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Troubleshooting

System

Before performing any troubleshooting procedures:
1. Relieve Pressure. See

Pressure Relief Procedure, page 42

2. Turn main power switch OFF.
3. Allow equipment to cool.

Problem

Cause

Solution

No power.

Turn main power switch ON.

Failed 24 V power supply.

Replace power supply.

Reactor ADM does not turn on.

Failed surge protector.

Replace surge protector.

Loose connections.

Check MCM connection 13.

Tripped circuit breaker (CB02).

Reset breaker, see

Repair Circuit

Breaker Module, page 54

. Check

240VAC at output of breaker.

Electric motor does not operate.

Shorted windings.

Replace motor, see

Repair Electric Motor, page 53

333024A

Содержание Reactor 2 E-30

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 69: ...Parts Parts Proportioners 333024A 69...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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