wire on the motor control board across the two pins that the two yellow wires plug into Then turn the unit on e The E27 as well as the E29 alarm should be gone If the E27 alarm is not gone double check your jumper e Ifthe jumper is installed correctly and the E29 alarm is still there replace the motor control board page 34 E31 Motor Control Failure E 30 and E XP2 only The E31 error code represents a motor drive error This indicates that the 24G881 motor control board has mal functioned and needs to be replaced A motor control board failure may also be indicated by the motor starting up immediately upon the application of power to the sys tem without pressing O This is an indication that the output drivers of the motor control have shorted out and are delivering full power to the motor at all times The cause of the failure may be one of the following con ditions motor failure capacitor failure shorted or frayed wiring or inadequate power supply Perform the follow ing procedure before replacing the motor control board 3120662 Motor Control Diagnostic Codes 1 Turn main power OFF Disconnect power supply Wait 5 minutes for stored voltage to discharge E 30
60. ing rod 205 or pump 206 were removed reassemble rod in housing and install pump page 26 5 Install bearing housing 203 screws 213 and washers 215 Pumps must be in phase both at same position in stroke 6 Install front cover 217 and screws 209 7 Install motor shield 9 and screws 38 312066Z Repair A Crankshaft must be in line with crankshaft at other end of motor TI3152 312066Z 20 Repair Motor Brushes 5 Loosen terminal screw R Pull away brush lead L being careful motor lead terminal T remains in place Remove and discard brush B Brush Removal Replace brushes worn to less than 1 2 in 13 mm Brushes wear differently on each side of motor check both sides Brush Repair Kit 234037 is available 1 Turn main power OFF Disconnect power B supply 01227 4 WM 6 Inspect commutator for excessive pitting burning l or gouging Black color on commutator is normal Wait 5 min for stored voltage to discharge E 30 and Have commutator resurfaced by qualified motor E XP2 models only repair shop if brushes wear too quickly 2 Relieve pressure page 23 RL 3 Remove motor cover screw and washers Remove inspection covers screws and gaskets from each end of motor 4 Push in spring clip C to release hooks H from brush holder Pull out clip and spring S S 01227 2 One brush has a wire on top for brush wear
61. ith ohm meter page 8 3 If an error occurred for the hose zone check FTS connections at each section of hose 4 Ifan error occurred for the hose zone test FTS by plugging directly into machine T110964a 10 5 To verify heater control module is not causing the problem use a wire to short circuit the two pins cor responding to the FTS red and yellow for A or B zone red and purple for hose The display will show the control heater module temperature 6 If an error occurred for the hose zone temporarily use the current control mode Refer to Reactor Operation manual 312062 E05 Circuit board overheated Each module has an on board temperature sensor Heat is turned off if module temperature exceeds 185 F 85 C within the heater module 1 Check that fan above electrical cabinet is operating 2 Check that electrical cabinet door is properly installed 3 Check for obstructions blocking cooling holes in bot tom of electrical cabinet 4 Clean heatsink fins behind heater control modules 5 Ambient temperature may be too high Allow Reac tor to cool by moving to a cooler location E06 Communication cable unplugged 1 Unplug and re plug cable that connects heater con trol module to heater module 2 Replace communication cable if problem persists 3120662 Motor Control Diagnostic Codes Motor Control Diagnostic Codes Motor control diagnostic codes E21 through E29 appear on pressure
62. ity supply Disconnect power If you are not sure which wire in green plug under hose module connects to transformer test both wires One wire should have continuity with the other transformer wire in breaker 909 and the other wire should not 2 Open Reactor cabinet 3 Remove bolts holding transformer to cabinet floor Slide transformer forward 4 Disconnect the transformer wires see Reactor Elec trical Diagrams manual 312067 5 Remove transformer from cabinet ti9884a 6 Install new transformer in reverse order Fic 10 Circuit Breaker Module 312066Z 45 Repair Display Module Temperature and Pressure Displays CAUTION Before handling board put on a static conductive wrist strap to protect against static discharge which can damage board Follow instructions provided with wrist strap 10 11 12 46 Turn main power OFF Disconnect power supply Relieve pressure page 23 Refer to electrical diagrams Put on static conductive wrist strap Disconnect main display cable 20 at lower left cor ner of display module see FIG 11 Remove screws 509 510 and cover 504 see Fic 11 If replacing both displays label temperature display cables TEMP and pressure display cables PUMP before disconnecting Disconnect cable connectors 506 and 511 from back of temperature display 501 or pressure dis play 502 see FIG 11
63. lelo dle Ale dip oll A SSS DH ES i 918 dl TES 922 B 400V 3 Phase Circuit Breaker Modules E 20 E XP1 For wiring and cable connections refer to electrical diagrams manual 312067 supplied See page 70 910 917 for parts 920 905 906 911 IM LY 99 913 918 II E EE 912 IM PS es 922 312066Z 67 Parts C 230V 1 Phase Circuit Breaker Modules E 20 EXP 1 910 iri 920 905 914 917 For wiring and cable connections refer to electrical 906 911 diagrams manual 312067 supplied See page 70 for parts 903 904 915 f 908 902 ji 901 916 TEST een e ee T 919 1819 922 D 230V 3 Phase Circuit Breaker Modules E 30 EXP 2 For wiring and cable connections refer to electrical diagrams manual 312067 supplied See page 70 for parts 910 920 905 906 944 914 917 903 904 gt 915 qe dB 908 TT 1688R p EIE v oe ee tod d um lo eda as mE id S T NE PE El one 919 922 68 312066Z Parts E 400V 3 Phase Circuit Breaker Modules E 30 E XP2 For wiring and cable connections refer to electrical diagrams manual 312067 supplied See page 70 for parts 910 917 920 905 906 911 903 904 918 F 230V 1 Phase Circuit Breaker Modules E 30 EXP 2 For wiring and cable connections refer to electrical 910 diagrams manual 312067 supplied See page 70 914 for pa
64. oc dures judiciaires executes donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice For patent information see www graco com patents Original instructions This manual contains English MM 312066 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2007 Graco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com Revision Z January 2015
65. ol boards socket If the gauge readings are not equal 1 Clear the error and balance the pressures using the dump valves 2 If you cannot get the pressures to balance e Check for pump failure e Check for adequate material e Using the feed pump to push fluid out through the gun manifold check for a plugged fluid path e Run the unit e Check and clean the gun inlet screens e Check and clean the mix chamber A and B impingement ports a well as the center port Note Some mix chambers have counter bored holes and require two drill sizes to clean impingement ports completely Slow E24 e When spraying gradual pressure imbalance and eventual E24 Possible Causes One side of the Gun is partially blocked The A or the B pump on the Reactor has failed The A or the B feed pump has failed The A or the B feed pump pressure is set too high The A or the B inlet screen is plugged The hose is not heating properly Kinked supply hose Bottom of the drum is damaged causing a blockage to the inlet of the feed pump e The drum is not vented properly Motor Control Diagnostic Codes E25 High line voltage Supply voltage too high Check Reactor voltage require ments page 73 E26 Low line voltage Supply voltage too low Check Reactor voltage require ments page 73 E27 High Motor Temperature 1 Motor temperature too high Reduce pressure gun tip size or move R
66. on to power l l ti9843a1 boards Right Side of PROGRAM E Software programming CONTON EATE MORUE BOOT F Software bootloader POWER RELAY G Circuit board power input and ontactor control output Table 6 Temperature Power Module Connections SENSOR B ti9875a 4 2 ti9843a4 COMMUNICATION Communication to control H board POWER J Power to heater Bottom of Power Modules FiG 5 Temperature Control Module Connections 312066Z 37 Repair Test SCR Circuit Replacing Temperature Control Assembly 1 Test the SCR circuit in the on position Modules a Make sure everything is connected including the hose b Turn main power ON c Adjust the hose heat setpoint above the ambi ent hose temperature d Turn on heat zone by pressing o e Hold down D to view electrical current Hose current should ramp up to 45A If there is no hose current see E03 No zone current page 10 If hose current exceeds 45A see E02 High zone current page 9 If hose current stays several amps below 45A hose is too long or voltage is too low Test the SCR circuit in the off position a Make sure everything is connected including the hose b Turn main power ON c Adjust the hose heat setpoint below the ambi ent hose temperature d Turn on heat zone by pressing O e Using a voltmeter carefully measure the volt age at the hose connector You should not get a voltage reading If you do the SCR
67. r unplug power cords or turn lights on or off when flammable fumes are present Ground equipment personnel object being sprayed and conductive objects in work area See Grounding instructions Use only Graco grounded hoses Check gun resistance daily If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem Do not flush with gun electrostatics on Do not turn on electrostatics until all solvent is removed from sys tem Keep a working fire extinguisher in the work area THERMAL EXPANSION HAZARD D Fluids subjected to heat in confined spaces including hoses can create a rapid rise in pressure due to the ther uhi mal expansion Over pressurization can result in equipment rupture and serious injury e Open a valve to relieve the fluid expansion during heating e Replace hoses proactively at regular intervals based on your operating conditions r PRESSURIZED ALUMINUM PARTS HAZARD Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids contain ing such solvents in pressurized aluminum equipment Such use can cause serious chemical reaction and equipment rupture and result in death serious injury and property damage EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury e This equipment is for professional use only e Do not leave the work area while the equipment is
68. re with screws 31 1 Heconnect wires If wires need replacement disconnect from temper ature control board See TABLE 5 page 37 and FIG 5 page 37 Heated Hose Refer to the heated hose manual 309572 for hose replacement parts Check Hose Connectors 1 Turn main power OFF Disconnect power supply 2 Relieve pressure page 23 NOR hose must be connected 3 Disconnect hose connector D at Reactor FIG 8 312066Z Repair 4 Using an ohmmeter check between the two termi nals of the connector D There should be continu ity 5 If hose fails test retest at each length of hose including whip hose until failure is isolated Check FTS Cables 1 Turn main power OFF Disconnect power supply 2 Relieve pressure page 23 3 Disconnect FTS cable F at Reactor FIG 8 T110964a Fic 8 Heated Hose 4 Test with ohmmeter between pins of cable connec tor Result 1to2 approximately 35 ohms per 50 ft 15 2 m of hose plus approximately 10 ohms for FTS 5 If cable fails test retest at FTS page 44 43 Repair Fluid Temperature Sensor FTS 4 f FTS fails any test replace FTS Test Removal 5 Disconnect air hoses C L and electrical connec tors D 6 Disconnect FTS from whip hose W and fluid hoses 1 Turn main power OFF Disconnect power A B supply 7 Remove ground wire K from ground screw on 2 Relieve pressure page 23 underside of FTS
69. rtioner Module 245956 Module for E 20 and EXP 1 245957 Module for E 30 245959 Module for EXP 2 226 209 TI2511a A Flat side faces up Detail of Cycle Counter Switch 221 TI3250a 58 312066Z Proportioner Assembly 245956 Module for E 20 and E XP1 245957 Module for E 30 245959 Module for E XP2 Ref 201 202 203 204 205 206A 206B 207 208 209 210 211 212 213 214 215 216 217 218 219 220 Part 24V618 24V500 245968 245969 240523 241015 245927 244264 244265 241008 241279 246830 246831 246832 245970 245971 245972 114699 114672 114418 114818 176817 183169 176818 183210 107218 114686 107210 114666 105510 104008 106115 192723 193031 193394 179899 241308 116191 116192 100644 101864 116618 3120662 Description MOTOR 245956 MOTOR 245957 245959 HOUSING drive 245956 HOUSING drive 245957 245959 HOUSING bearing 245956 HOUSING bearing 245959 HOUSING bearing 245957 GEAR includes items 207 208 245956 GEAR includes items 207 208 245957 245959 ROD connecting includes item 210 245956 ROD connecting includes item 210 245957 245959 PUMP displacement component A 245956 see 309577 PUMP displacement component A 245959 see 309577 PUMP displacement component A 245957 see 309577 PUMP displacement component B 245956 see 309577 PUMP displacement component B 245959 see 309577
70. rts 920 905 906 911 917 903 904 A 915 p Y B 908 902 a Ae SEIS aro ore ale o 916 HNI S lt Wi blo olo y E C 913 919 312066Z 69 Parts Circuit Breaker Modules Parts List Breaker Modules E 20 and EXP 1 Models E 30 and EXP 2 Models gt UJ O Og m T 230V 400V 230V 230V 400V 230V Description 3 phase 3 phase 1 phase 3 phase 3 phase 1 phase 901 RAIL mounting 255028 255028 255028 255028 255028 255028 902 ICLAMP block end 255045 255045 255045 255045 255045 255045 903 IHOLDER fuse terminal block 255043 255043 255043 255043 255043 255043 904 FUSE 255023 255023 255023 255023 255023 255023 905 TERMINAL block 255042 255042 255042 255042 255042 255042 ERMINAL end cover 907 BRIDGE plug in jumper 255044 255044 255044 255044 255044 255044 908 BLOCK terminal ground 255046 255046 255046 255046 255046 255046 209 REAKER 1 pole 50A 255026 255026 255026 255026 255026 255026 910 CONTACTOR relay 65A 255022 255022 255022 255022 255022 255022 247768 247768 247768 247768 247768 247768 co 11 BREAKER 2 phase 40A 255050 255050 255050 255050 255050 255050 co 12 BREAKER 2 phase 25A 247768 247768 247768 247768 247768 247768 REAKER 2 phase 40A E NEN i 255049 255049 255049 255049 255049 255049 co 13 BREAKER 2 phase 20A 117679 117679 co 14 CONNECTOR power lug 117679 117679 ONNECTOR power lug 117805 117805 AR power
71. sig nal Note which side of motor it is on Unplug at spade connector provided 30 312066Z Brush Installation CAUTION When installing brushes follow steps carefully Improper installation damages parts beyond use 1 2 3 Install brush with wires on same side of motor as before Plug spade terminal into connector Install new brush B so lead L is in long slot D of holder 01227 5 Slide terminal L under terminal screw R Make sure motor lead terminal T is still connected at screw Tighten screw 01227 4 Install spring S so it will uncoil onto brush B as shown Spring will be damaged if installed back wards A Note direction of spring coil 01227 312066Z Repair 4 Install spring clip C and push in until hooks H catch slots in housing Incorrect installation may jam clip 01227 2 01227 6 M Do not touch brushes leads springs or brush holders while equipment is plugged in to reduce the risk of electric shock and serious injury CAUTION Do not run pumps dry for more than 30 sec while checking brushes to avoid damaging pumps 5 Reinstall brush inspection covers gaskets and screws Reinstall motor cover screws washers and drive housing pump assemblies 6 Test brushes with both pump pins F disconnected page 30 Select J 1 jog mode Press motor O to start motor Slowly increase jog setting to J 6
72. ted to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du presente document sera en Anglais ainsi que tous documents avis et pr
73. trical diagrams Motor control board is Motor thermal overload signal on right side inside cabinet Brush wearsiofal 4 Put on static conductive wrist strap ala ander A BH 5 Disconnect all cables and connectors from board A 6 Remove nuts 40 and take entire motor control 5 6 Cycle switch signal assembly to workbench 7 10 Jumper 15C866 available in 7 Remove screws and take board off heatsink repair kit 246961 Data reporting To display board n a n a 34 312066Z Repair 24G879 Motor Control for E 20 and E XP1 DIP Switch SW2 Settings Model E 20 ON UP E y y J3 A J8 B 1234 T7935 Model E XP1 PS ON UP D11 J12 TH 1234 T7824 J1 SW2 TI3153A 1 24G881 Motor Control for E 30 and E XP2 DIP Switch SW2 Settings Model E 30 vez LLE ON Down Tis17e0 2 J3 B Model E XP2 vez d d ae rx wr B 0 E gt ON Down TI3178b 1 N Apply 110009 thermal heatsink compound to mating surfaces Fic 2 Motor Control Board 312066Z 35 Repair Transducers 1 Turn main power OFF Disconnect power supply 2 Relieve pressure page 23 3 Refer to electrical diagrams Motor control board is on right side inside cabinet 806 A Side Fic 3 Transducers Electric Fan 1 Turn main power OFF Disconnect power supply 2 Relieve pressure page 23 3 Check fuses F at left of break
74. ury including eye injury inhalation of toxic fumes burns and hear ing loss This equipment includes but is not limited to e Protective eyewear e Clothing and respirator as recommended by the fluid and solvent manufacturer e Gloves e Hearing protection SKIN INJECTION HAZARD High pressure fluid from gun 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 e 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 Do not spray without tip guard and trigger guard installed Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking 2 or servicing equipment Tighten all fluid connections before operating equipment Check hoses and couplings daily Replace worn or damaged parts immediately 312066Z 5 Warnings FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and explosion Use and clean equipment only in well ventilated area Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Keep work area free of debris including solvent rags and gasoline Do not plug o
75. voltage signifi cantly reduces power available to hose heat system affecting longer hose lengths Hose heats but heats slower than usual or it does not reach temperature A and B setpoints too low Increase A and B setpoints Hose is designed to maintain temperature not to increase it Ambient temperature is too cold Increase A and B setpoints to increase fluid temperature and keep it steady Flow too high Use smaller mix chamber Decrease pres sure Hose does not maintain tem Hose was not fully preheated Wait for hose to heat to correct tempera perature while spraying ture before spraying Low supply voltage Verify line voltage Low line voltage signifi cantly reduces power available to hose heat system affecting longer hose lengths A and or B heaters are overheating Check primary heaters for either a ther material mocouple problem or a failed element attached to thermocouple page 10 Faulty thermocouple connections Verify that all FTS connections are snug and that pins of connectors are clean Hose temperature exceeds set Examine connection of thermocouples to point long green plug on heater control board Unplug and re plug thermocouple wires cleaning off any debris Unplug and re plug long green connector on heater control board Missing damaged insulation around Ensure hose bundle has adequate insula FTS causing the hose heat to be ON tion evenly covering the entire length and

Graco 312066Z User's Manual

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