Graco 312066Z Reactor Electric Proportioners Users Manual 312066Z, Reactor, Proportioners, Repair Parts, (English)

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9902471

Conforms to ANSI/UL

Std. 499 Certified to

CAN/CSA Std.

C22.2 No. 88

Repair - Parts

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.

See page 3 for model information, including

maximum working pressure and approvals.

Important Safety Instructions

Read all warnings and instructions in this

manual. Save these instructions.

312066Z

EN

Model E-XP1 Shown

TI10953a

2312066Z

Contents

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Supplied Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Temperature Control Diagnostic Codes . . . . . . . . 8

E01: High fluid temperature . . . . . . . . . . . . . . . . 8

E02: High zone current . . . . . . . . . . . . . . . . . . . . 9

E03: No zone current . . . . . . . . . . . . . . . . . . . . 10

E04: Fluid Temperature Sensor (FTS) or

thermocouple disconnected . . . . . . . . . . . . 10

E05: Circuit board overheated . . . . . . . . . . . . . 10

E06: Communication cable unplugged . . . . . . . 10

Motor Control Diagnostic Codes . . . . . . . . . . . . . 11

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

E21: No component A transducer . . . . . . . . . . . 12

E22: No component B transducer . . . . . . . . . . . 12

E23: High fluid pressure . . . . . . . . . . . . . . . . . . 12

E24: Pressure Imbalance . . . . . . . . . . . . . . . . . 12

E25: High line voltage . . . . . . . . . . . . . . . . . . . . 14

E26: Low line voltage . . . . . . . . . . . . . . . . . . . . 14

E27: High Motor Temperature . . . . . . . . . . . . . 14

E28: High current in motor . . . . . . . . . . . . . . . . 14

E29: Brush Wear . . . . . . . . . . . . . . . . . . . . . . . . 14

E31: Motor Control Failure

(E-30 and E-XP2 only) . . . . . . . . . . . . . . . . 15

E32: Motor Control Overtemperature . . . . . . . . 16

Communication Diagnostic Codes . . . . . . . . . . . 16

E30: Momentary loss of communication . . . . . . 16

E99: Loss of communication . . . . . . . . . . . . . . . 16

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Reactor Electronics . . . . . . . . . . . . . . . . . . . . . . 18

Primary Heaters (A and B) . . . . . . . . . . . . . . . . 20

Hose Heat System . . . . . . . . . . . . . . . . . . . . . . 21

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Before Beginning Repair . . . . . . . . . . . . . . . . . . 23

Pressure Relief Procedure . . . . . . . . . . . . . . . . 23

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . 24

Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . 26

Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Capacitor Test . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Circuit Breaker Module . . . . . . . . . . . . . . . . . . . 32

Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Motor Control Board . . . . . . . . . . . . . . . . . . . . . 34

Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Electric Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Temperature Control Module . . . . . . . . . . . . . . . 37

Primary Heaters . . . . . . . . . . . . . . . . . . . . . . . . . 40

Heated Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Fluid Temperature Sensor (FTS) . . . . . . . . . . . . 44

Display Module . . . . . . . . . . . . . . . . . . . . . . . . . 46

Inlet Fluid Strainer Screen . . . . . . . . . . . . . . . . . 48

Pump Lubrication System . . . . . . . . . . . . . . . . . 48

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Reactor Assembly (Model E-XP1 Shown) . . . . . 50

Parts Used on All Models . . . . . . . . . . . . . . . . . 53

Parts that Vary by Model . . . . . . . . . . . . . . . . . . 54

Sub Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . 58

Proportioner Module . . . . . . . . . . . . . . . . . . . . . 58

Fluid Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

7.65 kW Single Zone Fluid Heater . . . . . . . . . . . 61

Reactor Frame . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Temperature Control . . . . . . . . . . . . . . . . . . . . . 64

Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Fluid Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Circuit Breaker Modules . . . . . . . . . . . . . . . . . . 67

248669 Conversion Kit . . . . . . . . . . . . . . . . . . . . . 71

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 74

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 74

Models

312066Z 3

Models

E-20 SERIES

E-30 SERIES

E-XP1 SERIES

E-XP2 SERIES

* Full load amps with all devices operating at maximum capabilities. Fuse requirements at various flow rates and mix

chamber sizes may be less.

†

Total system watts, based on maximum hose length for each unit:

• E-20 and E-XP1 series, 210 ft (64 m) maximum heated hose length, including whip hose.

• 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.

Part, Series

Full Load Peak

Amps*

Voltage

(phase)

System

Watts†

Primary

Heater

Watts

Max Flow

Rate◆

lb/min

(kg/min)

Approximate

Output per Cycle

(A+B)

gal. (liter)

Maximum Fluid

Working Pressure

psi (MPa, bar)

259025, E 48 230V (1) 10,200 6,000 20 (9) 0.0104 (0.04) 2000 (14, 140)

259030, E 24 400V (3) 10,200 6,000 20 (9) 0.0104 (0.04) 2000 (14, 140)

259034, E 32 230V (3) 10,200 6,000 20 (9) 0.0104 (0.04) 2000 (14, 140)

Part,

Series

Full Load Peak

Amps*

Voltage

(phase)

System

Watts†

Primary

Heater

Watts

Max Flow

Rate◆

lb/min

(kg/min)

Approximate

Output per Cycle

(A+B)

gal. (liter)

Maximum Fluid

Working Pressure

psi (MPa, bar)

259026, F 78 230V (1) 17,900 10,200 30 (13.5) 0.0272 (0.1034) 2000 (14, 140)

259031, F 34 400V (3) 17,900 10,200 30 (13.5) 0.0272 (0.1034) 2000 (14, 140)

259035, F 50 230V (3) 17,900 10,200 30 (13.5) 0.0272 (0.1034) 2000 (14, 140)

259057, F 100 230V (1) 23,000 15,300 30 (13.5) 0.0272 (0.1034) 2000 (14, 140)

259058, F 62 230V (3) 23,000 15,300 30 (13.5) 0.0272 (0.1034) 2000 (14, 140)

259059, F 35 400V (3) 23,000 15,300 30 (13.5) 0.0272 (0.1034) 2000 (14, 140)

Part, Series

Full Load Peak

Amps*

Voltage

(phase)

System

Watts†

Primary

Heater

Watts

Max Flow

Rate◆

gpm (lpm)

Approximate

Output per Cycle

(A+B)

gal. (liter)

Maximum Fluid

Working Pressure

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 24 400V (3) 15,800 10,200 1.0 (3.8) 0.0104 (0.04) 2500 (17.2, 172)

259033, E 43 230V (3) 15,800 10,200 1.0 (3.8) 0.0104 (0.04) 2500 (17.2, 172)

Part,

Series

Full Load Peak

Amps*

Voltage

(phase)

System

Watts†

Primary

Heater

Watts

Max Flow

Rate◆

gpm (lpm)

Approximate

Output per Cycle

(A+B)

gal. (liter)

Maximum Fluid

Working Pressure

psi (MPa, bar)

259028, F 100 230V (1) 23,000 15,300 2.0 (7.6) 0.0203 (0.0771) 3200 (22, 220)

259032, F 35 400V (3) 23,000 15,300 2.0 (7.6) 0.0203 (0.0771) 3200 (22, 220)

259036, F 62 230V (3) 23,000 15,300 2.0 (7.6) 0.0203 (0.0771) 3200 (22, 220)

Supplied Manuals

4312066Z

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.

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 Electric Proportioner

Part Description

312065 Reactor Electric Proportioner,

Operation Manual (English)

Reactor Electrical Diagrams

Part Description

312067 Reactor Electric Proportioner,

Electrical Diagrams (English)

Displacement Pump

Part Description

309577 Electric Reactor Displacement Pump

Repair-Parts Manual (English)

Reactor Data Reporting Kit

Part Description

309867 Instruction-Parts Manual (English)

Fusion Spray Gun

Part Description

309550 Instruction-Parts Manual (English)

Heated Hose

Part Description

309572 Instruction-Parts Manual (English)

Circulation and Return Tube Kit

Part Description

309852 Instruction-Parts Manual (English)

Rupture Disk Assembly Kit

Part Description

312416 Instruction-Parts Manual (English)

Electric Reactor Installation

Part Description

310815 Instruction Manual (English)

Warnings

312066Z 5

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.

WARNING

ELECTRIC SHOCK HAZARD

Improper grounding, setup, or usage of the system can cause electric shock.

• 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.

• Read MSDS’s to know the specific hazards of the fluids you are using.

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

• 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 injury, including eye injury, inhalation of toxic fumes, burns, and hear-

ing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

•Gloves

• 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.

• 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,

or servicing equipment.

• Tighten all fluid connections before operating equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

Warnings

6312066Z

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 or 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

Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure due to the ther-

mal expansion. Over-pressurization can result in equipment rupture and serious injury.

• Open a valve to relieve the fluid expansion during heating.

• Replace hoses proactively at regular intervals based on your operating conditions.

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.

• This equipment is for professional use only.

• Do not leave the work area while the equipment is energized or under pressure. Turn off all equipment and

follow Pressure Relief Procedure in this manual when the equipment is not in use.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component.

See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equip-

ment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your mate-

rial, request MSDS forms from distributor or retailer.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s

replacement parts only.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

WARNING

Warnings

312066Z 7

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, 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.

WARNING

Temperature Control Diagnostic Codes

8312066Z

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 . 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 models only: Jumper

wire on J1 connector, between module (3) and dis-

play (4), is loose or incorrectly wired.

Checks

Check which zone is displaying the E01 error.

1. Check that connector B is firmly plugged into tem-

perature control board (see F

IG

. 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.

Code Code Name Alarm

Zone

Corrective

Action page

01 High fluid temperature Individual

8

02 High zone current Individual

9

03 No zone current with

hose heater on

Individual

10

04 FTS not connected Individual

10

05 Board overtemperature Individual

10

06 Communication cable

unplugged from module

Individual

10

99 Loss of communication ALL

16

For hose zone only, if FTS is disconnected at

startup, display will show hose current 0A.

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.

Temperature Control Diagnostic Codes

312066Z 9

4. Remove connector B from temperature control mod-

ule, and 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 T

ABLE

1.

5. Verify fluid temperature, using an external tempera-

ture sensing device.

• 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. To test 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. If the 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.

E02: High zone current

1. Turn main power OFF .

2. Relieve pressure, page 23.

3. Disconnect hose connector (D) at Reactor.

4. Using an ohmmeter, check between the two termi-

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.

Before doing the following checks, note which zone

(A, B, FTS, or all) has high fluid temperature.

Table 1: Sensor Connector Continuity Checks

Pins Description Reading

1 & 2 OT switch A nearly 0 ohms

3 & 4 OT switch B nearly 0 ohms

5 & 6 Thermocouple A 4-6 ohms

8 & 9 Thermocouple B 4-6 ohms

11 & 12 FTS approximately 35

ohms per 50 ft (15.2

m) of hose, plus

approximately 10

ohms for FTS

10 & 12 FTS open

Disconnect whip hose.

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

10 312066Z

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. If 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.

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 with ohm-

meter, page 8.

3. If an error occurred for the hose zone, check FTS

connections at each section of hose.

4. If an error occurred for the hose zone, test FTS by

plugging directly into machine.

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

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.

When a no current error occurs, the LED on the

specific zone’s module turns red when the error is

displayed.

TI10964a

FD

Each module has an on-board temperature sensor.

Heat is turned off if module temperature exceeds

185°F (85°C) within the heater module.

Motor Control Diagnostic Codes

312066Z 11

Motor Control Diagnostic Codes

Motor control diagnostic codes E21 through E29 appear

on pressure 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.

Warnings

Reactor will continue to run. Press 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 .

Alarms can also be cleared, except for code 23, by

pressing .

Code Code Name Alarm (A) or

Warning (W)

Corrective

Action

page

21 No transducer (compo-

nent A)

A

16

22 No transducer (compo-

nent B)

A

16

23 High fluid pressure A

16

24 Pressure imbalance A/W (to

select, see

page 34)

16

25 High line voltage A

18

26 Low line voltage A

18

27 High motor temperature A

18

28 High current A

29

29 Brush wear W

19

30 Momentary loss of

communication

-

16

31 Motor control failure A

15

32 Motor control

overtemperature

A

16

99 Loss of communication -

16

Motor Control Diagnostic Codes

12 312066Z

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 fluid pressure

1. Relieve pressure. Verify low pressure with analog

gauges. Turn main power OFF then ON

. If error persists, do checks below.

1. Check the 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. To determine 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.

b. Turn on the Reactor master power.

• If the error is gone, turn off the Reactor main

power, remove test transducer, and replace “A”

transducer.

• If the error persists, unplug the “test” transducer

from the “A” socket, and reinstall the “A” pres-

sure transducer back into the “A” socket.

Repeat this test procedure on the “B” side.

4. If the error persists and no root cause is found

through the above testing, replace the motor control

board, page 34.

E24: Pressure Imbalance

Fast E24 Errors

Fast E24 errors occur:

• within 10 seconds of turning the pumps on, or

• 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

is set to PRESSURE RELIEF/CIRCULATION

If the pressure difference between components A

and B exceeds 500 psi (3.5 MPa, 35 bar), an E24

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.

Motor Control Diagnostic Codes

312066Z 13

Checks for Fast E24 Errors

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.

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.

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. If the problem stays with the same side as before,

then the pressure transducer is bad.

4. If the problem switches to the other transducer, then

the problem is in the motor control 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:

• Check for pump failure.

• Check for adequate material.

• Using the feed pump to push fluid out through the

gun manifold, check for a plugged fluid path.

• Run the unit.

• Check and clean the gun inlet screens.

• 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:

• 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.

• The drum is not vented properly.

If a fast E24 error occurs, first check the readings of

the analog gauges.

Motor Control Diagnostic Codes

14 312066Z

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 Reactor 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.

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. If the E28 error did not go away then there is a prob-

lem with the motor control board. Replace board,

page 34.

Check motor:

1. Check to see if the motor rotates freely.

2. Check to see if the brushes are damaged.

3. Check that the voltage going to the motor is good.

4. Check the 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. If the above does not resolve the problem, replace

the motor, page 33.

E29: Brush Wear

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.

CAUTION

Prolonged operation of motor after a brush wear

warning may result in failure of motor and motor con-

trol board.

Motor Control Diagnostic Codes

312066Z 15

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 coming out of the

brush, away from the commutator wiring.

4. Check motor control board.

• Remove the plug in J7 (E-20/E-XP1), or J6

(E-30/E-XP2). (This will cause an E27 alarm).

• 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.

• The E27 as well as the E29 alarm should be gone. If

the E27 alarm is not gone double-check your

jumper.

• If the 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 . 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.

1. Turn main power OFF . Disconnect power

supply.

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.

Wait 5 minutes for stored voltage to discharge (E-30

and E-XP2 models only).

Communication Diagnostic Codes

16 312066Z

E32: Motor Control

Overtemperature

The E32 error code indicates a high temperature condi-

tion within the motor control 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.

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 on plug J13 for each board.

2. Measure the incoming voltage to the board (it

should be ~ 230Vac).

3. If it was only receiving 1 leg of the 230Vac the board

may light up, and still not function properly. Correct

the incoming voltage problem.

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.

Troubleshooting

312066Z 17

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

holder.

Clean brush holder and align brush

leads for free movement.

Shorted armature. Replace motor, page 33.

Check motor commutator for burn

spots or other damage.

Remove motor. Have motor shop

resurface commutator, if possible.

Damaged motor control board. Replace board. See page 34.

Fan not working. Blown fuse. Replace, page 36.

Loose wire. Check.

Defective fan. Replace, page 36.

Pump output low. Obstructed fluid hose or gun; fluid

hose ID too small.

Open, clear; use hose with larger ID.

Worn piston valve or intake valve in

displacement pump.

See pump manual.

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

disk (314).

Check if heater (2) and PRESSURE

RELIEF/SPRAY valve (SA or SB) are

plugged. Clear. Replace rupture disk

(314) with a new one; do not replace

with a pipe plug.

Troubleshooting

18 312066Z

Reactor Electronics

Before performing any troubleshooting procedures:

1. Relieve pressure, page 23.

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.

PROBLEM CAUSE SOLUTION

Both sides of display do not

illuminate.

No power.

Plug in power cord.

Turn disconnect ON .

Low voltage. Ensure input voltage is within specifi-

cations, page 46.

Loose wire. Check connections, page 46.

Display disconnected. Check cable connections, page 46.

Temperature display does not

illuminate.

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 temperature

display illuminates, heater control

board is causing problem. Otherwise,

display cable or display is failing.

Pressure display does not

illuminate.

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.

Erratic display; display turns on and

off.

Low voltage. Ensure input voltage is within specifi-

cations, page 46.

Poor display connection. Check cable connections, page 46.

Replace damaged cable.

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

Operation manual 312065), or adjust

FTS to desired current setting.

Troubleshooting

312066Z 19

Display does not respond properly to

button pushes.

Poor display connection. Check cable connections, page 46.

Replace damaged cable.

Display cable damaged or corroded. Clean connections; replace cable if is

damaged.

Ribbon cable on display circuit board

disconnected or broken.

Connect cable (page 46) or replace.

Broken display button. Replace, page 46.

Red stop button does not work. Broken button (fused contact). Replace, page 46.

Loose wire. Check connections, page 46.

Fan not working.

Blown fuse. Verify with ohmmeter; replace if nec-

essary (page 46).

Loose wire. Check fan wire.

Defective fan. Replace, page 46.

PROBLEM CAUSE SOLUTION

Troubleshooting

20 312066Z

Primary Heaters (A and B)

Before performing any troubleshooting procedures:

1. Relieve pressure, page 23.

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.

PROBLEM CAUSE SOLUTION

Primary heater(s) does not heat.

Heat turned off.

Press or zone

keys.

Temperature control alarm. Check temperature display for diag-

nostic code, page 8.

Signal failure from thermocouple. See E04: Fluid Temperature Sen-

sor (FTS) or thermocouple discon-

nected, page 10.

Control of primary heat is abnormal;

high temperature overshoots or E01

error occurs intermittently.

Dirty thermocouple connections. 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.

Thermocouple not contacting heater

element.

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.

Failed heater element. See Primary Heaters, page 20.

Signal failure from thermocouple. See E04: Fluid Temperature Sen-

sor (FTS) or thermocouple discon-

nected, page 10.

Thermocouple wired incorrectly. 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.

AB

Troubleshooting

312066Z 21

Hose Heat System

Before performing any troubleshooting procedures:

1. Relieve pressure, page 23.

2. Turn main power OFF .

3. Allow equipment to cool.

Problems

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.

PROBLEM CAUSE SOLUTION

Hose heats but heats slower

than usual or it does not reach

temperature.

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 voltage signifi-

cantly reduces power available to hose

heat system, affecting longer hose

lengths.

Hose does not maintain tem-

perature while spraying.

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 was not fully preheated. Wait for hose to heat to correct tempera-

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.

Hose temperature exceeds set-

point.

A and/or B heaters are overheating

material.

Check primary heaters for either a ther-

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.

Examine connection of thermocouples 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 on heater

control board.

Missing/damaged insulation around

FTS, causing the hose heat to be ON

constantly.

Ensure hose bundle has adequate insula-

tion evenly covering the entire length and

connection joints.

Troubleshooting

22 312066Z

Erratic hose temperature.

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,

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

FTS, causing the hose heat to be ON

constantly.

Ensure hose bundle has adequate insula-

tion evenly covering the entire length and

connection joints.

Hose does not heat.

FTS failed or is not contacting

correctly.

Check FTS, page 44.

FTS not installed correctly. FTS should be installed close to end of

hose in same environment as gun. Verify

FTS installation, page 44.

Temperature control alarm. Check temperature display or diagnostic

code, page 44.

Hoses near Reactor are warm,

but hoses downstream are cold.

Shorted connection or failed hose

heating element.

With hose heat on and temperature set-

point above displayed hose zone tem-

perature, verify voltage between

connectors at each section of hose.

Voltage should drop incrementally for

each section of hose further from Reactor.

Use safety precautions when hose heat is

turned on.

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 key.

A and B temperature setpoints too

low.

Check. Increase if necessary.

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.

Low hose heat. A and 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.

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

enough.

Allow hose to heat up, or preheat fluid.

Loose hose electrical connections. Check connections. Repair as necessary.

PROBLEM CAUSE SOLUTION

Repair

312066Z 23

Repair

Before Beginning Repair

1. Flush if necessary; see Flushing.

2. Park component A pump.

a. Press .

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.

2. Engage gun piston safety lock.

3. Close gun fluid manifold valves A and B.

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

5. Turn PRESSURE RELIEF/SPRAY valves (SA, SB)

to PRESSURE RELIEF/CIRCULATION .

Route fluid to waste containers or supply tanks.

Ensure gauges drop to 0.

6. Disconnect gun air line and remove gun fluid mani-

fold.

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.

ti2409a

ti2421a

ti10955a

SA SB

ti2554a

Repair

24 312066Z

Flushing

• 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 moisture-free solvents.

• To flush feed hoses, pumps, and heaters separately

from heated hoses, set PRESSURE

RELIEF/SPRAY valves (SA, SB) to PRESSURE

RELIEF/CIRCULATION . Flush through bleed

lines (N).

• 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.

Pump Removal

1. Shut off , , and heat zones.

2. Flush pump.

3. If pumps are not parked, press . 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).

6. Turn both PRESSURE RELIEF/SPRAY valves (SA,

SB) to PRESSURE RELIEF. Route fluid to waste

containers or supply tanks. Ensure gauges drop to

0.

Flush equipment only in a well-ventilated area. Do not

spray flammable fluids. Do not turn on heaters while

flushing with flammable solvents.

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.

SA

SB

TI10954a

N

N

See manual 309577 for pump repair instructions.

AB

ti4147a

TI10956a

SA

SB

Repair

312066Z 25

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). Remove 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.

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.

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.

TI3765a-2

C

U

G

D

T

P

Steps 10 and 11 apply to pump B.

TI3765a-1

C

F

GD

E

Repair

26 312066Z

Pump Installation

1. Ensure locknut (G) is screwed on pump with flat

side up. Screw pump into bearing housing (M) until

pin holes align. Push pin (F) in. Pull retaining wire

clip (E) down.

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).

3. Tighten locknut (G) by hitting firmly with a

non-sparking hammer.

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

5. Go to step 13.

Steps 1-5 supply to pump B. To reconnect pump A,

proceed to step 6.

C

D

F

E

G

M

N

1

TI3765a-1

Flat side faces up.

1

Lubricate threads with ISO

oil or grease.

2

22

2

3

Pump top threads must be

nearly flush with bearing face

(N).

3

Repair

312066Z 27

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.

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

that barbed fittings at wet-cup flush ports are acces-

sible.

9. Connect component A outlet tube loosely at pump

and at heater. Line up tube, then tighten fittings

securely.

10. Tighten star-shaped locknut (G) by hitting firmly with

a non-sparking hammer.

11. 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.

12. Reconnect fluid inlet (C).

13. Purge air and prime the system. See Reactor opera-

tion manual.

Steps 6-12 apply to pump A only.

Finger guard is not used on Model E-30.

C

D

T

G

M

N

1

TI3765a-2

Flat side faces up.

1

Lubricate threads with ISO oil

or grease.

2

2

2

2

3

Pump top threads must be nearly

flush with bearing face (N).

3

U

Finger guard (P) not used on

Model E-30.

4

P

4

Repair

28 312066Z

Drive Housing

Removal

1. 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).

5. Disconnect pump inlet and outlet lines. Remove

screws (213), washers (215), and bearing housing

(203).

6. Remove screws (212, 219) and washers (214) and

pull drive housing (202) off motor (201).

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.

4. Push drive housing (202) onto motor (201). Install

screws (212, 219) and washers (214).

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).

Examine bearing housing (203) and connecting

rod (205). If these parts need replacing, first

remove the pump (206), page 28.

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.

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

221

P

Drive housing crankshaft (S) must be in line with

crankshaft at other end of motor.

If bearing housing (203), connecting rod (205), or

pump (206) were removed, reassemble rod in

housing and install pump, page 26.

Repair

312066Z 29

201

202

203

204

205

206B

207208

209

212

213

214

215

217

218

219

208

214

TI3152

S

1

Crankshaft must be in line with

crankshaft at other end of motor.

1

S

R

R

206A

Repair

30 312066Z

Motor Brushes

Brush Removal

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 23.

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).

5. Loosen terminal screw (R). Pull away brush lead

(L), being careful motor lead terminal (T) remains in

place. Remove and discard brush (B).

6. Inspect commutator for excessive pitting, burning,

or gouging. Black color on commutator is normal.

Have commutator resurfaced by qualified motor

repair shop if brushes wear too quickly.

7. Repeat for other side.

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.

Wait 5 min for stored voltage to discharge (E-30 and

E-XP2 models only).

One brush has a wire on top for brush wear sig-

nal. Note which side of motor it is on. Unplug at

spade connector provided.

01227-2

H

C

S

RLT

B

01227-4

Repair

312066Z 31

Brush Installation

1. Install new brush (B) so lead (L) is in long slot (D) of

holder.

2. Slide terminal (L) under terminal screw (R). Make

sure motor lead terminal (T) is still connected at

screw. Tighten screw.

3. Install spring (S) so it will uncoil onto brush (B), as

shown. Spring will be damaged if installed back-

wards.

4. Install spring clip (C) and push in until hooks (H)

catch slots in housing. Incorrect installation may jam

clip.

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 to start

motor. Slowly increase jog setting to J 6. 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.

CAUTION

When installing brushes, follow steps carefully.

Improper installation damages parts beyond use.

Install brush with wires on same side of motor as

before. Plug spade terminal into connector.

D

B

01227-5

L

R

L

T

B

01227-4

B

01227

Note direction of spring coil.

1

1

S

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.

H

C

01227-2 01227-6

Repair

32 312066Z

Capacitor Test

1. Turn main power OFF . Disconnect power

supply.

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.

5. With an insulated handle screw driver, short across

the two contacts on the end of the capacitor to com-

plete discharging it. Hold for two seconds.

NOTE: A small spark may issue from the contact point.

6. Inspect the capacitor for irregularities such as

cracks, leakage, burn marks, or irregular shape.

7. Set an Ohmmeter to a range of at least 1K

Ω

and

connect the meter leads to the capacitor with the

red lead to the positive (+) terminal and the black

lead to the negative (-) terminal.

8. Observe the meter reading. It should start near 0

Ω

and climb up to 10K

Ω

, 20K

Ω

, etc., as the meter

battery charges the capacitor. This indicates a good

capacitor.

9. A reading of 0

Ω

(shorted) or O.L (open) indicates a

bad capacitor. In this case, replace the capacitor.

with the exact replacement part, item 76 on pages

55 and 56.

Circuit Breaker Module

1. Turn main power OFF . Disconnect power

supply. Turn circuit breakers on to test.

2. Relieve pressure, page 23.

3. Using an ohmmeter, check for continuity across cir-

cuit breaker (top to bottom). If no continuity, trip

breaker, reset, and retest. If still no continuity,

replace breaker as follows:

a. Refer to electrical diagrams and to T

ABLE

2. Dis-

connect wires and remove bad breaker.

b. Install new breaker and reconnect wires.

* Depending on model.

Table 2: Circuit Breakers, see F

IG

. 1

Ref. Size Component

909 50A Hose/Transformer

Secondary Side

911 40A Transformer

Primary

912A 25A, 40A* Heater A

912B 25A, 40A* Heater B

913 20A Motor/Pumps

F

IG

. 1. Circuit Breaker Module

ti9884a

912A

913

909

911

NOTE: To reference cables and con-

nectors, see the electrical diagrams and

the parts drawings on pages 67-68.

912B

Repair

312066Z 33

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 F

IG

. 2, page 35.

c. Unplug 3-pin connector J7 from board.

d. Thread cables through top of cabinet to free

motor.

5. Remove screws holding motor to bracket. Lift motor

off unit.

Installation

1. Place motor on unit. Thread motor cables into cabi-

net and into bundles as before. See electrical dia-

grams.

2. Fasten motor with screws.

3. Plug 3-pin connector J7 to board.

4. Plug motor power harness to connector J4 on

board.

5. Install drive housing/pump assemblies, page 28.

6. Return to service.

CAUTION

Motor is heavy. Two people may be required to lift.

Repair

34 312066Z

Motor Control Board

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.

4. Put on static conductive wrist strap.

5. Disconnect all cables and connectors from board.

6. Remove nuts (40) and take entire motor control

assembly to workbench.

7. Remove screws and take board off heatsink.

8. Set DIP switch (SW2) on new board. See T

ABLE

3

for factory settings. See F

IG

. 2 for location on board.

9. Install new board in reverse order. Apply thermal

heatsink compound to mating surfaces of board and

heatsink.

Motor control board has one red LED (D11). Power

must be on to check. See F

IG

. 2 for location. Func-

tion is:

• Startup: 1 blink for 60 Hz, 2 blinks for 50 Hz.

• Motor running: LED on.

• Motor not running: LED off.

• Diagnostic code (motor not running): LED

blinks diagnostic code, pauses, then repeats

(for example, E21=21 blinks, pause, 21 blinks).

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.

Wait 5 minutes for stored voltage to discharge (E-30

and E-XP2 models only).

Table 3: DIP Switch (SW2) Settings

DIP

Switch Switch Position

Switch 1 not used

Switch 2 ON for E-20 and

E-30 models

OFF for E-XP1 and

E-XP2

Switch 3 ON to enable pres-

sure imbalance

warning

OFF to enable

pressure imbalance

alarm

Switch 4 not used

Order Part 110009 Thermal Compound.

Table 4: Motor Control Board Connectors

Model

E-20

and

E-XP1

Model

E-30

and

E-XP2 Pin Description

J1 N, L n/a Main motor power

J8 J3 n/a Transducer B

J4 J1 n/a Motor output

J7 J6 1, 2 Motor thermal overload signal

3 Brush wear signal

J3 J5 n/a Transducer A

J10 J7 1-4 Not used

5, 6 Cycle switch signal

7-10 Jumper 15C866 (available in

repair kit 246961)

J12 J12 n/a Data reporting

J13 J13 n/a To display board

Repair

312066Z 35

F

IG

. 2. Motor Control Board

1

Apply 110009 thermal heatsink

compound to mating surfaces.

1

TI2576A-1

TI3153A-1

24G879 Motor Control, for E-20 and E-XP1

24G881 Motor Control, for E-30 and E-XP2

J3 (A)

J8 (B)

J1

J4

J7 J13 J10

L

J1

J6

J13

J7

J3 (B)

J5 (A)

1

D11

D7

J12

J12

SW2

SW2

N

DIP Switch (SW2) Settings

TI3178b-2

TI3178b-1

Model E-XP2

Model E-30

DIP Switch (SW2) Settings

Model E-20

Model E-XP1

TI3178b-3

TI3178b-4

ON (UP)

ON (UP)

ON (Down)

ON (Down)

Repair

36 312066Z

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.

4. Disconnect transducer cables at board; see F

IG

. 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), F

IG

. 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 F

IG

. 2, page

35.

Electric Fan

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 23.

3. Check fuses (F) at left of breaker module, F

IG

. 4.

Replace if blown. If good, continue with step 4.

4. Refer to electrical diagrams. Disconnect fan wires

from fuses (F).

5. Remove fan.

6. Install fan in reverse order.

F

IG

. 3. Transducers

TI10957a

820

806 (B Side)

801

806 (A Side)

F

IG

. 4. Fan Fuses

F

ti9884a-1

Repair

312066Z 37

Temperature Control Module

Table 6: Temperature Power Module Connections

Table 5: Temperature Control Module Connections

Connector Description

DATA (A) Data reporting

SENSOR (B)

PIN

HOSE T/C P; FTS (purple)

12

11 HOSE T/C R; FTS (red)

10 HOSE T/C S; FTS (silver

(unshielded bare wire))

9 HEATER T/C B, Y;

Thermocouple (yellow)

8 HEATER T/C B, R;

Thermocouple (red)

7 Not used

6 HEATER T/C A, Y;

Thermocouple (yellow)

5 HEATER T/C A, R;

Thermocouple (red)

4, 3 OVERTEMPERATURE B;

Overtemperature switch B

2, 1 OVERTEMPERATURE A;

Overtemperature switch A

DISPLAY (C) Display

COMMUNICATION (D) Communication to power

boards

PROGRAM (E) Software programming

BOOT (F) Software bootloader

POWER/RELAY (G) Circuit board power input and

contactor control output

Connector Description

COMMUNICATION

(H)

Communication to control

board

POWER (J) Power to heater

F

IG

. 5: Temperature Control Module Connections

A

B

C

Bottom of Power Modules

Right Side of

Control Heater Module

D

E

F

G

ti9875a

ti9843a1

ti9843a4

H

J

Repair

38 312066Z

Test SCR Circuit

1. Test the SCR circuit in the on position:

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 .

e. Hold down 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.

2. 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 .

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 on the tem-

perature control board is bad. Replace the tem-

perature control assembly.

Replacing Temperature Control Assembly

Modules

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.

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.

Repair

312066Z 39

Repair

40 312066Z

Primary Heaters

Heater Element

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 F

IG

. 6. Disconnect heater element wires from

heater wire connector. Test with ohmmeter.

6. To remove 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.

Line Voltage

The primary heaters output their rated wattage at 230

Vac. Low line voltage will reduce power available and

the heaters will not perform at full capability.

Total Heater

Wattage Element Ohms

6,000 1500 30-35

7,650 2550 18-21

10,200 2550 18-21

Repair

312066Z 41

F

IG

. 6. Heater (7.5 kW Single Zone Heater Shown)

303

304

309

315

308

310

311

301

r_247813_312066

305

306

Apply 110009 thermal heatsink compound.

1

1

304

313

313

307

Repair

42 312066Z

Thermocouple

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 23.

3. Wait for heaters to cool.

4. Remove heater shroud.

5. Disconnect thermocouple wires from B on tempera-

ture control module. See T

ABLE

5, page 37 and F

IG

.

5, page 37.

6. Feed thermocouple wires out of cabinet. Note path

as wires must be replaced in the same way.

7. See F

IG

. 7. Loosen ferrule nut (N). Remove thermo-

couple (310) from heater housing (301), then

remove thermocouple housing (H). Do not remove

the thermocouple adapter (305) unless necessary. If

adapter must be removed, ensure that mixer (309)

is out of the way when replacing the adapter.

8. Replace thermocouple, F

IG

. 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 (307).

d. Holding thermocouple (T) against heater ele-

ment, tighten ferrule nut (N) 1/4 turn past tight.

9. Route wires (S) into cabinet and thread into bundle

as before. Reconnect wires to board.

10. Replace heater shroud.

11. Turn on heaters A and B simultaneously to test.

Temperatures should rise at same rate. If one

heater is low, loosen ferrule nut (N) and tighten ther-

mocouple housing (H) to ensure thermocouple tip

(T) contacts element (307).

F

IG

. 7. Thermocouple

309

301

S

N

H

T

307

Apply PTFE tape and thread sealant.

1

1

308

ti7924a

Apply 110009 thermal heatsink compound.

2

2

310

35

Repair

312066Z 43

Overtemperature Switch

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 23.

3. Wait for heaters to cool.

4. Remove heater shroud.

5. Disconnect one leadwire from overtemperature

switch (308), F

IG

. 7. Test across switch with ohm-

meter. Resistance must be approximately 0 ohms.

6. If switch fails test, remove wires and screws. Dis-

card failed switch. Apply thermal compound

110009, install new switch in same location on

housing (301), and secure with screws (311).

Reconnect wires.

Heated Hose

Check Hose Connectors

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 23.

3. Disconnect hose connector (D) at Reactor, F

IG

. 8.

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, F

IG

. 8.

4. Test with ohmmeter between pins of cable connec-

tor.

5. If cable fails test, retest at FTS, page 44.

If wires need replacement, disconnect from temper-

ature control board. See T

ABLE

5, page 37 and F

IG

.

5, page 37.

Refer to the heated hose manual 309572 for hose

replacement parts.

Whip hose must be connected.

F

IG

. 8. Heated Hose

Pins Result

1 to 2 approximately 35 ohms per 50 ft (15.2 m) of

hose, plus approximately 10 ohms for FTS

1 to 3 infinity

TI10964a

FD

Repair

44 312066Z

Fluid Temperature Sensor (FTS)

Test/Removal

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 23.

3. Remove tape and protective covering from FTS

(21), F

IG

. 8. Disconnect hose cable (F). Test with

ohmmeter between pins of cable connector.

4. If FTS fails any test, replace FTS.

5. Disconnect air hoses (C, L), and electrical connec-

tors (D).

6. Disconnect FTS from whip hose (W) and fluid hoses

(A, B).

7. Remove ground wire (K) from ground screw on

underside of FTS.

8. Remove FTS probe (H) from component A (ISO)

side of hose.

Installation

The Fluid Temperature Sensor (FTS) is supplied. Install

FTS between main hose and whip hose. See Heated

Hose manual 309572 for instructions.

Pins Result

1 to 2 approximately 10 ohms

1 to 3 infinity

3 to FTS groundscrew 0 ohms

1 to FTS component A

fitting (ISO)

infinity

F

IG

. 9: Fluid Temperature Sensor and Heated Hoses

WLE

A

B

HC

L

ISO

A

W

B

D

K

ti17029b

Repair

312066Z 45

Transformer Primary Check

1. Turn main power OFF .

2. Locate the two smaller (10 AWG) wires coming out

of transformer. Trace these wires back to contactor

and circuit breaker (911). Use an ohmmeter to test

for continuity between two wires; there should be

continuity.

Transformer Secondary Check

1. Turn main power OFF .

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-

ity between two wires; there should be continuity.

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.

3. To verify transformer voltage, turn on hose zone.

Measure voltage from 18CB-2 to

POD-HOSE-P15-2; see Reactor Electrical Dia-

grams manual 312067.

* For 230 Vac line voltage.

Replace Transformer

1. Turn main power OFF . Disconnect power

supply.

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.

6. Install new transformer in reverse order.

F

IG

. 10: Circuit Breaker Module

909 911

ti9884a

Model Secondary Voltage

310 ft. 90 Vac*

210 ft. 62 Vac*

Use this procedure to replace transformer.

Repair

46 312066Z

Display Module

Temperature and Pressure Displays

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 23.

3. Refer to electrical diagrams.

4. Put on static conductive wrist strap.

5. Disconnect main display cable (20) at lower left cor-

ner of display module; see F

IG

. 11.

6. Remove screws (509, 510) and cover (504); see

F

IG

. 11.

7. Disconnect cable connectors (506 and 511) from

back of temperature display (501) or pressure dis-

play (502); see F

IG

. 11.

8. Disconnect ribbon cable(s) (R) from back of display;

see F

IG

. 11.

9. Remove nuts (508) and plate (505).

10. Disassemble display, see detail in F

IG

. 11.

11. Replace board (501a or 502a) or membrane switch

(501b or 502b) as necessary.

12. Reassemble in reverse order, see F

IG

. 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

1. Turn main power OFF . Disconnect power

supply.

2. Relieve pressure, page 23.

3. Refer to electrical diagrams.

4. Put on static conductive wrist strap.

5. Remove screws (509, 510) and cover (504), F

IG

.

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).

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.

If replacing both displays, label temperature display

cables TEMP and pressure display cables PUMP

before disconnecting.

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.

Repair

312066Z 47

F

IG

. 11. Display Module

ti2574a

502

501

503

504

505

506

507

508

510

511

512

506

ti3172a

20

501a

501c

501b

502b

502c

502a

G

511

R

R

Detail of Membrane Switches and Display Boards

Temperature Display Pressure Display

Apply medium strength thread sealant.

1

1

1

1

1

Repair

48 312066Z

Inlet Fluid Strainer Screen

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.

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. Proceed with operation.

* Fluid filter screen (59g) replacements:

Pump Lubrication System

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. Lift the 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

F

IG

. 13.

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.

F

IG

. 12. Y Strainer Components

Part Description

180199 20 mesh (standard); 1 pack

255082 80 mesh (optional); 2 pack

255083 80 mesh (optional); 10 pack

A*

B

C

D

TI10974a

Repair

312066Z 49

3. Drain the reservoir and flush it with clean lubricant.

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

lubricant.

5. 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.

F

IG

. 13. Pump Lubrication System

LR

RT

ST

RB

TI10970a

TI10969a

LR

ST

RT

Parts

50 312066Z

Parts

Reactor Assembly (Model E-XP1 Shown)

TI10961a

57

65a

65b, 65c65d

65e

65f

72

14

17

2

41

40

45

58

59

3

7

10

44

38

9

115

TI10953a

120

15

16

90

41

41, 102 21

109,

110 113, 119

TI10960a

121

34

48

60

88

51

TI10977a

97

41

122

95

96

72

111,

112

41

122

TI18608a

Strut Channel

Style Support

Rail

Slotted U-Channel

Style Support Rail

16

Parts

312066Z 51

8

Left Side of Cabinet

Right Side of Cabinet

42

5

123

61, 62

39, 52, 71, 73

76

33

27

6

29, 42

TI9835a

TI10968a

41

77

31, 42

36 (400V

models only)

28

Parts

52 312066Z

TI10962a

Detail, Fluid Manifold Area

89

106

41

107

78

7, see page 66

14

16

127 19

90

90

817 (Ref) 12

Detail, Fluid Manifold Area

Detail, Cabinet Area

TI10978a

35

87

13

26

41

38

41

61

24

25

57

mounting base (from motor)

Parts

312066Z 53

Parts Used on All Models

See pages 54 through 56 for parts that vary by model.

▲

Replacement Danger and Warning labels, tags, and

cards are available at no cost.

* See quantity on referenced pages.

† Not shown.

★

Required for all A-D series models. Included in

Knob Repair Kit 258920 (purchase separately).

◆

Not required for slotted U-Channel style heater sup-

port rails.

Ref. Part Description Qty

1 FRAME; page 62 1

2 HEATER; pages 60 and 61 *

3 MODULE, proportioner; page 58 *

4 245974 DISPLAY; page 63 1

5 CONTROL, temperature; page 64 1

6 CONTROL, motor; page 65 *

7 247823 MANIFOLD, fluid; page 66 1

8 TRANSFORMER; pages 54-56 *

9 SHIELD; page pages 54-56 *

10 246976 DOOR, cabinet 1

11† 261669 SENSOR, fluid temperature 1

12 15B456 GASKET, manifold 1

13 115834 FAN 1

14 TUBE, heater component A; pages

54-56

*

15 TUBE, pump, component A; pages

54-56

*

16 TUBE, heater component B; pages

54-56

*

17 TUBE, pump, component B; pages

54-56

*

18† 247787 CABLE, overtemperature; see electrical

diagrams

1

19† 15B380 CABLE, hose control; see electrical

diagrams

1

20 15B383 CABLE, display 1

21 CONNECTOR, tube; pages 54-56 *

22 116773 CONNECTOR, plug 1

23 C38163 WASHER, lock, external tooth 1

24 15B361 BOOT, wire feed through 1

25 15B510 PLATE, cover, wire 1

26 15B360 GASKET, fan 1

27 255047 STRAIN RELIEF 1

28 MODULE, breaker; pages 54-56 *

29 116149 SPACER 8

31 117666 TERMINAL, ground 1

33

★

123969 SWITCH, disconnect 1

34

★

123967 SWITCH, main power 1

35 117723 SCREW, machine; 6-32 x 2 in. (51 mm) 4

36 SWITCH, added pole; 380V; page 54 *

38 115492 SCREW, machine; 8-32 x 0.345 in. (9

mm)

13

39 FILTER; 230V; page 54 *

40 117623 NUT, cap; 3/8-16 4

41 113796 SCREW, flanged, hex hd; 1/4-20 x 3/4

in. (19 mm)

15

42 115942 NUT, hex flange; 1/4-20 15

44 15K817 LABEL, diagnostic codes 1

45 189930 LABEL, caution 3

48

▲

189285 LABEL, caution 3

51

▲

LABEL, warning; pages 54-56 *

52 CABLE. harness, filter; pages 54-56 *

53 15B593 SHIELD, membrane switch; pack of 10 1

57 15B775 COVER, wire access 2

58 247524 COVER, heater, back 1

59 256732 COVER, heater, front 1

60

▲

15G280 LABEL, warning 1

61 113505 NUT, hex, keps; 10-24 6

62 112776 WASHER, plain; no. 10 2

65 KIT, fluid inlet 1

65a FITTING, swivel, elbow 2

65b 101078 Y-STRAINER 2

65c† 180199 ELEMENT, 20 mesh 2

65d C20487 NIPPLE, 3/4 npt 2

65e 109077 VALVE, ball; 3/4 npt (fbe) 2

65f 118459 FITTING, union, swivel; 3/4-14 npt(m) x

3/4-14 npt(f)

2

66 101078 Y-STRAINER; includes 66a 2

66a† 180199 ELEMENT, 20 mesh 1

67 109077 VALVE, ball; 3/4 npt (fbe) 2

68 C20487 NIPPLE; 3/4 npt 2

69 157785 UNION, swivel; 3/4 npt(m) x 3/4

npsm(f)

2

71 SCREW, machine; pages 54-56 *

72

◆

BRACKET. heater; pages 54-56 *

73 WASHER, lock; pages 54-56 *

76 CAPACITOR; pages 54-56 *

77 BRACKET; pages 54-56 *

86 CABLE, overtemperature, jumper;

pages 54-56

*

87 15B807 SHIELD, fan 1

88 186494 CLIP, spring 6

89 205447 COUPLING, hose 2

90 15M338 TUBE, low pressure; 1/4 in. (6 mm) ID;

3/8 in. (16 mm) OD; 4 ft (1.2 m); PTFE

1

95

◆

BOLT; hex hd; pages 54-56 *

96

◆

LOCKWASHER; 3/8; pages 54-56 *

97

◆

NUT, channel; pages 54-56 *

102 STRAP, motor; pages 54-56 *

106 117502 REDUCER; #5 x #8 JIC 1

107 117677 REDUCER; #6 x #10 JIC 1

109 246928 RESERVOIR; includes 110-119; see

309911

1

110 054826 TUBE; PTFE; 1/4 in. (6 mm) ID;

2 ft (0.6 m)

2

111 118433 VALVE, check 1

112 118432 VALVE, check 1

113 116746 FITTING, barbed 2

115 15C568 BRACKET, reservoir 1

117 206995 THROAT SEAL LIQUID; 1 qt (1 liter) 1

119 191892 ELBOW; 1/8 npt (m x f) 2

120

▲

171001 LABEL, warning 1

121 LABEL; pages 54-56 *

122 INSULATOR, heat; pages 54-56 *

123 247782 SPACER 4

124 247854 COVER, connector, module 1

125 114331 SCREW, machine; 6-32 x 0.375 in. (9.5

mm)

2

Ref. Part Description Qty

Parts

54 312066Z

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.

Ref. Description

Reactor Models

Qty

259024

E-XP1

259025

E-20

259026

E-30

259028

E-XP2

259029

E-XP1

259030

E-20

259031

E-30

259032

E-XP2

259033

E-XP1

259034

E-20

259035

E-30

259036

E-XP2

2 HEATER; pages

60 and 61 247507 247506 247507 247509

(qty: 2) 247507 247506 247507 247509

(qty: 2) 247507 247506 247507 247509

(qty: 2) 1

3MODULE, pro-

portioner; page

58

245956 245956 245957 245959 245956 245956 245957 245959 245956 245956 245957 245959 1

6CONTROL,

motor; page 65 24G879 24G879 24G881 24G881 24G879 24G879 24G881 24G881 24G879 24G879 24G881 24G881 1

8TRANS-

FORMER; 247840 247840 247812 247812 247840 247840 247812 247812 247840 247840 247812 247812 1

9 SHIELD 276878 276878 276879 276879 276878 276878 276879 276879 276878 276878 276879 276879 1

14 TUBE, heater,

component A 247920 247920 247920 247915 247920 247920 247920 247915 247920 247920 247920 247915 1

15 TUBE, pump,

component A 247912 247912 247919 247914 247912 247912 247919 247914 247912 247912 247919 247914 1

16 TUBE, heater,

component B 247918 247918 247918 247917 247918 247918 247918 247917 247918 247918 247918 247917 1

17 TUBE, pump,

component B 247913 247913 247921 247916 247913 247913 247921 247916 247913 247913 247921 247916 1

21 CONNECTOR,

tube 121310 121310 121311 121311 121310 121310 121311 121311 121310 121310 121311 121311 2

28 MODULE,

breaker; page 67 CCFFBBEEAADD1

36 SWITCH, added

pole; 380V 123968 123968 123968 123968 1

39 FILTER; 230V 117667 117667 117667 117667 117667 117667 1

Parts

312066Z 55

51▲LABEL, warning 198278 198278 198278 198278 198278 198278 1

52 CABLE, harness,

filter 15B385 15B385 15B385 15B385 15B385 15B385 1

65 KIT, fluid inlet 234366 234366 234367 234366 234366 234366 234367 234366 234366 234366 234367 234366 1

65a ELBOW, swivel;

3/4 npt(m) x 1”

npt(f)

160327 160327 118463 160327 160327 160327 118463 160327 160327 160327 118463 160327 2

71 SCREW,

machine --- --- --- --- --- --- 2

72

◆

BRACKET,

heater 247523 247523 247523 247523 247523 247523 247523 247523 247523 2

BRACKET,

heater 247523 247523 247523 4

73 WASHER, lock 103181 103181 103181 103181 103181 103181 2

76 CAPACITOR 244733 244733 244733 244733 244733 244733 1

77 BRACKET 197999 197999 197999 197999 197999 197999 1

86 CABLE, over-

temperature,

jumper

15H187 15H187 15H187 15H187 15H187 15H187 15H187 15H187 15H187

1

95

◆

BOLT; hex hd;

3/8-16 100469 100469 100469 100469 100469 100469 100469 100469 100469 2

BOLT; hex hd;

3/8-16 100469 100469 100469 4

96

◆

LOCKWASHER;

3/8 100133 100133 100133 100133 100133 100133 100133 100133 100133 2

LOCKWASHER;

3/8 100133 100133 100133 4

97

◆

NUT, channel 118446 118446 118446 118446 118446 118446 118446 118446 118446 2

NUT, channel 118446 118446 118446 4

102 STRAP, motor 15B107 15B107 15B108 15B108 15B107 15B107 15B108 15B108 15B107 15B107 15B108 15B108 1

121 LABEL

15M504 15M500 15M499 15M501 15M504 15M500 15M499 15M501 15M504 15M500 15M499 15M501

1

122 INSULATOR 167002 167002 167002 167002

(qty: 4) 167002 167002 167002 167002

(qty: 4) 167002 167002 167002 167002

(qty: 4) 2

Ref. Description

Reactor Models

Qty

259024

E-XP1

259025

E-20

259026

E-30

259028

E-XP2

259029

E-XP1

259030

E-20

259031

E-30

259032

E-XP2

259033

E-XP1

259034

E-20

259035

E-30

259036

E-XP2

Parts

56 312066Z

Parts that Vary by Model (continued)

▲

Replacement 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.

Ref. Description

Reactor Models

Qty

259057

E-30

w/15.3kW

259058

E-30

w/15.3kW

259059

E-30

w/15.3kW

2 HEATER; pages

60 and 61 247509 247509 247509 2

3MODULE, pro-

portioner; page

58

245957 245957 245957 1

6CONTROL,

motor; page 65 24G881 24G881 24G881 1

8TRANSFORMER; 247812 247812 247812 1

9 SHIELD 276879 276879 276879 1

14 TUBE, heater,

component A 247915 247915 247915 1

15 TUBE, pump,

component A 247914 247914 247914 1

16 TUBE, heater,

component B 247917 247917 247917 1

17 TUBE, pump,

component B 247916 247916 247916 1

21 CONNECTOR,

tube 121311 121311 121311 2

28 MODULE,

breaker; page 67 FDE1

36 SWITCH, added

pole; 380V 123968 1

39 FILTER; 230V 117667 117667 117667 1

51▲LABEL, warning 198278 198278 198278 1

52 CABLE, harness,

filter 15B385 15B385 15B385 1

65 KIT, fluid inlet 234367 234367 234367 1

65a ELBOW, swivel;

3/4 npt(m) x 1”

npt(f)

118463 118463 118463 2

71 SCREW, machine --- --- --- 2

72

◆

BRACKET, heater 247523 247523 247523 4

73 WASHER, lock 103181 103181 103181 2

76 CAPACITOR 244733 244733 244733 1

77 BRACKET 197999 197999 197999 1

95

◆

BOLT; hex hd;

3/8-16 100469 100469 100469 4

96

◆

LOCKWASHER;

3/8

LOCKWASHER;

3/8 100133 100133 100133 4

97

◆

NUT, channel

NUT, channel 118446 118446 118446 4

102 STRAP, motor 15B108 15B108 15B108 1

121 LABEL 15M499 15M499 15M499 1

122 Insulator 167002 167002 167002 4

Ref. Description

Reactor Models

Qty

259057

E-30

w/15.3kW

259058

E-30

w/15.3kW

259059

E-30

w/15.3kW

Parts

312066Z 57

Parts

58 312066Z

Sub Assemblies

Proportioner Module

Detail of Cycle Counter Switch

TI2511a

TI3250a

245956 Module for E-20 and EXP-1

245957 Module for E-30

245959 Module for EXP-2

201

202

203

204

205

206A

*207

208

209

**210

211

212

213

214

215

216

217

218

219

*208

214

221

1

Flat side faces up.

1

220

206B 211

210**

216

1

225

224

226

Parts

312066Z 59

Proportioner Assembly

245956 Module, for E-20 and E-XP1

245957 Module, for E-30

245959 Module, for E-XP2

* Parts included in Gear Kit 244264 (245956) or

244265 (245957, 245959).

** Parts included in Connecting Rod Kit 241008

(245956) or 241279 (245957, 245959).

Ref. Part Description Qty

201 24V618 MOTOR; 245956 1

24V500 MOTOR; 245957, 245959 1

202 245968 HOUSING, drive; 245956 2

245969 HOUSING, drive; 245957, 245959 2

203 240523 HOUSING, bearing; 245956 2

241015 HOUSING, bearing; 245959 2

245927 HOUSING, bearing; 245957 2

204 244264 GEAR; includes items 207, 208;

245956

2

244265 GEAR; includes items 207, 208;

245957, 245959

2

205 241008 ROD, connecting; includes item 210;

245956

2

241279 ROD, connecting; includes item 210;

245957, 245959

2

206A 246830 PUMP, displacement, component A;

245956; see 309577

1

246831 PUMP, displacement, component A;

245959; see 309577

1

246832 PUMP, displacement, component A;

245957; see 309577

1

206B 245970 PUMP, displacement, component B;

245956; see 309577

1

245971 PUMP, displacement, component B;

245959; see 309577

1

245972 PUMP, displacement, component B;

245957; see 309577

1

207* 114699 WASHER, thrust; steel 2

208* 114672 WASHER, thrust; bronze 4

209 114418 SCREW, self-tapping; 8-32 x 1 in. (25

mm); 245956

8

114818 SCREW, self-tapping; 8-32 x 1-1/4 in.

(31 mm); 245957, 245959

8

210** 176817 CLIP, wire; 245956 2

183169 CLIP, wire; 245957, 245959 2

211 176818 PIN; 245956 2

183210 PIN; 245957, 245959 2

212 107218 SCREW, cap, socket-hd; 1/4-20 x 2-3/4

in. (70 mm); 245956

4

114686 SCREW, cap, socket-hd; 5/16-18 x

3-1/4 in. (83 mm); 245957, 245959

4

213 107210 SCREW, cap, socket-hd; 3/8-16 x 1-1/2

in. (38 mm); 245956

8

114666 SCREW, cap, socket-hd; 3/8-16 x 2-1/4

in. (57 mm); 245957, 245959

8

214 105510 WASHER, lock; 1/4; 245956 12

104008 WASHER, lock; 5/16; 245957, 245959 12

215 106115 WASHER, lock; 3/8 size 8

216 192723 NUT, retaining; 245956 2

193031 NUT, retaining; 245959 2

193394 NUT, retaining; 245957 2

217 179899 COVER; 245956 2

241308 COVER; 245957, 245959 2

218 116191 WASHER, thrust; 245956 2

116192 WASHER, thrust; 245957, 245959 2

219 100644 SCREW, cap, socket-hd; 1/4-20 x 3/4

in. (19 mm); 245956

4

101864 SCREW, cap, socket-hd; 5/16-18 x 1 in.

(25 mm); 245957, 245959

4

220 116618 MAGNET 1

221 117770 SWITCH, cycle counter 1

223 100643 SCREW, cap, socket-hd; 1/4-20 x 1 in.

(25 mm); 245956

4

102962 SCREW, cap, socket-hd; 5/16-18 x

1-1/4 in. (31 mm); 245957, 245959

4

224 104765 PLUG 2

225 15C587 GUARD, finger; 245956 1

15C588 GUARD, finger; 245959 1

226 15M507 LABEL; 245956 1

15M508 LABEL; 245957, 245959 1

Ref. Part Description Qty

Parts

60 312066Z

Fluid Heaters

247506, 6.0 kW Fluid Heaters

247507, 10.2 kW Fluid Heaters

r_247507_312408

Apply 110009 thermal heatsink compound.

1

313

304

309

307

303

305

310

306

311

308

1

301

314

315

Ref Part Description Qty.

301 HOUSING, heater 1

303 121309 ADAPTER 4

304 15H304 PLUG 2

305 15H306 ADAPTER, thermocouple 2

306 120336 O-RING; fluoroelastomer 2

307 HEATER, immersion 4

16A110 2550W; 10.2kW heater only

16A112 1500 W; 6.0 kW heater only

308 15B137 SWITCH, overtemperature 1

309 15B135 MIXER, immersion heater 4

310 117484 SENSOR 2

311 100518 SCREW, machine, pan hd 2

313 15H305 PLUG, hollow 4

314 247520 DISC, rupture 2

315 124132 O-RINGS 4

Ref Part Description Qty.

Parts

312066Z 61

7.65 kW Single Zone Fluid Heater

(Two Per Machine)

Part 247509

303

301

304

307

308

310 311

305

306

1

304

313

313

r_247813_312066

Apply 110009 thermal heatsink compound.

1

309

314

315

Ref. Part Description Qty

301 HOUSING, heater 1

303 121309 ADAPTER 2

304 15H304 PLUG 3

305 15H306 ADAPTER, thermocouple 1

306 120336 O-RING; fluoroelastomer 1

307 16A110 HEATER, immersion; 2550 W 3

308 15B137 SWITCH, overtemperature 1

309 15B135 MIXER, immersion heater 3

310 117484 SENSOR 1

311 100518 SCREW, machine, pan hd 2

313 15H305 PLUG, hollow 5

314 247520 DISC, rupture; not shown 1

315 124132 O-RING 3

Ref. Part Description Qty

Parts

62 312066Z

Reactor Frame

TI2513a

405

401

406 404

402

404

403

407

Ref. Part Description Qty

401 FRAME 1

402 116478 WHEEL 2

403 101242 RING, retaining 2

404 116477 WASHER, flat; nylon 4

405 112125 PLUG 2

406 116411 SPRING 2

407 154636 WASHER, flat 4

Parts

312066Z 63

Display

--- Not for sale.

ti2574a

502

501

503

504

505

506

507

508

510

511

512

506

511

ti3172a

501a

501c

501b

502b

502c502a

20 (Ref)

Ref. Part Description Qty.

501 24G884 DISPLAY, pressure; includes

501a-501c

1

501a 24G882 .BOARD, circuit 1

501b 246479 .SWITCH, membrane 1

501c 112324 .SCREW 4

502 24G883 DISPLAY, temperature; includes

502a-502c

1

502a 24G882 .BOARD, circuit 1

502b 246479 .SWITCH, membrane 1

502c 112324 .SCREW 4

503 15B293 GASKET 1

504 15B292 COVER 1

505 15B291 PLATE 1

506 246287 HARNESS, wire, red stop button 1

507 117499 HANDLE 2

508 117523 NUT, cap; 10-24 8

510 --- SCREW, machine, pan-hd; M5 x

0.8; 16 mm

4

511 15B386 CABLE, display 1

512 195853 SCREW, machine; M2.5 x 6 2

Ref. Part Description Qty.

Parts

64 312066Z

Temperature Control

TI9843a

602

604

601

603

604

604

604

603

603

605

To B

Heater

Module

To A

Heater

Module

To Hose

Heater

Module

606

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

Parts

312066Z 65

Motor Control

24G879 Motor Control for E-20 and EXP-1 24G881 Motor Control for E-30 and EXP-2

--- Not for sale.

24G879 Motor Control for E-20 and EXP-1

24G881 Motor Control for E-30 and EXP-2

TI3153a

TI2576a

702

703

701

1

Apply 110009 thermal heatsink compound to mating surfaces.

1

701

702

705

703

704

707

2

Motor harness (609) plugs in here.

2

1

Ref. Part Description Qty.

701 15B297 HEAT SINK 1

702 24G878 BOARD, motor control 1

703 107156 SCREW, machine; 6-32 7

Ref. Part Description Qty.

701 16F745 HEAT SINK 1

702 --- BOARD, motor control 1

703 --- SCREW, machine;

6-32 x 3/8 in. (10 mm)

6

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

Parts

66 312066Z

Fluid Manifold

▲

Replacement Warning labels, signs, tags, and cards

are available at no cost.

† 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.

* Complete valve kits also include thread sealant.

(Purchase kits separately).

TI10959a

Torque to 355-395 in-lb (40.1-44.6 N•m).

Apply sealant (113500) to threads.

Valve must be closed with handle position as shown on drawing.

** Apply PTFE tape or thread sealant to tapered threads.

1

2

3

808

806

818

802

803

805

814

815

804

801 812

813 817

814

807

816

1

2

3

2

3

3

802a

802b

Ref. Part Description Qty.

801 247837 MANIFOLD, fluid 1

802† 247824 VALVE, drain cartridge 2

802a† 158674 . O-RING 1

802b† 247779 . SEAL, seat, valve 1

803 102814 GAUGE, pressure, fluid 2

804 162453 FITTING, 1/4 npsm x 1/4 npt 2

805 24K999 TRANSDUCER, pressure, control 2

806 247788 HANDLE, red 1

807 247789 HANDLE, blue 1

808† 112309 NUT, hex, jam 2

812 117556 NIPPLE, #8 JIC x 1/2 npt 1

813 117557 NIPPLE, #10 JIC x 1/2 npt 1

814 121312 ELBOW, 90 degrees 2

815 100840 ELBOW, street; 1/4 npsm x 1/4 npt 2

816 111457 O-RING, PTFE 2

817▲189285 LABEL, caution 1

818† 150829 SPRING, compression 2

Ref. Part Description Qty.

Parts

312066Z 67

Circuit Breaker Modules

178CB

187CB

197CB 172CB

238CR

172CB

197CB

187CB

178CB

238CR

168BR

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

for parts.

A - 230V, 3 Phase Circuit Breaker Modules

(E-20, EXP-1)

For wiring and cable connections, refer to electrical

diagrams manual 312067, supplied. See page 70

for parts.

918

907

909 912

913 919

901

908

915

917

914

916

911

910

906

905

920

902

903, 904

918

907

909 912

913 919

901

908

917

916

911

910

906

905

920

902

903, 904

922

922

Parts

68 312066Z

#"

#"

#"

#"

2#

"2

172CB

197CB

187CB

178CB

238CR

168BR

C - 230V, 1 Phase Circuit Breaker Modules

(E-20, EXP-1)

For wiring and cable connections, refer to electrical

diagrams manual 312067, supplied. See page 70

for parts.

918

907

909 912

913 919

901

908

915

917

914

916

911

910

906

905

920

902

903, 904

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.

918

907

909 912

913

901

908

915

917

914

916

911

910

906

905

920

902

903, 904

919

922

922

Parts

312066Z 69

#"

#"

#"

#"

2#

"2

#"

#"

#" #"

2#

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.

918

907

909 912

913

901

908

917

916

911

910

906

905

920

902

903, 904

F - 230V, 1 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.

918

907

909 912

913

919

901

908

915

917

914

916

911

910

906

905

920

902

903, 904

919

922

922

Parts

70 312066Z

Circuit Breaker Modules Parts List

--- Not for sale.

Ref. Description

Breaker Modules

Qty

E-20 and EXP-1 Models E-30 and EXP-2 Models

A

230V,

3 phase

B

400V,

3 phase

C

230V,

1 phase

D

230V,

3 phase

E

400V,

3 phase

F

230V,

1 phase

901 RAIL, mounting 255028 255028 255028 255028 255028 255028 1

902 CLAMP, block, end 255045 255045 255045 255045 255045 255045 1

903 HOLDER, fuse terminal, block 255043 255043 255043 255043 255043 255043 2

904 FUSE 255023 255023 255023 255023 255023 255023 2

905 TERMINAL, block 255042 255042 255042 255042 255042 255042 4

906 TERMINAL, end cover --- --- --- --- --- --- 1

907 BRIDGE, plug in, jumper 255044 255044 255044 255044 255044 255044 2

908 BLOCK, terminal ground 255046 255046 255046 255046 255046 255046 1

909 BREAKER, 1 pole, 50A 255026 255026 255026 255026 255026 255026 1

910 CONTACTOR, relay, 65A 255022 255022 255022 255022 255022 255022 1

911 BREAKER, 2 phase, 40A 247768 247768 247768 247768 247768 247768 1

912 BREAKER, 2 phase, 25A 255050 255050 255050 255050 255050 255050 2

BREAKER, 2 phase, 40A 247768 247768 247768 247768 247768 247768 2

913 BREAKER, 2 phase, 20A 255049 255049 255049 255049 255049 255049 1

914 CONNECTOR, power lug 117679 117679 3

CONNECTOR, power lug 117679 117679 2

915 BAR, power buss, 3 phase 117805 117805 1

BAR, power buss, 1 phase 117678 117678 1

916 CABLE, harness lower 247802 247802 247802 247802 247802 247802 1

917 CABLE, harness upper 247805 247806 247804 247805 247806 247804 1

918 CONNECTOR, 2 pin large 255027 255027 255027 255027 255027 255027 3

919 CONNECTOR, 3 pin 247522 247522 247522 247567 247567 247567 1

920 CONNECTOR, 4 pin 255031 255031 255031 255031 255031 255031 1

922 CABLE, harness 247791 247791 247791 247791 247791 247791 1

248669 Conversion Kit

312066Z 71

248669 Conversion Kit

Convert and phase E-XP2 to and E-30 with 15.3 kW of

heat by changing displacement pumps, bearings, and

changing the Motor Control DIP settings to that of an

E-30. For removal and installation of displacement

pumps and bearings, see Pump Removal (page 24)

and Pump Installation (page 26). For changing Motor

Control DIP settings, see Motor Control Board, page

34.

Ref. Part Description Qty.

65 118463 ELBOW, swivel; 3/4 npt(m) x 1 in.

npt(f)

2

303 245927 HOUSING, bearing 2

306A 246832 PUMP, displacement, component

A; see 309557

1

306B 245972 PUMP, displacement, component

B; see 309577

1

316 193394 NUT, retaining 2

TI10966a

303

316

306B

65

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.

Dimensions

72 312066Z

Dimensions

Dimension in. (mm)

A 46.0 (1168)

B 31.0 (787)

C 33.0 (838)

TI10953a

B

A

C

Technical Data

312066Z 73

Technical Data

All other brand names or marks are used for identification purposes and are trademarks of their respective owners.

Category Data

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 lb/min (9 kg/min)

Model E-30: 30 lb/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 lpm)

Model E-30: 93.5 dB(A) at 1000 psi (7 MPa, 70 bar), 3.0 gpm (11.4 lpm)

Model E-XP1: 80 dB(A) at 2000 psi (14 MPa, 140 bar), 0.5 gpm (1.9 lpm)

Model E-XP2: 83.5 dB(A) at 3000 psi (21 MPa, 210 bar), 1.0 gpm (3.8 lpm)

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 lpm)

Model E-30: 83.6 dB(A) at 1000 psi (7 MPa, 70 bar), 3.0 gpm (11.4 lpm)

Model E-XP1: 70.2 dB(A) at 2000 psi (14 MPa, 140 bar), 0.5 gpm (1.9 lpm)

Model E-XP2: 73.6 dB(A) at 3000 psi (21 MPa, 210 bar), 1.0 gpm (3.8 lpm)

Fluid Inlets 3/4 npt(f), with 3/4 npsm(f) union

Fluid Outlets 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

Fluid Circulation Ports 1/4 npsm(m), with plastic tubing; 250 psi (1.75 MPa, 17.5 bar) maximum

Weight Model E-20 and E-XP1: 342 lb (155 kg)

Model E-30: 400 lb (181kg)

Models E-XP2 and E-30 with 15.3kW of heat: 438 lb (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 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.

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

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 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 limited 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

rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite

de ou en rapport, directement ou indirectement, avec les procédures concernées.

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