Graco Reactor 2 E-30 Repair Parts Download

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Repair-Parts

Reactor 2 E-30 and E-XP2
Proportioning System

333024A

Electric, Heated, Plural Component Proportioning System. For spraying polyurethane foam and

polyurea coatings. For professional use only. Not approved for use in explosive atmospheres or

hazardous locations.

Important Safety Instructions. Read all warnings and instructions in

this manual. Save these instructions.

PROVEN QUALITY. LEADING TECHNOLOGY.

Summary of Contents for Reactor 2 E-30

Page 1: ...oportioning System For spraying polyurethane foam and polyurea coatings For professional use only Not approved for use in explosive atmospheres or hazardous locations Important Safety Instructions Rea...

Page 2: ...ir Drive Housing 50 Repair Electric Motor 53 Repair Circuit Breaker Module 54 Replace Fluid Inlet Sensor 55 Replace Pressure Transducers 55 Replace Fans 56 Repair Primary Heater 59 Repair Heated Hose...

Page 3: ...ower source All electrical wiring must be done by a quali ed electrician and comply with all local codes and regulations Do not expose to rain Store indoors TOXIC FLUID OR FUMES Toxic uids or fumes ca...

Page 4: ...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...

Page 5: ...lcohol Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals Use uids and solvents that are compatible with...

Page 6: ...h protective guards or covers removed Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure and disconnect all power source...

Page 7: ...B Separate Cross contamination can result in cured material in uid lines which could cause serious injury or damage equipment To prevent cross contamination Never interchange component A and component...

Page 8: ...n your equipment requires special attention to avoid equipment damage and downtime When changing materials ush the equipment multiple times to ensure it is thoroughly clean Always clean the uid inlet...

Page 9: ...230 1 230 3 380 3 Y Full Load Peak Current 78 50 34 100 62 35 78 50 34 100 62 35 Base Machine 272010 272110 272011 272111 Heated Hose 50 ft 15 m 24K240 scuff guard 24K240 scuff guard 24Y240 Xtreme Wra...

Page 10: ...gurable Voltage Phase 230 1 230 3 380 3 Y 230 1 230 3 380 3 Y Full Load Peak Current amps 100 62 35 100 62 35 Fusion AP Package Gun Part No AP2012 246101 AP2112 246101 Probler P2 Package Gun Part No...

Page 11: ...m CAN cable for remote display module 24K207 Fluid Temperature Sensor FTS with RTD 24U174 Remote Display Module Kit 24K337 Light Tower Kit 15V551 ADM Protective Covers 10 pack 15M483 Remote Display Mo...

Page 12: ...graco com System Manuals 333023 Reactor 2 E 30 and E XP2 Operation Displacement Pump Manual 309577 Electric Reactor Displacement Pump Repair Parts Feed System Manuals 309572 Heated Hose Instructions P...

Page 13: ...rameter that is not immediately critical to the process The advisory needs attention to prevent more serious issues in the future See Error Codes page 14 for causes and solutions to each error code To...

Page 14: ...ons Short circuit in heater wiring Check wiring for touching wires A4DA Heater A High Current A Bad Heater Con rm resistance of heater Heater resistance should be 18 21 for each heater element 9 12 co...

Page 15: ...ng Damaged gear train Check pump gear trains for damage and repair or replace as necessary A4NM MCM High Motor Current Chemical pump is stuck Repair or replace chemical pump A7DA Heater A Unexpected C...

Page 16: ...system token into the ADM module and cycle the power Wait until the upload is complete before removing the token Dial set to wrong position Ensure the MCM dial is set to the correct position 2 for E 3...

Page 17: ...tween GCA modules and tighten of needed If the problem still persists move each cable around the connector and watch the ashing yellow light on the GCA modules If the yellow light stops ashing replace...

Page 18: ...oming power is between 45 and 65 Hz H2MB Heater B Low Frequency B Line frequency is below 45 Hz Ensure line frequency of incoming power is between 45 and 65 Hz H2MH Hose Low Frequency Hose Line freque...

Page 19: ...he ADM and download all logs Pressure difference between A and B material is greater than the de ned value Ensure material ow is equally restricted on both material lines Pressure imbalance is de ned...

Page 20: ...nce B High Feed system defective Check feed pump and hoses for blockage Check that feed pumps have correct air pressure Inlet pressure lower than de ned value Ensure that inlet pressure to the pump is...

Page 21: ...pressure transducer Verify the ADM pressure reading and the analog guages at the manifold P4AX MCM High Pressure A E XP2 system con gured as E 30 Alarm level is lower for E 30 than for E XP2 Ensure d...

Page 22: ...M Pressure Sensor Error B Bad sensor Check if the error follows the transducer Disconnect transducer cables from the MCM connectors 6 and 7 Reverse A and B connections and check if the errors follows...

Page 23: ...s the sensor replace the inlet sensor Pressure difference between A and B material is greater than the de ned value Ensure material ow is equally restricted on both material lines Pressure imbalance i...

Page 24: ...disk Do not replace with a pipe plug P7BX MCM Pressure Imbalance B High Feed system defective Check feed pump and hoses for blockage Check that feed pumps have correct air pressure Flow is too high at...

Page 25: ...ary Flow is too high at current setpoint Use a smaller mix chamber that is rated for the unit in use If recirculating decrease ow or decrease temperature setpoint T2DH Hose Low Temperature Hose Cold c...

Page 26: ...osure is spinning If it is not check fan wiring or replace fan T3CT TCM TCM Cutback Module fan not operating If a TCM fan error WMI0 has occurred fan inside the module is not working properly Check TC...

Page 27: ...necessary Bad RTD or bad RTD placement against heater Swap A and B heater output cables and RTD cables and see if issue follows If so replace RTD T4DA Heater A High Temperature A Flow too high for te...

Page 28: ...ng to reach the FTS Increase hose setpoint so it is closer to A and B setpoints Overtemperature switch sensed a uid temperature above 230 F 110 C Heater was delivered too much power causing the overte...

Page 29: ...ertemperature switch Cooling fan is not operating properly Check to see that the motor fan is moving Measure voltage to fan There should be 24 VDC If no voltage is measured check fan wiring If the fan...

Page 30: ...d FTS continuity Order RTD Test kit 24N365 for measurement Disconnect hose RTD and use manual hose mode to nish job until repair can be completed Broken RTD cable in hose or bad FTS Expose each hose R...

Page 31: ...RTD cables and see if issue follows If so replace RTD Bad heater rod or loose heater wire Con rm resistance of heater Heater resistance should be 9 12 for 10 kW systems and 6 8 for 15 kW systems If ou...

Page 32: ...se connection or tripped circuit breaker Check wiring for loose connection or tripped circuit breaker V2MB TCM Low Voltage B Low incoming line voltage Measure voltage at circuit breaker and ensure vol...

Page 33: ...e at each circuit breaker is between 195 and 264 VAC V4IT TCM High Voltage CAN Bad 24 VDC power supply Check voltage of power supply Voltage should be 23 25 VDC If out of tolerance replace power suppl...

Page 34: ...is in the TCM fan and clear with forced air if necessary WSUX USB Con guration Error USB A valid con guration le can t be found for the USB Inset a system token into the ADM and cycle power Wait until...

Page 35: ...Turn main power switch ON Failed 24 V power supply Replace power supply Reactor ADM does not turn on Failed surge protector Replace surge protector Loose connections Check MCM connection 13 Tripped ci...

Page 36: ...ith larger ID Worn piston valve or intake valve in displacement pump See pump manual Pump output low Pressure setpoint too high Reduce setpoint and output will increase Fluid leak in pump packing nut...

Page 37: ...to increase it Ambient temperature is too cold Increase A and B setpoints to increase uid temperature and keep it steady Flow too high Use smaller mix chamber Decrease pressure Hose was not fully pre...

Page 38: ...uid Temperature Sensor FTS page 64 FTS failed Check FTS see Repair Fluid Temperature Sensor FTS page 64 FTS not installed correctly FTS should be installed close to end of hose in same environment as...

Page 39: ...B temperature setpoints too low Increase A and B setpoints Hose designed to maintain temperature not increase temperature Hose temperature setpoint too low Check Increase if necessary to maintain heat...

Page 40: ...Check ADM for error codes Primary Heater s does not heat Signal failure from RTD Signal failure from RTD Dirty RTD connections Examine RTD cables connected to TCMs Con rm RTDs are not plugged into op...

Page 41: ...ellular connection Wait a few minutes for the unit to establish the connection Move system to a location with cellular service to establish cellular connection Has not established cellular connection...

Page 42: ...Procedure when you stop spraying and before cleaning checking or servicing equipment The Fusion AP gun is shown 1 Relieve pressure in gun and perform gun shutdown procedure See gun manual 2 Close gun...

Page 43: ...pment reliability The following procedures ensure steady voltage Failure to follow these procedures will cause voltage uctuations that can damage electrical equipment and void the warranty 1 Press to...

Page 44: ...Shutdown 8 Close all uid supply valves 9 Engage gun piston safety lock then close uid inlet valves A and B Fusion Probler 44 333024A...

Page 45: ...ith common solvents Use only moisture free solvents To ush feed hoses pumps and heaters separately from heated hoses set PRESSURE RELIEF SPRAY valves SA SB to PRESSURE RELIEF CIRCULATION Flush through...

Page 46: ...edures are followed there should be minimal contamination of the A side screen Note Clean the A side screen only during daily startup This minimizes moisture contamination by immediately ushing out an...

Page 47: ...peration 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 Follow Pressure Relief...

Page 48: ...7 for pump repair instructions 1 Press to stop the pumps 2 Turn off heat zones 3 Flush pump 4 Press to park the pumps in the down position 5 Press to deactivate the system 6 Turn main power switch off...

Page 49: ...13 Push retaining wire clip E up Push pin F out Loosen locknut G by hitting rmly with a non sparking hammer Unscrew pump Pump B Figure 4 1 Flat side faces up 2 Lubricate threads with ISO oil or greas...

Page 50: ...securely 10 Tighten star shaped locknut G by hitting rmly with a non sparking hammer 11 Apply thin lm of TSL to barbed ttings Using two hands support tubes T while pushing straight onto barbed ttings...

Page 51: ...Pump page 48 11 Remove cover 60 and screws 21 12 Remove cycle counter 121 from housing by removing screw 122 13 Disconnect pump inlet and outlet lines Remove screws 113 washers 115 and bearing housing...

Page 52: ...ine with crankshaft at other end of motor 4 Push drive housing 102 onto motor 101 Install screws 112 and washers 114 Note If bearing housing 103 connecting rod 105 or pump 106 were removed reassemble...

Page 53: ...ness to remove cable 6 Remove four screws 25 holding motor 101 to bracket Lift motor off unit Installation 1 Place motor on unit Thread motor cables into conduit as before See Electrical Schematics pa...

Page 54: ...ge 43 c Refer to circuit breaker identi cation table and electrical diagrams in Reactor repair manual d Loosen two screws connecting wires and bus bar to circuit breaker that will be replaced Disconne...

Page 55: ...secure cable in wire bundle with wire ties 5 Replace sensor 602 Replace Pressure Transducers 1 Perform Shutdown page 43 2 Perform Pressure Relief Procedure page 42 3 Disconnect transducer cables 405...

Page 56: ...Open cabinet door and disconnect fan cables from terminal blocks See Electrical Schematics page 89 3 Remove four screws 21 from motor cover 11 If necessary fold frame 1 to remove motor cover 10 See Re...

Page 57: ...Fan 1 Perform Shutdown page 43 2 Open electrical enclosure door 401 Loosen four nuts 421 and remove fan 404 3 Install new fan 404 in reverse order of disassembly so that the fan blows out of the elect...

Page 58: ...4 Disconnect fan and transformer connections from terminal blocks Connections are on left side labeled V V 1 2 3 and 4 5 Remove four nuts 27 holding metal transformer cover 8 to frame Carefully remov...

Page 59: ...e four bolts 23 and shroud 10 10 Remove screw 20 and lower din rail cover 48 11 Disconnect heater wires a A Side Disconnect A side heater wires transformer and transformer fan wires from lower din rai...

Page 60: ...emove heater element 208 19 Inspect element It should be relatively smooth and shiny Replace element if there is a crusted burnt ash like material adhered to element or sheath shows pitting marks 20 I...

Page 61: ...ep 5 b If the resistance is approximately 0 ohms inspect cable 46 to ensure it is not cut or open Reconnect the overtemperature switch 209 and cable 46 Disconnect cable from TCM Test from pin 1 to 3 a...

Page 62: ...212 from woven wrap 8 Replace RTD 212 a Apply PTFE tape and thread sealant to male threads and tighten RTD housing H into adapter 206 b Push in RTD 212 so tip contacts heater element 208 c Holding RTD...

Page 63: ...oximately 1090 ohms 1 to 4 0 2 0 4 ohms 2 to any in nity open 4 Retest at each length of hose including whip hose until failure is located 5 If the FTS is not reading properly at the end of the hose c...

Page 64: ...oval 1 Perform Shutdown page 43 2 Remove tape and protective covering from FTS Disconnect hose cable F 3 If FTS is not reading properly at the end of the hose see Check RTD Cables and FTS page 63 4 If...

Page 65: ...ere should be continuity If there is no continuity check transformer c Reconnect 7 pin green connector to TCM 2 Check transformer a Remove lower shroud b Locate the two larger 6 AWG wires labeled 3 an...

Page 66: ...fan and transformer connections from terminal blocks Connections are on left side labeled V V 1 2 3 and 4 5 Remove four nuts 27 holding metal transformer cover 8 to frame Carefully remove cover while...

Page 67: ...19 24 VDC Power Supply Replace Surge Protector 1 Loosen connections on terminals 1 and 3 on CB02 2 Loosen connections on input to power supply 515 on N and L connections 3 Remove two screws 413 and su...

Page 68: ...itch 2 E 30 and 3 E XP2 5 Replace MCM in enclosure 6 Connect cables to MCM See Electrical Schematics page 89 Figure 22 Replace MCM Replace Temperature Control Module TCM 1 Perform Shutdown page 43 2 O...

Page 69: ...Parts Parts Proportioners 333024A 69...

Page 70: ...1 Apply anaerobic polyacrylate pipe sealant to all non swiveling pipe threads 2 Apply grease to tube tting threads Torque to 43 ft lbs 58 N m 3 Safety and warning labels are from label sheet 68 70 33...

Page 71: ...4 4 8 24R684 COVER transformer 1 1 1 1 1 1 9 261821 CONNECTOR wire 6awg 1 1 1 1 1 1 10 24U841 COVER heater 1 1 1 1 1 1 11 16W765 COVER motor 1 1 1 1 1 1 12 16W764 COVER heater rear 1 1 1 1 1 1 24U837...

Page 72: ...115836 GUARD nger 1 1 1 1 1 1 32 24U847 FAN cooling 120mm 24vdc 2 2 2 2 2 2 33 24R685 ENCLOSURE lower dinrail includes 33a 33d 1 1 1 1 1 1 33a 24U849 KIT module din rail heater see Heater and Transfor...

Page 73: ...ROPORTIONER module E XP2 see Proportioner Module page 76 1 1 24U321 KIT asm pair elite reactor see Fluid Inlet Kits page 87 1 1 1 51 24U320 KIT assembly pair std reactor see Fluid Inlet Kits page 87 1...

Page 74: ...th wash M4 x 0 7 4 4 4 4 4 4 71 16X129 SCREW mach phillips tooth wash 5 16 x 8 32 3 3 3 3 3 3 72 117502 FITTING reducer 5 x 8 JIC 1 1 1 1 1 1 73 117677 FITTING reducer 6 x 10 JIC 1 1 1 1 1 1 74 299521...

Page 75: ...1 1 1 1 93 127368 SLEEVE split wire 1 50 ID 2 2 2 2 2 2 94 127377 TIE cable 6 in 1 1 1 95 16X154 LABEL InSite 1 1 1 96 333091 MANUAL quick guide startup 1 1 1 1 1 1 97 333092 MANUAL quick guide shutdo...

Page 76: ...il or grease Assemble pump cylinders ush to one full thread under ush of housing surface 3 Apply grease to all gear teeth proportionally motor pinion and drive housing 4 Torque to 20 30 ft lbs 27 40 6...

Page 77: ...11 183210 PIN str hdls 2 2 112 15C753 SCREW machine hex wash hd 1 25 in x 5 16 18 10 10 113 114666 SCREW cap socket head 2 25 x 3 8 16 8 8 114 106115 WASHER lock hi collar 8 8 246831 PUMP displacement...

Page 78: ...thermal paste 5 Apply pipe sealant and PTFE tape to all non swiveling threads and threads without o rings 6 Apply lithium grease lubricant to o rings before assembling in block 1 7 Remove tape from p...

Page 79: ...9 16 sae 2 3 206 15H306 ADAPTER thermocouple 9 16 x 1 8 2 1 207 120336 O RING packing 2 1 208 16A110 HEATER immersion 2550W 230V 4 3 209 15B137 SWITCH over temperature 1 1 210 15B135 MIXER immersion h...

Page 80: ...s 40 44 6 N m 2 Apply sealant 113500 to threads 3 Valve must be closed with handle position as shown on drawing 4 Apply PTFE tape and thread sealant to gauge threads 5 Apply grease on valve Apply PTFE...

Page 81: ...112309 NUT hex jam 2 411 117556 NIPPLE 8 JIC x 1 2 NPT 1 412 121312 FITTING elbow 3 4 SAE x 1 2 JIC 1 Ref Part Description Qty 413 100840 FITTING elbow street 2 414 111457 O RING PTFE 2 415 189285 LAB...

Page 82: ...Parts Electrical Enclosure 82 333024A...

Page 83: ...SCREW machine pan head 5 16 in x 6 32 2 464 194337 WIRE grounding door 1 Ref Part Description Qty 466 113505 NUT keps hex head 6 468 111218 CAP tube square 2 469 114269 GROMMET rubber 1 470 127282 GR...

Page 84: ...il and Harness Module Kit 24U850 System DIN Rail and Harness Module Kit See Electrical Schematics page 89 1 Torque to 6 8 in lbs 0 7 1 N m 2 Torque to 28 33 in lbs 3 3 8 N m 3 Torque to 23 26 in lbs 2...

Page 85: ...breakers see Power Supply and Terminal Block Module page 86 1 505 16U530 MODULE sys surge protector 1 Heater and Transformer Terminal Block Module 24U849 Ref Part Description Qty 511 24T315 RAIL DIN 3...

Page 86: ...Qty 524 126128 CIRCUIT breaker 2P 20A UL489 2 525 126131 CIRCUIT breaker 2P 40A UL489 3 Power Supply and Terminal Block Module 16U522 Ref Part Description Qty 531 514014 RAIL DIN 35 mm x 7 5 mm x 8 62...

Page 87: ...U321 Elite 1 Apply sealant to all tapered pipe threads Apply sealant to female threads Apply to at least the rst four threads and approximately 1 4 turn wide 2 Apply thermal paste to the stem of dial...

Page 88: ...ner inlet 2 2 604 24U852 THERMOMETER dial 2 2 605 24U853 GAUGE press uid 2 2 606 180199 FILTER replacement 2 2 607 C20203 PACKING o ring 1 17 uoroelastomer 2 2 608 16V879 CAP lter 2 2 609 555808 PLUG...

Page 89: ...Electrical Schematics Electrical Schematics To TCM Reactor 2 E 30 Reactor 2 E XP2 24U831 24U832 16X118 333024A 89...

Page 90: ...Electrical Schematics Available Circuit Breakers Part Amps 126128 20 126131 40 24L960 50 90 333024A...

Page 91: ...Electrical Schematics 1 16U529 16V515 15D906 24U855 1 Locate near TCM 333024A 91...

Page 92: ...based on a material viscosity of 60 cps NOTICE To prevent system damage do not pressurize the system above the line for the gun tip size being used Proportioners For Foam AR6060 03 AR7070 04 AR5252 02...

Page 93: ...9 00 E XP2 0 0 5 1 9 1 5 5 7 1 0 3 8 2 0 7 6 PRESSURE psi bar FLOW gal min l min Table 2 Fusion Air Purge Flat Pattern 3500 241 24 1 3000 207 20 7 2500 174 17 4 2000 138 13 8 1500 103 10 3 1000 69 6 9...

Page 94: ...47 RTM055 PRESSURE psi bar FLOW gal min l min Table 4 Fusion Mechanical Purge Flat Pattern 3500 241 24 1 3000 207 20 7 2500 174 17 4 2000 138 13 8 1500 103 10 3 1000 69 6 9 500 35 3 5 E XP2 0 0 4 1 5...

Page 95: ...lpm Maximum Heated Hose Length Length 310 ft 94 m Output per Cycle ISO and RES E 30 0 0272 gal 0 1034 liter E XP2 0 0203 gal 0 0771 liter Operating Ambient Temperature Range Temperature 20 to 120 F 7...

Page 96: ...ith 5 5 16 in JIC adapter Component B RES 10 5 8 in JIC with 6 3 8 in JIC adapter Fluid Circulation Ports Size 1 4 NPSM m Maximum Pressure 250 psi 1 75 MPa 17 5 bar Dimensions Width 26 3 in 668 mm Hei...

Page 97: ...f 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...

Page 98: ...ects 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...

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