Graco 333024E Reactor 2 E 30 And Xp2 Proportioning System Users Manual System, Repair Parts, English

2015-04-02

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Repair-Parts

Reactor 2 E-30 and E-XP2
Proportioning System

333024E

Electric, Heated, Plural Component Proportioning System. For spraying polyurethane foam and
polyurea coatings. For professional use only. Not approved for use in explosive atmospheres or
hazardous locations.
Important Safety Instructions. Read all warnings and instructions in
this manual. Save these instructions.

PROVEN QUALITY. LEADING TECHNOLOGY.

Contents
Warnings ........................................................... 3
Important Isocyanate Information......................... 7
Models............................................................... 9
Approvals........................................................... 11
Accessories........................................................ 11
Supplied Manuals............................................... 12
Related Manuals ................................................ 12
Troubleshooting.................................................. 13
Troubleshoot Errors ..................................... 13
Pressure Relief Procedure .................................. 42
Shutdown........................................................... 43
Flushing............................................................. 45
Repair................................................................ 46
Before Beginning Repair............................... 46
Flush Inlet Strainer Screen ........................... 46
Change Pump Lubricant............................... 47
Remove Pump............................................. 48
Install Pump ................................................ 49
Repair Drive Housing ................................... 50
Repair Electric Motor.................................... 53
Repair Circuit Breaker Module ...................... 54
Replace Fluid Inlet Sensor............................ 55

Replace Pressure Transducers..................... 55
Replace Fans .............................................. 56
Repair Primary Heater.................................. 59
Repair Heated Hose..................................... 63
Repair Fluid Temperature Sensor
(FTS)............................................. 64
Replace Power Supply ................................. 67
Replace Surge Protector .............................. 67
Replace Advanced Display Module
(ADM)............................................ 67
Replace Motor Control Module (MCM)........... 68
Software Update Procedure.......................... 68
Replace Temperature Control Module
(TCM)............................................ 68
Parts.................................................................. 69
Electrical Schematics.......................................... 89
Reactor 2 Repair Spare Parts Reference ............. 92
Performance Charts............................................ 93
Technical Speciﬁcations...................................... 96
Notes ............................................................... 98
Graco Extended Warranty for Reactor® 2
Components ......................................... 99

333024E

Warnings

Warnings
The following warnings are for the setup, use, grounding, maintenance and repair of this equipment. The
exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-speciﬁc
risks. When these symbols appear in the body of this manual refer back to these Warnings. Product-speciﬁc
hazard symbols and warnings not covered in this section may appear throughout the body of this manual
where applicable.

WARNING
ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can
cause electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before
servicing or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualiﬁed electrician and comply with all local codes
and regulations.
• Do not expose to rain. Store indoors.
Toxic ﬂuids or fumes can cause serious injury or death if splashed in the eyes or on skin,
inhaled, or swallowed.
• Read MSDSs 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 chemically impermeable gloves when spraying, dispensing, or cleaning
equipment.
TOXIC FLUID OR FUMES

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury,
including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective
equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the ﬂuid and solvent
manufacturer.

333024E

Warnings

WARNING
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.
.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deﬂect leaks with your hand, body, glove, or rag.
• Follow the
when you stop spraying and before cleaning, checking,
or servicing equipment.
• Tighten all ﬂuid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
Get immediate surgical

treatment

Pressure Relief Procedure

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in
can ignite or explode. To help
prevent ﬁre and explosion:
• Use 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 power or light switches on or off when ﬂammable
fumes are present.
• Ground all equipment in the work area. See
instructions.
• Use only grounded hoses.
• Hold gun ﬁrmly to side of grounded pail when triggering into pail. Do not use pail liners unless
they are antistatic or conductive.
•
if static sparking occurs or you feel a shock Do not use
equipment until you identify and correct the problem.
• Keep a working ﬁre extinguisher in the work area.
work area

Grounding

Stop operation immediately

THERMAL EXPANSION HAZARD

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

333024E

Warnings

WARNING
PRESSURIZED ALUMINUM PARTS HAZARD

Use of ﬂuids that are incompatible with aluminum in pressurized equipment can cause serious
chemical reaction and equipment rupture. Failure to follow this warning can result in death,
serious injury, or property damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon
solvents or ﬂuids containing such solvents.
• Many other ﬂuids may contain chemicals that can react with aluminum. Contact your material
supplier for compatibility.
PLASTIC PARTS CLEANING SOLVENT HAZARD

Many solvents can degrade plastic parts and cause them to fail, which could cause serious
injury or property damage.
• Use only compatible water-based solvents to clean plastic structural or pressure-containing
parts.
• See
in this and all other equipment instruction manuals. Read ﬂuid and
solvent manufacturer’s MSDSs and recommendations.
Technical Data

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the inﬂuence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated
system component. See
in all equipment manuals.
• Use ﬂuids and solvents that are compatible with equipment wetted parts. See Technical Data
in all equipment manuals. Read ﬂuid and solvent manufacturer’s warnings. For complete
information about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the
when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modiﬁcations may void agency approvals
and create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from trafﬁc areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
Technical Data

Pressure Relief Procedure

333024E

Warnings

WARNING
MOVING PARTS HAZARD

Moving parts can pinch, cut or amputate ﬁngers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing
equipment, follow the
and disconnect all power sources.
Pressure Relief Procedure

BURN HAZARD

Equipment surfaces and ﬂuid that is heated can become very hot during operation. To avoid
severe burns:
• Do not touch hot ﬂuid or equipment.

333024E

Important Isocyanate Information

Important Isocyanate Information
Isocyanates (ISO) are catalysts used in two component materials.
Isocyanate Conditions

Spraying or dispensing materials containing
isocyanates creates potentially harmful mists,
vapors, and atomized particulates.
Read material manufacturer’s warnings and
material MSDS to know speciﬁc hazards and
precautions related to isocyanates.
Prevent inhalation of isocyanate mists, vapors,
and atomized particulates by providing sufﬁcient
ventilation in the work area. If sufﬁcient ventilation
is not available, a supplied-air respirator is required
for everyone in the work area.
To prevent contact with isocyanates, appropriate
personal protective equipment, including
chemically impermeable gloves, boots, aprons,
and goggles, is also required for everyone in the
work area.
Material Self-Ignition

Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings
and material MSDS.

333024E

Keep Components A and B Separate

Cross-contamination can result in cured
material in ﬂuid lines which could cause serious
injury or damage equipment. To prevent
cross-contamination:
•
interchange component A and component
B wetted parts.
• Never use solvent on one side if it has been
contaminated from the other side.
Never

Moisture Sensitivity of Isocyanates

Exposure to moisture (such as humidity) will cause
ISO to partially cure; forming small, hard, abrasive
crystals, which become suspended in the ﬂuid.
Eventually a ﬁlm will form on the surface and the ISO
will begin to gel, increasing in viscosity
NOTICE

Partially cured ISO will reduce performance and
the life of all wetted parts.
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere.
store ISO in an open container.
• Keep the ISO pump wet cup or reservoir (if
installed) ﬁlled with appropriate lubricant. The
lubricant creates a barrier between the ISO and
the atmosphere.
• Use only moisture-proof hoses compatible with
ISO.
• Never use reclaimed solvents, which may
contain moisture. Always keep solvent
containers closed when not in use.
• Always lubricate threaded parts with an
appropriate lubricant when reassembling.
Never

Important Isocyanate Information

Foam Resins with 245 fa Blowing
Agents

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

Changing Materials
NOTICE

Changing the material types used in your
equipment requires special attention to avoid
equipment damage and downtime.
• When changing materials, ﬂush the equipment
multiple times to ensure it is thoroughly clean.
• Always clean the ﬂuid inlet strainers after
ﬂushing.
• Check with your material manufacturer for
chemical compatibility.
• When changing between epoxies and urethanes
or polyureas, disassemble and clean all ﬂuid
components and change hoses. Epoxies often
have amines on the B (hardener) side. Polyureas
often have amines on the B (resin) side.

333024E

Models

Models
Reactor 2 E-30 and E-30 Elite

All elite systems include ﬂuid inlet pressure and temperature sensors, Graco InSite™, and Xtreme-Wrap 50 ft
(15 m) head hose. For part numbers, see Accessories, page 11
E-30 Model
Model

10 kW

15 kW

10 kW

15kW

272010
2000 (14, 140)
0.0272 (0.1034)
30 (13.5)
17,900
230 230 380
1Ø 3Ø∆ 3ØY
78 50 34

272011
2000 (14, 140)
0.0272 (0.1034)
30 (13.5)
23,000
230 230 380
1Ø 3Ø∆ 3ØY
100 62 35

272110
2000 (14, 140)
0.0272 (0.1034)
30 (13.5)
17,900
230 230 380
1Ø 3Ø∆ 3ØY
78 50 34

272111
2000 (14, 140)
0.0272 (0.1034)
30 (13.5)
23,000
230 230 380
1Ø 3Ø∆ 3ØY
100 62 35

Fusion AP Package 

AP2010

AH2010

AP2011

AH2011

AP2110

AH2110

AP2111

AH2111

(Gun Part No.)

(246102)

(Gun Part No.)

(CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD) (CS02RD)

(CS02RD) (CS02RD)

(Gun Part No.)

(GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2) (GCP2R2)

(GCP2R2) (GCP2R2)

Proportioner

★

E-30 Elite Model

Maximum Fluid Working
Pressure psi (MPa, bar)
Approximate Output per
Cycle (A+B) gal. (liter)
Max Flow Rate lb/min
(kg/min)
Total System Load †

(Watts)
Conﬁgurable Voltage



Phase

Full Load Peak Current*

Fusion CS Package 
Probler P2 Package 
Heated Hose
50 ft (15 m)

24K240 (scuff guard)
24Y240 (Xtreme-Wrap)
Heated Whip Hose
10 ft (3 m)
Graco Insite™
Fluid Inlet Sensors (2)

CS2010
P22010

24K240

Qty: 1

246050

CH2010
PH2010

24K240

Qty: 5

CS2011
P22011

24K240

Qty: 1

333024E

PH2011

24K240

Qty: 5

246050

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 used by system, based on
maximum heated hose length for each unit.
• E–30 and E–XP2 series: 310 ft (94.5 m)
maximum heated hose length, including
whip hose.
★ See Approvals, page 11.
*

CH2011





CS2110
P22110

24Y240

Qty: 1

CH2110
PH2110

24Y240

Qty: 5

CS2111
P22111

24Y240

Qty: 1

246050

✓
✓

CH2111
PH2111

24Y240

Qty: 5

Packages include gun, heated hose, and
whip hose. Elite packages also include Graco
InSite and ﬂuid inlet sensors.
Low line input voltage will reduce power
available and heaters will not perform at full
capacity.

Voltage Conﬁgurations Key

Ø Phase
∆ DELTA
Y WYE

Models

Reactor 2 E-XP2 and E-XP2 Elite

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

E–XP2 Model
15 kW

★

Proportioner

Maximum Fluid Working
Pressure psi (MPa, bar)
Approximate Output per
Cycle (A+B) gal. (liter)
Max Flow Rate gpm/min
(l/min)
Total System Load †



(Watts)
Conﬁgurable Voltage



Phase

E–XP2 Elite Model

Full Load Peak Current

272012
3500 (24.1, 241)
0.0203 (0.0771)
2 (7.6)
23,000
230 1Ø
230 3Ø∆
100
62

15 kW

380 3ØY
35

272112
3500 (24.1, 241)
0.0203 (0.0771)
2 (7.6)
23,000
230 1Ø
230 3Ø∆
100
62

380 3ØY
35

(amps)

Fusion AP Package



Probler P2 Package



(Gun Part No.)
(Gun Part No.)
Heated Hose
50 ft (15 m)

Heated Whip Hose
10 ft (3 m)

AP2012
(246101)
P22012
(GCP2R1)
24K241
(scuff guard)
246055

™

Graco InSite

Fluid Inlet Sensors (2)

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 used by system, based on
maximum heated hose length for each unit.
• E–30 and E–XP2 series: 310 ft (94.5 m)
maximum heated hose length, including
whip hose.
★ See Approvals, page 11.
*





AP2112
(246101)
P22112
(GCP2R1)
24Y241
(Xtreme-Wrap)
246055
✓
✓
Packages include gun, heated hose, and
whip hose. Elite packages also include
Graco InSite and ﬂuid inlet sensors.
Low line input voltage will reduce power
available and heaters will not perform at full
capacity.

Voltage Conﬁgurations Key

Ø Phase
∆ DELTA
Y WYE

333024E

Approvals

Accessories

Intertek approvals apply to proportioners without
hoses.
Proportioner Approvals:

Kit Number

24U315
24U314
24T280
16X521
24N449

9902471

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

Note

Heated hoses provided with a system or sold
individually are not approved by Intertek.

333024E

24K207
24U174
24K337
15V551
15M483
24M174
121006
24N365

Description

Air Manifold Kit (4 outlets)
Wheel and Handle Kit
Graco InSite Kit
Graco InSite Extension cable 24.6 ft
(7.5 m)
50 ft (15 m) CAN cable (for remote
display module)
Fluid Temperature Sensor (FTS)
with RTD
Remote Display Module Kit
Light Tower Kit
ADM Protective Covers (10 pack)
Remote Display Module Protective
Covers (10 pack)
Drum Level Sticks
150 ft (45 m) CAN cable (for remote
display module)
RTD Test Cables (to aide resistance
measurements)

Supplied Manuals

Supplied Manuals
The following manuals are shipped with the Reactor
2. Refer to these manuals for detailed equipment
information.
Manuals are also available at www.graco.com.
Manual

333023
333091
333092

Description

Reactor 2 E-30 and E-XP2
Operation
Reactor 2 E-30 and E-XP2 Startup
Quick Guide
Reactor 2 E-30 and E-XP2
Shutdown Quick Guide

Related Manuals

The following manuals are for accessories used with
the Reactor.
Component Manuals in English:

Manuals are available at www.graco.com.
System Manuals

333023

Reactor 2 E-30 and E-XP2 Operation

Displacement Pump Manual

309577

Electric Reactor Displacement Pump,
Repair-Parts
Heated Hose, Instructions-Parts
Circulation and Return Tube Kit,
Instructions-Parts
Feed Pump Kits, Instructions-Parts
Feed Pump Air Supply Kit,
Instructions-Parts
Fusion ™ AP Gun
Fusion ™ CS Gun
Probler® P2 Gun

Feed System Manuals

309572
309852
309815
309827

Spray Gun Manuals

309550
312666
313213

Accessory Manuals

3A1905
3A1906
3A1907
332735
332736
333276
12

Feed Pump Shutdown Kit,
Instructions-Parts
Light Tower Kit, Instructions-Parts
Remote Display Module Kit,
Instructions-Parts
Air Manifold Kit, Instructions-Parts
Handle and Wheel Kit,
Instructions-Parts
Graco InSite ™ Kit, Instructions-Parts
333024E

Troubleshooting

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

Troubleshoot Errors

There are three types of errors that can occur. Errors
are indicated on the display as well as by the light
tower (optional).
Error

Description

A parameter critical to
the process has reached
a level requiring the
system to stop. The
alarm needs to be
addressed immediately.
A parameter critical
to the process has
reached a level requiring
attention, but not
sufﬁcient enough to
stop the system at this
time.
A parameter that is
not immediately critical
to the process. The
advisory needs attention
to prevent more serious
issues in the future.
See Error Codes, page 14 for causes and solutions
to each error code.
To troubleshoot the error:
Alarms

Deviations

Note

Press or to return to the
previously displayed screen.
2. The QR code screen will be displayed. Scan
the QR code with your smartphone to be sent
directly to online troubleshooting for the active
error code. Otherwise, manually navigate to
http://help.graco.com and search for the active
error.

Advisories

333024E

3. If no internet connection is available, see
Error Codes, page 14 for causes and solutions
for each error code.

Troubleshooting

Error Codes
Note

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

Location

A1NM MCM

Type

Description

Low Motor Current

Cause

Loose/broken
connection.
Bad Motor.

A4DA

Heater A

High Current A

Short circuit in
heater wiring.
Bad Heater.

A4DB

Heater B

High Current B

Short circuit in
heater wiring.
Bad Heater.

High Current Hose

Short circuit in
hose wiring.

A4DH Hose

Solution

Check for loose wire
terminations at MCM motor
connector.
Disconnect motor output
connector from MCM.
Conﬁrm less than 8 ohms
resistance between each
pair of motor power leads
(M1 to M2, M1 to M3, M2 to
M3). If any readings greater
than 8 ohms, check motor
wiring for damage and/or
loose terminations.
Check wiring for touching
wires.
Conﬁrm resistance of
heater. Heater resistance
should be 18–21 Ω for
each heater element, 9–12
Ω combined for 10 kW
systems, and 6-8 Ω for
15 kW systems. If out of
tolerance, replace heater
element.
Check wiring for touching
wires.
Conﬁrm resistance of
heater. Heater resistance
should be 9-12 Ω for 10
kW systems and 6-8 Ω for
15 kW systems. If out of
tolerance, replace heater.
Check continuity of
transformer windings.
Normal readings are about
0.2Ω on both primary and
secondary. If reading is 0Ω
replace transformer.
Check for shorts between
the primary winding and the
support frame or enclosure.

333024E

Troubleshooting

Error

Location

A7DA

Heater A

A7DB

Heater B

A4NM MCM

A7DH Hose

333024E

Type

Description

Cause

High Motor Current Short circuit of
motor wiring.

Solution

Check wiring to the motor
to ensure no bare wires are
touching and that no wires
are shorted to ground.
Motor will not
Remove pump gear
rotate.
housings from motor
and check that motor shaft
rotates freely in direction
indicated on motor housing.
Damaged gear Check pump gear trains
train.
for damage and repair or
replace as necessary.
Chemical pump is Repair or replace chemical
stuck.
pump.
Unexpected Current Shorted TCM
If error cannot be cleared
A
or regenerates consistently,
replace module.
Unexpected Current Shorted TCM
If error cannot be cleared
B
or regenerates consistently,
replace module.
Unexpected Current Shorted TCM
If error cannot be cleared
Hose
or regenerates consistently,
replace module.

Troubleshooting

Error

Location

A8DA

Heater A

A8DB

Heater B

Type

Description

No Current A
No Current B

A8DH Hose

No Current Hose

CACM MCM

MCM Communication Error

Cause

Tripped circuit
breaker.

Solution

Visually check circuit
breaker for a tripped
condition.
Loose/broken
Check heater wiring for
connection.
loose wires.
Tripped circuit
Visually check circuit
breaker.
breaker for a tripped
condition.
Loose/broken
Check heater wiring for
connection.
loose wires.
Tripped circuit
Visually check circuit
breaker.
breaker for a tripped
condition.
Loose/broken
Check heater wiring for
connection.
loose wires.
Module does not Insert a system token into
have software.
the ADM module and cycle
the power. Wait until the
upload is complete before
removing the token.
Dial set to wrong Ensure the MCM dial is set
position.
to the correct position: 2 for
E-30, 3 for E-XP2
No 24 VDC supply Green light on each module
to module.
should be lit. If green light is
not lit, check to make sure
each CAN cable connection
is tight. Verify the power
supply is outputting 24
VDC. If not, check power
supply wiring. If wiring is
okay, replace the power
supply.
Loose or broken Check the CAN cables
CAN cable.
running between GCA
modules and tighten of
needed. If the problem
still persists move each
cable around the connector
and watch the ﬂashing
yellow light on the GCA
modules. If the yellow light
stops ﬂashing, replace the
CAN cable.

333024E

Troubleshooting

Error

Location

CACT TCM

Type

Description

TCM Communication Module does not
have software.
Error

DADX MCM

Pump Runaway

DE0X

Cycle Switch Error

333024E

MCM

Cause

Solution

Insert a system token into
the ADM module and cycle
the power. Wait until the
upload is complete before
removing the token.
No 24 VDC supply Green light on each module
to module.
should be lit. If green light is
not lit, check to make sure
each CAN cable connection
is tight. Verify the power
supply is outputting 24
VDC. If not, check power
supply wiring. If wiring is
okay, replace the power
supply.
Loose or broken Check the CAN cables
CAN cable.
running between GCA
modules and tighten of
needed. If the problem
still persists move each
cable around the connector
and watch the ﬂashing
yellow light on the GCA
modules. If the yellow light
stops ﬂashing, replace the
CAN cable.
Flow rate is too Mix chamber too large for
large.
system selected. Use mix
chamber rated for system.
Ensure the system has
chemical and the feed
pumps are operating
correctly.
No material in pumps.
Verify pumps are supplying
chemical. If necessary,
replace or reﬁll drums.
Inlet ball valves are closed.
Open ball valves.
Faulty or missing Check wiring between cycle
cycle switch.
switch and MCM.
Missing or out of Check presence and
place cycle switch position of cycle switch
magnet on output crank
magnet.
arm.

Troubleshooting

Error

Location

Description

Cause

EAUX ADM

USB Busy

EVUX ADM

USB disabled

USB drive has
been inserted to
the ADM.
USB
download/uploads
are disabled.

F9DX

High Pressure/Flow Mix chamber is
Cutback
too large for set
pressure.

EVCH ADM

MCM

Type

Manual Hose Mode Manual hose mode
Enabled
has been enabled
in System Setup
screen.

H2MA Heater A

Low Frequency A

Line frequency is
below 45 Hz

H2MB Heater B

Low Frequency B

Line frequency is
below 45 Hz

H2MH Hose

Low Frequency Hose Line frequency is
below 45 Hz

H3MA Heater A

High Frequency A

Line frequency is
above 65 Hz

H3MB Heater B

High Frequency B

Line frequency is
above 65 Hz

H3MH Hose

High Frequency
Hose

Line frequency is
above 65 Hz

K8NM MCM

Locked Rotor Motor Motor will not
rotate.
Damaged gear
train.
Chemical pump is
stuck.

Solution

Install a functioning ﬂuid
temperature sensor (FTS)
on the hose. Manual hose
mode will automatically turn
off.
Do not remove USB drive
until download/upload is
complete.
Enable USB download/uploads on the Advanced
Setup screen before inserting a USB drive.
Reference the pressure
ﬂow curves and select a tip
size that is the correct size
for the set pressure.
Ensure line frequency of
incoming power is between
45 and 65 Hz.
Ensure line frequency of
incoming power is between
45 and 65 Hz.
Ensure line frequency of
incoming power is between
45 and 65 Hz.
Ensure line frequency of
incoming power is between
45 and 65 Hz.
Ensure line frequency of
incoming power is between
45 and 65 Hz.
Ensure line frequency of
incoming power is between
45 and 65 Hz.
Remove pump gear
housings from motor
and check that motor shaft
rotates freely in direction
indicated on motor housing.
Check motor/pump gear
trains for damage and repair
or replace as necessary.
Repair or replace chemical
pump.

333024E

Troubleshooting

Error

Location

L1BX

ADM

L1AX

ADM

MMUX USB
P0AX

333024E

MCM

Type

Description

Cause

Solution

Low Chemical Level Low material level. Reﬁll material and update
A
drum level on ADM
Maintenance screen.
Alarm can be disabled on
the System Setup screen.
Low Chemical Level Low material level. Reﬁll material and update
B
drum level on ADM
Maintenance screen.
Alarm can be disabled on
the System Setup screen.
Maintenance Due - USB logs have Insert a USB drive into the
USB
reached a level ADM and download all logs.
where data loss
will occur if logs are
not downloaded.
Pressure Imbalance Pressure
Ensure material ﬂow is
A High
difference between equally restricted on both
A and B material material lines.
is greater than the
deﬁned value.
Ensure that the pressure
Pressure
imbalance value, on the
imbalance is
deﬁned too low. System Setup screen, is at
an acceptable maximum
pressure to prevent
unnecessary alarms and
abort dispenses.
Out of material. Fill tanks with material
Fluid leaking from Check if heater
heater inlet rupture and PRESSURE
RELIEF/SPRAY valve are
disk.
plugged. Clear. Replace
rupture disk. Do not replace
with a pipe plug.
Feed system
Check feed pump and
defective.
hoses for blockage. Check
that feed pumps have
correct air pressure.

Troubleshooting

Error

P0BX

Location

MCM

P1FA

MCM

P1FB

MCM

P2FA

MCM

Type

Description

Cause

Pressure Imbalance Pressure
B High
difference between
A and B material
is greater than the
deﬁned value.
Pressure
imbalance is
deﬁned too low.

Solution

Ensure material ﬂow is
equally restricted on both
material lines.

Ensure that the pressure
imbalance value, on the
System Setup screen, is at
an acceptable maximum
pressure to prevent
unnecessary alarms and
abort dispenses.
Out of material. Fill tanks with material
Fluid leaking from Check if heater
heater inlet rupture and PRESSURE
RELIEF/SPRAY valve are
disk.
plugged. Clear. Replace
rupture disk. Do not replace
with a pipe plug.
Feed system
Check feed pump and
defective.
hoses for blockage. Check
that feed pumps have
correct air pressure.
Ensure that inlet pressure
Low Inlet Pressure A Inlet pressure
lower than deﬁned to the pump is sufﬁcient.
value.
Value deﬁned too Ensure that the low
pressure alarm level
high.
deﬁned on the System
Setup screen is acceptable.
Ensure that inlet pressure
Low Inlet Pressure B Inlet pressure
lower than deﬁned to the pump is sufﬁcient.
value.
Value deﬁned too Ensure that the low
pressure alarm level
high.
deﬁned on the System
Setup screen is acceptable.
Ensure that inlet pressure
Low Inlet Pressure A Inlet pressure
lower than deﬁned to the pump is sufﬁcient.
value.
Value deﬁned too Ensure that the low
pressure alarm level
high.
deﬁned on the System
Setup screen is acceptable.

333024E

Troubleshooting

Error

P2FB

P4AX

Location

MCM

Type

Description

Cause

Low Inlet Pressure B Inlet pressure
lower than deﬁned
value.
Value deﬁned too
high.
High Pressure A

System
pressurized before
allowing heat to
reach setpoint.
Bad pressure
transducer.
E-XP2 system
conﬁgured as E-30.

P4BX

MCM

High Pressure B

System
pressurized before
allowing heat to
reach setpoint.
Bad pressure
transducer.
E-XP2 system
conﬁgured as E-30.

333024E

Solution

Ensure that inlet pressure
to the pump is sufﬁcient.
Ensure that the low
pressure alarm level
deﬁned on the System
Setup screen is acceptable.
Pressure in the hose and
pumps will increase as the
system heats up. Turn on
heat and allow all zones
to reach the temperature
setpoint before turning on
the pumps.
Verify the ADM pressure
reading and the analog
gauges at the manifold.
Alarm level is lower for E-30
than for E-XP2. Ensure dial
on MCM is set to position
"3" for E-XP2.
Pressure in the hose and
pumps will increase as the
system heats up. Turn on
heat and allow all zones
to reach the temperature
setpoint before turning on
the pumps.
Verify the ADM pressure
reading and the analog
guages at the manifold.
Alarm level is lower for E-30
than for E-XP2. Ensure dial
on MCM is set to position
"3" for E-XP2.

Troubleshooting

Error

P6AX

Location

MCM

Type

Description

Pressure Sensor
Error A

Cause

Loose/bad
connection.
Bad sensor.

P6BX

MCM

Pressure Sensor
Error B

Loose/bad
connection.
Bad sensor.

P6FA

MCM

Pressure Sensor
Error Inlet A

Inlet sensors not
installed.
Loose/bad
connection.
Bad sensor.

Solution

Check to ensure the
pressure transducer is
properly installed and
all wires are properly
connected.
Check if the error follows
the transducer. Disconnect
transducer cables from
the MCM (connectors 6
and 7). Reverse A and B
connections and check if
the errors follows. If the
error follows the transducer,
replace the pressure
transducer.
Check to ensure the
pressure transducer is
properly installed and
all wires are properly
connected.
Check if the error follows
the transducer. Disconnect
transducer cables from
the MCM (connectors 6
and 7). Reverse A and B
connections and check if
the errors follows. If the
error follows the transducer,
replace the pressure
transducer.
If inlet sensors are not
installed, inlet sensors
should be disabled on the
System Setup screen.
Check to ensure inlet
sensor is properly installed
and all wires are properly
connected.
Check if the error follows
the inlet sensor. Disconnect
inlet sensor cables from
the MCM (connectors 8
and 9). Reverse A and B
connections and check if
the errors follows. If the
error follows the sensor,
replace the inlet sensor.

333024E

Troubleshooting

Error

Location

P6FB

MCM

P7AX

MCM

333024E

Type

Description

Cause

Inlet sensors not
installed.

Solution

If inlet sensors are not
installed, inlet sensors
should be disabled on the
System Setup screen.
Loose/bad
Check to ensure inlet
connection.
sensor is properly installed
and all wires are properly
connected.
Bad sensor.
Check if the error follows
the inlet sensor. Disconnect
inlet sensor cables from
the MCM (connectors 8
and 9). Reverse A and B
connections and check if
the errors follows. If the
error follows the sensor,
replace the inlet sensor.
Pressure Imbalance Pressure
Ensure material ﬂow is
A High
difference between equally restricted on both
A and B material material lines.
is greater than the
deﬁned value.
Ensure that the pressure
Pressure
imbalance value, on the
imbalance is
deﬁned too low. System Setup screen, is at
an acceptable maximum
pressure to prevent
unnecessary alarms and
abort dispenses.
Out of material. Fill tanks with material
Fluid leaking from Check if heater
heater inlet rupture and PRESSURE
RELIEF/SPRAY valve are
disk.
plugged. Clear. Replace
rupture disk. Do not replace
with a pipe plug.
Feed system
Check feed pump and
defective.
hoses for blockage. Check
that feed pumps have
correct air pressure.
Pressure Sensor
Error Inlet B

Troubleshooting

Error

P7BX

Location

MCM

Type

Description

Cause

Pressure Imbalance Pressure
B High
difference between
A and B material
is greater than the
deﬁned value.
Pressure
imbalance is
deﬁned too low.
Out of material.
Fluid leaking from
heater inlet rupture
disk.
Feed system
defective.

T2DA

Heater A

Low Temperature A Flow is too high at
current setpoint.
Bad RTD or bad
RTD placement
against heater.
Bad heater rod or
loose heater wire.

Solution

Ensure material ﬂow is
equally restricted on both
material lines.
Ensure that the pressure
imbalance value, on the
System Setup screen, is at
an acceptable maximum
pressure to prevent
unnecessary alarms and
abort dispenses.
Fill tanks with material
Check if heater
and PRESSURE
RELIEF/SPRAY valve are
plugged. Clear. Replace
rupture disk. Do not replace
with a pipe plug.
Check feed pump and
hoses for blockage. Check
that feed pumps have
correct air pressure.
Use a smaller mix chamber
that is rated for the unit
in use. If recirculating,
decrease ﬂow or decrease
temperature setpoint.
Swap A and B heater output
cables and RTD cables and
see if issue follows. If so,
replace RTD.
Conﬁrm resistance of
heater. Heater resistance
should be 9-12 Ω for 10
kW systems and 6-8 Ω
for 15 kW systems. If out
of tolerance, check for
loose heater rod wire(s).
Reconnect wires or replace
heater rod if necessary.

333024E

Troubleshooting

Error

Location

T2DB

Heater B

T2DH

Hose

T2FA

MCM

T2FB

MCM

333024E

Type

Description

Cause

Solution

Low Temperature B Flow is too high at Use a smaller mix chamber
current setpoint. that is rated for the unit
in use. If recirculating,
decrease ﬂow or decrease
temperature setpoint.
Bad RTD or bad Swap A and B heater output
RTD placement cables and RTD cables and
against heater.
see if issue follows. If so,
replace RTD.
Bad heater rod or Conﬁrm resistance of
loose heater wire. heater. Heater resistance
should be 9-12 Ω for 10
kW systems and 6-8 Ω
for 15 kW systems. If out
of tolerance, check for
loose heater rod wire(s).
Reconnect wires or replace
heater rod if necessary.
Low Temperature Flow is too high at Use a smaller mix chamber
Hose
current setpoint. that is rated for the unit
in use. If recirculating,
decrease ﬂow or decrease
temperature setpoint.
Cold chemical in Recirculate heated
unheated portion chemical back to drum
of system passed in cold conditions before
startup.
hose FTS at
startup.
Low Temperature Inlet ﬂuid
Recirculate ﬂuid through
Inlet A
temperature is
heaters until inlet ﬂuid
below the deﬁned temperature is above
level.
deﬁned error level.
Increase the low
temperature deviation
level on the System Setup
screen.
Low Temperature Inlet ﬂuid
Recirculate ﬂuid through
Inlet B
temperature is
heaters until inlet ﬂuid
below the deﬁned temperature is above
level.
deﬁned error level.
Increase the low
temperature deviation
level on the System Setup
screen.

Troubleshooting

Error

Location

Type

Description

T3CH

Hose

T3CT

TCM

TCM Cutback

T3NM MCM

MCM Cutback

T4CM MCM

High Temperature
MCM

Hose Cutback

Cause

Hose current has
been reduced
because hose
has been drawing
current for an
extended period.

Solution

Hose setpoint higher than A
and B setpoints. Decrease
hose setpoint.
Hose FTS is in a colder
environment than the rest
of the hose. Expose FTS to
the same environment as
the rest of the hose.
High ambient
Ensure ambient
temperature.
temperature is below
120°F(48°C) before using
the system.
Enclosure fan not Ensure fan in electrical
operating.
enclosure is spinning. If it
is not, check fan wiring or
replace fan.
Module fan not If a TCM fan error (WMI0)
operating.
has occurred, fan inside
the module is not working
properly. Check TCM fan
for debris and clear with
forced air if necessary.
Motor is operating The system is running at a
lower setpoint to preserve
outside of the
motor life. Run the system
pressure ﬂow
at a lower duty cycle or with
curve.
a smaller mix chamber.
High ambient
Ensure ambient
temperature.
temperature is below
120°F(48°C) before using
the system.
Enclosure fan not Ensure fan in electrical
operating.
enclosure is spinning. If it
is not, check fan wiring or
replace fan.

333024E

Troubleshooting

Error

Location

T4DA

Heater A

T4DB

Heater B

T4CT

333024E

TCM

Type

Description

High Temperature
TCM

Cause

High ambient
temperature.

Solution

Ensure ambient
temperature is below
120°F(48°C) before using
the system.
Enclosure fan not Ensure fan in electrical
operating.
enclosure is spinning. If it
is not, check fan wiring or
replace fan.
Module fan not If a TCM fan error (WMI0)
operating.
has occurred, fan inside
the module is not working
properly. Check TCM fan
for debris and clear with
forced air if necessary.
High Temperature A Bad RTD or bad Swap A and B heater output
RTD placement cables and RTD cables and
see if issue follows. If so,
against heater.
replace RTD.
Use a smaller mix chamber
Flow too high
for temperature that is rated for the unit in
setpoint, causing use.
temperature
overshoots when
gun is de-triggered.
High Temperature B Bad RTD or bad Swap A and B heater output
RTD placement cables and RTD cables and
against heater.
see if issue follows. If so,
replace RTD.
Use a smaller mix chamber
Flow too high
for temperature that is rated for the unit in
setpoint, causing use.
temperature
overshoots when
gun is de-triggered.

Troubleshooting

Error

T4DH

T4EA

Location

Hose

Heater A

Type

Description

High Temperature
Hose

High Temperature
Switch A

Cause

Hose portion
exposed to an
excessive heat
source, like hot
sun or coiled
hose, can pass
ﬂuid more than
27°F (15°C) over
hose temperature
setting to the FTS.
Setting the A or
B setpoint much
higher than hose
setpoint can cause
ﬂuid more than
27°F (15°C) over
hose temperature
setting to reach the
FTS.
Overtemperature
switch sensed a
ﬂuid temperature
above 230°F
(110°C).

Solution

Shade exposed hose from
hot sun or expose FTS to
same environment when
at rest. Uncoil entire hose
before heating to avoid
self-heating.
Increase hose setpoint
so it is closer to A and B
setpoints.

333024E

Troubleshooting

Error

T4EB

Location

Heater B

Type

Description

High Temperature
Switch B

T4NM MCM

High Temperature
Motor

T6DA

Sensor Error A

333024E

Heater A

Cause

Solution

Heater was delivered too
much power, causing the
overtemperature switch to
open. RTD is not reading
properly. After the heater
cools down, replace RTD.
Switch closes and the error
can be cleared when the
heater temperature falls
below 190°F (87°C).
Disconnected
If heater is not actually
or loose
over temperature, check
overtemperature all wiring and connections
switch
between the TCM and the
cable/connection. overtemperature switches.
Overtemperature Replace overtemperature
switch failed in the switch.
open position.
Cooling fan is not Check to see that the motor
operating properly. fan is moving. Measure
voltage to fan. There should
be 24 VDC.
If no voltage is measured,
check fan wiring. If the
fan has voltage but is not
moving, replace fan.
If necessary use an air hose
to blow out around the fan
housings and remove any
built-up debris.
Disconnected
Verify wiring between the
or loose motor
motor temperature sensor
temperature cable. and the MCM.
High ambient
Ensure ambient
temperature.
temperature is below
120°F(48°C) before using
the system.
Bad electric motor. Replace electric motor.
Disconnected or Check all wiring and
loose RTD cable or connection to RTD.
connection.
Bad RTD.
Switch the RTD with
another and see if the error
message follows the RTD.
Replace RTD if the error
follows the RTD.
Overtemperature
switch sensed a
ﬂuid temperature
above 230°F
(110°C).

Troubleshooting

Error

Location

Type

Description

T6DB

Heater B

T6DH

Hose

Sensor Error Hose

T6DT

TCM

Sensor Error TCM

Sensor Error B

Cause

Solution

Disconnected or Check all wiring and
loose RTD cable or connection to RTD.
connection.
Bad RTD.
Switch the RTD with
another and see if the error
message follows the RTD.
Replace RTD if the error
follows the RTD.
Disconnected or Expose each hose RTD
shorted RTD cable connection to check and
in hose or bad FTS. retighten any loose connector. Measure hose RTD
cable and FTS continuity.
See Repair Heated Hose,
page 63. Order RTD Test
kit 24N365 for measurement.
Disconnect hose RTD and
use manual hose mode to
ﬁnish job until repair can be
completed.
Shorted RTD cable Expose each hose RTD
in hose or FTS. connection to check for
exposed and shorted RTD
wires. Measure hose RTD
cable and FTS continuity.
See Repair Heated Hose,
page 63. Order RTD Test
kit 24N365 for measurement.
Disconnect hose RTD and
use manual hose mode to
ﬁnish job until repair can be
completed.
Shorted A or B If the error still occurs with
Heater RTD
the hose FTS unplugged,
one of the heater RTDs
is bad. Unplug the A or
B RTD from the TCM. If
unplugging an RTD ﬁxes
the T6DT error, replace the
RTD.

333024E

Troubleshooting

Error

T8DA

Location

Heater A

Type

Description

No Temperature
Rise A

Cause

Bad RTD or bad
RTD placement
against heater.
Bad heater rod or
loose heater wire.

T8DB

Heater B

No Temperature
Rise B

Started spraying
before heater
reached operating
temperature.
Bad RTD or bad
RTD placement
against heater.
Bad heater rod or
loose heater wire.

T8DH

Hose

V1CM MCM

333024E

No Temperature
Rise Hose
Low Voltage MCM

Solution

Swap A and B heater output
cables and RTD cables and
see if issue follows. If so,
replace RTD.
Conﬁrm resistance of
heater. Heater resistance
should be 9-12 Ω for 10
kW systems and 6-8 Ω
for 15 kW systems. If out
of tolerance, check for
loose heater rod wire(s).
Reconnect wires or replace
heater rod if necessary.
Wait until operating
temperature has been
reached before spraying or
recirculating.
Swap A and B heater output
cables and RTD cables and
see if issue follows. If so,
replace RTD.
Conﬁrm resistance of
heater. Heater resistance
should be 9-12 Ω for 10
kW systems and 6-8 Ω
for 15 kW systems. If out
of tolerance, check for
loose heater rod wire(s).
Reconnect wires or replace
heater rod if necessary.
Wait until operating
temperature has been
reached before spraying or
recirculating.
Wait until operating
temperature has been
reached before spraying or
recirculating.
Check wiring for loose
connection or tripped circuit
breaker.

Started spraying
before heater
reached operating
temperature.
Started spraying
before heater
reached operating
temperature.
Loose/bad
connection or
tripped circuit
breaker.
Low incoming line Measure voltage at circuit
voltage.
breaker and ensure voltage
is greater than 195 VAC.

Troubleshooting

Error

Location

V1IT

TCM

V2IT

TCM

Type

Description

Low Voltage CAN
Low Voltage CAN

V2MA TCM

Low Voltage A

V2MB TCM

Low Voltage B

V2MH TCM

Low Voltage Hose

V3IT

High Voltage CAN

TCM

V3MA TCM

High Voltage A

Cause

Solution

Bad 24 VDC power Check voltage of power
supply.
supply. Voltage should
be 23-25 VDC. If out of
tolerance, replace power
supply.
Bad 24 VDC power Check voltage of power
supply.
supply. Voltage should
be 23-25 VDC. If out of
tolerance, replace power
supply.
Loose connection Check wiring for loose
or tripped circuit connection or tripped circuit
breaker.
breaker.
Low incoming line Measure voltage at circuit
voltage.
breaker and ensure voltage
is greater than 195 VAC.
Loose connection Check wiring for loose
or tripped circuit connection or tripped circuit
breaker.
breaker.
Low incoming line Measure voltage at circuit
voltage.
breaker and ensure voltage
is greater than 195 VAC.
Loose connection Check wiring for loose
or tripped circuit connection or tripped circuit
breaker.
breaker.
Low incoming line Measure voltage at circuit
voltage.
breaker and ensure voltage
is greater than 195 VAC.
Bad 24 VDC power Check voltage of power
supply.
supply. Voltage should
be 23-25 VDC. If out of
tolerance, replace power
supply.
Incoming line
Ensure incoming system
voltage is too high. power is wired properly.
Verify voltage at each circuit
breaker is between 195 and
264 VAC.

333024E

Troubleshooting

Error

Location

V3MB TCM

Type

Description

High Voltage B

V3MH TCM

High Voltage Hose

V4CM MCM

High Voltage MCM

V4IT

High Voltage CAN

TCM

V4MA TCM

High Voltage A

V4MB TCM

High Voltage B

V4MH TCM

High Voltage Hose

333024E

Cause

Solution

Incoming line
Ensure incoming system
voltage is too high. power is wired properly.
Verify voltage at each circuit
breaker is between 195 and
264 VAC.
Incoming line
Ensure incoming system
voltage is too high. power is wired properly.
Verify voltage at each circuit
breaker is between 195 and
264 VAC.
Incoming line
Ensure incoming system
voltage is too high. power is wired properly.
Verify voltage at each circuit
breaker is between 195 and
264 VAC.
Bad 24 VDC power Check voltage of power
supply.
supply. Voltage should
be 23-25 VDC. If out of
tolerance, replace power
supply.
Incoming line
Ensure incoming system
voltage is too high. power is wired properly.
Verify voltage at each circuit
breaker is between 195 and
264 VAC.
Incoming line
Ensure incoming system
voltage is too high. power is wired properly.
Verify voltage at each circuit
breaker is between 195 and
264 VAC.
Incoming line
Ensure incoming system
voltage is too high. power is wired properly.
Verify voltage at each circuit
breaker is between 195 and
264 VAC.

Troubleshooting

Error

Location

WMI0

TCM

WBC0 MCM

WSUX USB
WXUD ADM
WXUU ADM

Type

Description

Cause

Solution

Incorrect software Insert a system token into
the ADM module and cycle
version.
the power. Wait until the
upload is complete before
removing the token.
MCM does not If V1CM also exists, see
have line voltage. troubleshooting for V1CM.
The software version
cannot be read if the MCM
does not have line voltage.
TCM Fan Error
Fan inside TCM Check for debris in the TCM
is not operating fan and clear with forced air
if necessary.
properly.
Inset a system token into
Conﬁguration Error A valid
USB
conﬁguration ﬁle the ADM and cycle power.
can't be found for Wait until the lights on the
USB port stop ﬂashing
the USB.
before removing token.
Backup and reformat the
USB Download Error Log download
failed.
USB drive. Retry download.
USB Upload Error Custom language Perform normal USB
ﬁle failed to upload. download and use the new
disptext.txt ﬁle to upload the
custom language.
Software Version
Error

333024E

Troubleshooting

System

Before performing any troubleshooting procedures:
1. Relieve Pressure. See Pressure Relief Procedure, page 42.
2. Turn main power switch OFF.
3. Allow equipment to cool.
Problem

Reactor ADM does not turn on.
Electric motor does not operate.

Electric motor runs erratically.

333024E

Cause

No power.
Failed 24 V power supply.
Failed surge protector.
Loose connections.
Tripped circuit breaker (CB02).
Shorted windings.
Failed motor bearing.

Solution

Turn main power switch ON.
Replace power supply.
Replace surge protector.
Check MCM connection 13.
Reset breaker, see Repair Circuit
Breaker Module, page 54. Check
240VAC at output of breaker.
Replace motor, see
Repair Electric Motor, page 53.
Replace motor, see
Repair Electric Motor, page 53.

Troubleshooting

Problem

Cooling fans not working.
Pump output low.

Fluid leak in pump packing nut
area.
No pressure on one side.

Cause

Loose wire.
Fan blade obstructed.
Defective fan.
Obstructed ﬂuid hose or gun; ﬂuid
hose ID too small.
Worn piston valve or intake valve
in displacement pump.
Pressure setpoint too high.
Worn throat seals.
Fluid leaking from heater inlet
rupture disk (372).

Solution

Check. See
Electrical Schematics, page 89.
Remove obstruction.
Replace. See
Replace Motor Fan, page 56.
Open, clear; use hose with larger
ID.
See pump manual.
Reduce setpoint and output will
increase.
Replace. See pump manual.
Check if heater and PRESSURE
RELIEF/SPRAY valve (SA or SB)
are plugged. Clear. Replace
rupture disk (372) with a new one;
do not replace with a pipe plug.

333024E

Troubleshooting

Hose Heat System

Before performing any troubleshooting procedures:
1. Relieve Pressure. See Pressure Relief Procedure, page 42.
2. Turn main power switch OFF.
3. Allow equipment to cool.
Problem

Hose heats but heats slower
than usual or it does not reach
temperature.

Hose does not maintain
temperature while spraying.

Hose temperature exceeds
setpoint.

333024E

Cause

Solution

Ambient temperature is too cold. Relocate hoses to a warmer area
or recirculate heated ﬂuid through
the hose.
FTS failed or not installed correctly. Check FTS, see Check RTD
Cables and FTS, page 63.
Low supply voltage.
Verify line voltage. Low line
voltage signiﬁcantly reduces
power available to the hose heat
system, affecting longer hose
lengths.
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 pressure.
Hose was not fully preheated.
Wait for hose to heat to correct
temperature before spraying.
Low supply voltage.
Verify line voltage. Low line
voltage signiﬁcantly reduces
power available to the hose heat
system, affecting longer hose
lengths.
A and/or B heaters are overheating Check primary heaters for either
a RTD problem or a failed
material.
element attached to RTD, see
Electrical Schematics, page 89.
Faulty FTS connections.
Verify that all FTS connections are
snug and that pins of connectors
are clean. Unplug and re-plug
RTD wires, cleaning off any debris.
Ambient temperature is too high. Cover hoses or move to a location
with a lower ambient temperature.
37

Troubleshooting

Problem

Erratic hose temperature.

Hose does not heat.

Cause

Faulty FTS connections.

Solution

Verify that all FTS connections are
snug and that pins of connectors
are clean. Unplug and re-plug
FTS wires along length of hose,
cleaning off any debris.
FTS not installed correctly.
FTS should be installed close to
end of hose in same environment
as gun. Verify FTS installation,
see Repair Fluid Temperature
Sensor (FTS), page 64.
FTS failed.
Check FTS, see Repair Fluid
Temperature Sensor (FTS), page
64.
FTS not installed correctly.
FTS should be installed close to
end of hose in same environment
as gun. Verify FTS installation,
see Repair Fluid Temperature
Sensor (FTS), page 64.
Loose hose electrical connections. Check connections. Repair as
necessary.
Circuit breakers tripped.
Reset breakers (CB01 ), see
Repair Circuit Breaker Module,
page 54.
Hose zone not turned on.
Turn on hose heat zone.
A and B temperature setpoints too Check. Increase if necessary.
low.

333024E

Troubleshooting

Problem

Cause

Solution

Hoses near Reactor are warm, but Shorted connection or failed hose With power off, check the hose
hoses downstream are cold.
heating element.
resistance with and without the
whip hose attached. With the whip
hose attached, the reading should
be less than 3 ohm. Without the
whip hose attached, the reading
should be OL (open loop). See
Check Hose Heat Connectors,
page 63.
Low hose heat.
A and B temperature setpoints too Increase A and B setpoints. Hose
low.
designed to maintain temperature,
not increase temperature.
Hose temperature setpoint too Check. Increase if necessary to
low.
maintain heat.
Flow too high.
Use smaller mix chamber.
Decrease pressure.
Low current; FTS not installed. Install FTS, see operation manual.
Hose heat zone not turned on long Allow hose to heat up, or preheat
enough to reach setpoint.
ﬂuid.
Loose hose electrical connections. Check connections. Repair as
necessary.
Ambient temperature is to low
Relocate hoses to a warmer area
or increase A and B setpoints.

333024E

Troubleshooting

Primary Heater

Before performing any troubleshooting procedures:
1. Relieve Pressure. See Pressure Relief Procedure, page 42.
2. Turn main power switch OFF.
3. Allow equipment to cool.
Problems

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

Cause

Primary Heater(s) does not heat. Heat turned off.
Temperature control alarm.
Signal failure from RTD.
Dirty RTD connections.
Control of primary heat is
abnormal; high temperature
overshoots (T4DA, T4DB) occurs
intermittently.
RTD not contacting heater
element.
Failed heater element.
Signal failure from RTD.

Solution

Turn on heat zones.
Check ADM for error codes.
Signal failure from RTD.
Examine RTD cables connected
to TCMs. Conﬁrm RTDs are
not plugged into opposite heat
zone. Unplug and re-plug RTD
connectors. Unplug and re-plug
RTD connectors. Ensure RTD tip
contacts the heater element.
Loosen ferrule nut, push in RTD
so tip contacts heater element.
Holding RTD tip against heater
element, tighten ferrule nut 1/4
turn past tight.
See
Replace Heater Element, page 59.
See (T6DA, T6DB), Error Codes.

333024E

Troubleshooting

Graco InSite
Problem

No module status LEDs are
illuminated.

Cause

No power to cellular module.

Solution

Turn Reactor ON.
Ensure unit is properly installed.
Verify 24V at output of the power
supply.
Make sure the M8, 4–pin to M12,
8–pin cable is installed between
cellular module and power supply.
Has not identiﬁed GPS location Still identifying location.
Wait a few minutes for the unit to
(green module status LED
identify the location.
Unable to identify location. In a Move system to a location with a
ﬂashing).
location where GPS lock cannot clear view of the sky.
occur. Buildings and warehouses Use extension cable 16X521 and
move cellular module to a location
often prevent GPS locks.
with a clear view of the sky.
Has not established cellular
Still establishing cellular
Wait a few minutes for the unit to
connection (orange module status connection.
establish the connection.
Unable to establish cellular
Move system to a location with
LED ﬂashing).
connection.
cellular service to establish cellular
connection.
Use extension cable 16X521 and
move cellular module to a location
with a clear view of the sky.
Cannot view data for my unit(s) on Graco InSite unit has not been Activate unit. See Registering
website.
activated.
and Activating the Graco InSite
section.
Temperature data not displayed Reactor temperature
See System troubleshooting
on website.
measurement is not working.
section.
Hose zone temperature data not The RTD or thermocouple is not See RTD or Thermocouple repair
displayed on website.
correctly installed on the hose or section.
is broken.
Pressure data not displayed on Reactor pressure measurement is See System troubleshooting
website.
not working.
section.

333024E

Pressure Relief Procedure

Route ﬂuid to waste containers or supply tanks.
Pressure Relief Procedure 4. Turn
PRESSURE RELIEF/SPRAY valves (SA,
Follow the Pressure Relief Procedure
whenever you see this symbol.

This equipment stays pressurized until pressure
is manually relieved. To help prevent serious
injury from pressurized ﬂuid, such as skin injection,
splashing ﬂuid and moving parts, follow the
Pressure Relief Procedure when you stop spraying
and before cleaning, checking, or servicing
equipment.

SB) to PRESSURE RELIEF/CIRCULATION
. Ensure gauges drop to 0.

5. Engage gun piston safety lock.

The Fusion AP gun is shown.

1. Relieve pressure in gun and perform gun
shutdown procedure. See gun manual.
2. Close gun ﬂuid inlet valves A and B.

6. Disconnect gun air line and remove gun ﬂuid
manifold.

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

333024E

Shutdown

4. Press to park the Component A Pump. The
park operation is complete when green dot goes
out. Verify the park operation is complete before
moving to next step.

Shutdown system to avoid electric shock. All
electrical wiring must be done by a qualiﬁed
electrician and comply with all local codes and
regulations. To help prevent serious injury from
pressurized ﬂuid, such as skin injection, splashing
ﬂuid and moving parts, follow the Pressure Relief
Procedure when you stop spraying and before
cleaning, checking, or servicing equipment.
NOTICE

Proper system setup, startup, and shutdown
procedures are critical to electrical equipment
reliability. The following procedures ensure steady
voltage. Failure to follow these procedures will
cause voltage ﬂuctuations that can damage
electrical equipment and void the warranty.
1. Press

to deactivate the system.

6. Turn off the air compressor, air dryer, and
breathing air.

to stop the pumps.

2. Turn off all heat zones.

3. Relieve pressure. See
Pressure Relief Procedure, page 42.

333024E

5. Press

7. Turn main power switch OFF.

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

Shutdown

8. Close all ﬂuid supply valves.

9. Engage gun piston safety lock then close ﬂuid
inlet valves A and B.

Fusion

Probler

333024E

Flushing

To avoid ﬁre and explosion:
• Flush equipment only in a well-ventilated area.
• Do not turn on heaters until ﬂuid lines are clear
of solvent.
• 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 wetted parts are compatible with common
solvents. Use only moisture-free solvents.

333024E

To ﬂush feed hoses, pumps, and heaters
separately from heated hoses, set PRESSURE
RELIEF/SPRAY valves (SA, SB) to PRESSURE
RELIEF/CIRCULATION
lines (N).

. Flush through bleed

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 ﬁlled
with a moisture-free plasticizer or oil. Do not
use water. Never leave the system dry. See
Important Isocyanate Information, page 7 .

Repair

Repairing this equipment requires access to parts
that may cause electric shock or other serious
injury if work is not performed properly. Be sure to
shut off all power to equipment before repairing.
Before Beginning Repair
NOTICE

1. Close the ﬂuid inlet valve on the y-strainer inlet
and shut off the appropriate feed pump. This
prevents material from being pumped while
cleaning the screen.
2. Place a container under the strainer base to catch
drain off when removing the strainer plug (C).
3. Remove the screen (A) from the strainer
manifold. Thoroughly ﬂush the screen with
compatible solvent and shake it dry. Inspect the
screen. No more than 25% of the mesh should
be restricted. If more than 25% of the mesh is
blocked, replace the screen. Inspect the o—ring
(B) and replace as required.
4. Ensure the pipe plug (D) is screwed into the
strainer plug (C). Install the strainer plug with the
screen (A) and o—ring (B) in place and tighten.
Do not overtighten. Let the gasket make the seal.
5. Open the ﬂuid inlet valve, ensure that there are
no leaks, and wipe the equipment clean. Proceed
with operation.

Flush Inlet Strainer Screen

The inlet strainers ﬁlter out particles that can plug the
pump 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.

Figure 1

Note

Clean the A-side screen only during
daily startup. This minimizes moisture
contamination by immediately ﬂushing
out any isocyanate residue at the start of
dispensing operations.

333024E

Repair

Change Pump Lubricant

Check the condition of the ISO pump lubricant daily.
Change the lubricant if it becomes a gel, its color
darkens, 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 moisture, 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. Follow Pressure Relief Procedure, page 42.
2. Lift the lubricant reservoir (R) out of the bracket
and remove the container from the cap. Holding
the cap over a suitable container, remove the
check valve and allow the lubricant to drain.
Reattach the check valve to the inlet hose.
3. Drain the reservoir and ﬂush it with clean
lubricant.

333024E

4. When the reservoir is ﬂushed clean, ﬁll with fresh
lubricant.
5. Thread the reservoir onto the cap assembly and
place it in the bracket.
6. The lubrication system is ready for operation. No
priming is required.

Pump Lubrication System
Figure 2

Repair

Remove Pump

Pump rod and connecting rod move during
operation. Moving parts can cause serious injury
such as pinching or amputation. Keep hands and
ﬁngers away from connecting rod during operation.
Note

1.
2.
3.
4.
5.
6.

See manual 309577 for pump repair
instructions.
Press to stop the pumps.
Turn off heat zones.
8. Route ﬂuid to waste containers or supply tanks.
Turn PRESSURE RELIEF/SPRAY valves (SA,
Flush pump.
SB) to PRESSURE RELIEF/CIRCULATION
Press to park the pumps in the down position.
. Ensure gauges drop to 0.
Press to deactivate the system.
Turn main power switch off.

7. Shut off both feed pumps. Close all ﬂuid supply
valves.

333024E

Repair
Note

Use drop cloth or rags to protect Reactor
and surrounding areas from spills.
Note

Steps 9–11 apply to pump A. To
disconnect pump B, go to steps 12 and
13.
9. Disconnect ﬁttings at ﬂuid inlet (C) and outlet (D).
Also disconnect steel outlet tube from heater
inlet.
10. Disconnect tubes (T). Remove both tube ﬁttings
(U) from wet-cup.
11. Loosen locknut (G) by hitting ﬁrmly with a
non-sparking hammer. Unscrew pump far
enough to expose rod retaining pin. Push
retaining wire clip up. Push pin out. Continue
unscrewing pump.

Pump B
Figure 4
Flat side faces up.
Lubricate threads with ISO oil or grease.
Pump top threads must be nearly ﬂush with
bearing face (N).

1
2
3

Install Pump
Note

1.
Pump A
Figure 3
1
2
3

2.
Flat side faces up.
Lubricate threads with ISO oil or grease.
Pump top threads must be nearly ﬂush with
bearing face (N).

Note

Steps 12 and 13 apply to pump B.
12. Disconnect ﬂuid inlet (C) and outlet (D). Also
disconnect steel outlet tube from heater inlet.
13. Push retaining wire clip (E) up. Push pin (F)
out. Loosen locknut (G) by hitting ﬁrmly with a
non-sparking hammer. Unscrew pump.
333024E

3.
4.
5.

Steps 1–5 apply to pump B. To reconnect
pump A, proceed to step 6.
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. See Fig. 4 for view
and assembly notes.
Continue screwing pump into housing until ﬂuid
outlet (D) is aligned with steel tube and top
threads are +/- 1/16 in. (2 mm) of bearing face
(N).
Tighten locknut (G) by hitting ﬁrmly with a
non-sparking hammer.
Reconnect ﬂuid inlet (C) and outlet (D).
Go to step 13.
Note

Steps 6–12 apply to pump A only.
6. Ensure star-shaped locknut (G) is screwed on
pump with ﬂat side up. Carefully twist and extend
displacement rod 2 in. (51 mm) above wet-cup.
49

Repair

11. Apply thin ﬁlm of TSL to barbed ﬁttings. Using
two hands, support tubes (T) while pushing
straight onto barbed ﬁttings. Secure each tube
with a wire tie between two barbs.
Note

Do not let tubes kink or buckle.
12. Reconnect ﬂuid inlet (C).
13. Purge air and prime the system. See Reactor
operation manual.
Repair Drive Housing

Removal

Figure 5
7. Start threading pump into bearing housing (M).
When pin holes align, insert pin. Pull retaining
wire clip down.
8. Continue threading 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 accessible.
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.

1.
2.
3.
4.
5.
6.

Press to stop the pumps.
Turn off heat zones.
Flush pump.
Press to park the pumps in the down position.
Press to deactivate the system.
Turn main power switch off.

333024E

Repair

7. Perform Pressure Relief Procedure, page 42.
8. Remove the system frame from the ﬂoor and
L-brackets.

NOTICE

Do not drop gear cluster (104) when removing
drive housing (102). Gear cluster may stay
engaged in motor front end bell or drive
housing.
14. Remove screws (112, 119) and washers (114)
and pull drive housing (102) off motor (101).
Note

The A side drive housing includes cycle
counter switch (121). If replacing this
housing, remove screws (122) and
switch. Reinstall screws and switch on
new drive housing.

9. Remove two bolts and nuts and fold the electrical
enclosure backward.
10. Remove screws (21) and motor shroud (11).
Rest the motor shroud behind the motor without
straining the fan power cable.
Note

Examine bearing housing (103) and
connecting rod (105). If these parts need
replacing, ﬁrst remove the pump (106),
see Remove Pump, page 48.
11. Remove cover (60) and screws (21).
12. Remove cycle counter (121) from housing by
removing screw (122).
13. Disconnect pump inlet and outlet lines. Remove
screws (113), washers (115), and bearing
housing (103).

333024E

Figure 6

Repair

Installation

1. Apply heavy duty extreme pressure grease
liberally to washers (107, 108, 118), all gears,
and inside drive housing (102).
2. Install one bronze washer (108) in drive housing,
then install steel washers (107, 118) as shown.
3. Install second bronze washer (108) on gear
cluster (104) and insert gear cluster in drive
housing.
Note

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

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

5.
6.
7.
8.

If bearing housing (103), connecting rod
(105), or pump (106) were removed,
reassemble rod in housing and install
pump, see Install Pump, page 49 .
Route cycle counter switch cable (121) around
the motor fan and reattach to housing (102) with
screws (122).
Install bearing housing (103), screws (113), and
washers (114). Pumps must be in phase (both at
same position in stroke).
Install cover (60) and screws (21).
Install motor shield (11) and screws (21).

Figure 7

333024E

Repair

Repair Electric Motor

Removal
NOTICE

Be careful not to drop or damage the motor. The
motor is heavy and may require two people to lift.
1. Remove the system frame from the ﬂoor and
L-brackets.

Installation

2.
3.
4.
5.
6.

1. Place motor on unit. Thread motor
cables into conduit as before. See
Electrical Schematics, page 89.
2. Fasten motor with screws (25) until screws are
fully threaded in frame. Do not tighten screws
until drive housing and pumps are connected to
Remove drive housing and pump assemblies.
the motor.
See Repair Drive Housing, page 50.
drive housing and pump assemblies, see
Disconnect electric motor (101) power cable from 3. Install
Installation,
page 52.
port #15 on the MCM. Remove connector by
loosening four terminal screws.
4. Route motor (101) power cord from motor
through conduit and connect to port #15 on
Remove motor shroud (11). Rest the motor
MCM. Route over temperature cable up from
shroud assembly behind the motor without
motor and connect to port #2 on MCM. Insert
straining the fan power cable.
cables in conduit and use tie wraps to secure the
Disconnect over temperature cable from port
conduit together.
#2 on MCM. Cut tie wraps around harness to
5. Connect motor shroud assembly to motor (101).
remove cable.
Remove four screws (25) holding motor (101) to 6. Install drive housing covers and motor cover.
7. Return to service.
bracket. Lift motor off unit.

333024E

Repair

new circuit breaker. Insert wires and tighten
down all screws.

Repair Circuit Breaker Module

1. See Before Beginning Repair, page 46.
2. Using an ohmmeter, check for continuity across
circuit breaker (top to bottom). If no continuity,
trip breaker, reset, and retest. If still no continuity,
replace breaker as follows:
a. Refer to Electrical Schematics, page 89, and
circuit breaker table.
b. Follow Shutdown instructions. See
Shutdown, page 43.
c. Refer to circuit breaker identiﬁcation table
and electrical diagrams in Reactor repair
manual.
d. Loosen two screws connecting wires and bus
bar to circuit breaker that will be replaced.
Disconnect wires.
e. Pull locking tab out 1/4 in. (6mm) and pull
circuit breaker away from the din rail. Install

Figure 8

Circuit Breakers
Circuit Breakers
Ref.

Size

CB01
CB02

50 A
20 A

CB03
CB04
CB05

40 A
40 A
40 A

Component

Heated Hose
Motor Control Module
(MCM)
ISO Heater
RES Heater
Hose Heat Transformer

333024E

Repair

Replace Fluid Inlet Sensor

5. Replace sensor (602).
Replace Pressure Transducers

Note

For Elite models only.
1. Perform Shutdown, page 43.
2. Perform Pressure Relief Procedure, page 42.
3. Disconnect inlet sensor cable from the ﬂuid inlet
assembly. Inspect cable for damage and replace
if necessary. See Electrical Schematics, page 89.

1. Perform Shutdown, page 43.
2. Perform Pressure Relief Procedure, page 42.
3. Disconnect transducer cables (405) from #6 and
#7 connectors on the MCM.
4. Remove wire ties constraining transducer cable
and remove cable from cabinet.
5. Install o-ring (416) on new transducer (405).
6. Install transducer in manifold. Mark end of cable
with tape (red=transducer A, blue=transducer B).
7. Route new cable into cabinet and thread into
bundle as before. Attach cable ties to bundle
as before.
8. Connect A side pressure transducer cable
to MCM port #6. Connect B side pressure
transducer cable to MCM port #7.

Figure 9 Fluid Inlet Sensor
4. To replace sensor cable:
a. Open wire bundle and remove sensor cable.
b. Cut any wire ties and disconnect from MCM.
See Electrical Schematics, page 89.
NOTICE

To prevent damage to cable, route and secure
cable in wire bundle with wire ties.

333024E

Repair

Replace Fans

Shutdown system to avoid electric shock. To avoid
burns, do not perform maintenance on the fan until
the system has reached ambient temperature.
Replace Motor Fan

1. Perform Shutdown, page 43.
2. Open cabinet door and disconnect
fan cables from terminal blocks. See
Electrical Schematics, page 89.
3. Remove four screws (21) from motor cover (11).
If necessary, fold frame (1) to remove motor
cover (10). See Repair Drive Housing, page 50,
steps 1–10.
4. Cut tie wraps to remove cable.
5. Remove nuts (39), screws (22), washers (34)
and fan (32). Install new fan in reverse order.
Note

Ensure fan (32) blows onto motor.

Figure 10

333024E

Repair

Replace Electrical Enclosure Fan

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

Figure 11

333024E

Repair

Replace Transformer Fan

1. Perform Shutdown, page 43.
2. Remove four bolts (23) and shroud (10).
3. Remove bolt (20) on top of the heater junction
box (48).

4. Disconnect fan and transformer connections
from terminal blocks. Connections are on left
side labeled: V+, V-, 1, 2, 3, and 4.
5. Remove four nuts (27) holding metal transformer
cover (8) to frame. Carefully remove cover while
sliding wires through hole in cover.
6. Remove four screws (23), washers (29), and fan
(32).
7. Install fan in reverse order.

Figure 12

333024E

Repair

Repair Primary Heater

Replace Heater Element

8. Wait for heater to cool.
9. Remove four bolts (23) and shroud (10).

1. Press to stop the pumps.
2. Turn off heat zones.

3. Flush pump.
10. Remove screw (20) and lower din rail cover (48).
4. Press to park the pumps in the down position. 11. Disconnect heater wires:
The park operation is complete when green dot
a. A Side: Disconnect A side heater wires,
goes out. Verify the park operation is complete
transformer, and transformer fan wires from
before moving to next step.
lower din rail (33).
b. B Side: Disconnect B side heater wires and
remove lower din rail (33) from B side heater
(5).
12. Test heater wires with ohmmeter.
5. Press to deactivate the system.
System

Total

Element

Ohms

2,550

18–21 per
element
18–21 per
element

Heater
Wattage

6. Turn main power switch off.

E-30 (10 10,200
kw)
E-XP2, 15,300
E-30 (15
kw)

2,550

NOTICE

7. Relieve pressure. See
Pressure Relief Procedure, page 42.

333024E

To prevent a short circuit or lowering the
transformer life, do not splash ﬂuid on
transformer. Cover transformer with a plastic
sheet or piece of cardboard.

Repair

13. Remove nuts (27) and transformer cover
(8). Cover transformer with plastic sheet or
cardboard.
14. Disconnect overtemperature switches (209) from
cable.
15. Loosen ferrule nut (N). Remove RTD (212) from
heater housing. Do not remove adapter (206)
unless necessary. If adapter must be removed,
ensure that mixer (210) is out of the way when
replacing adapter.
16. Disconnect inlet and outlet ﬂuid tubes from
heater.
17. Remove two bolts (23) and lift heater over
transformer.
18. Place heater block (201) in a vise. Use a wrench
to remove heater element (208).
19. Inspect element. It should be relatively smooth
and shiny. Replace element if there is a crusted,

burnt, ash-like material adhered to element, or
sheath shows pitting marks.
20. Install new heater element (208), holding mixer
(210) so it does not block RTD port.
21. Secure heater to frame with bolts (23).
22. Reinstall RTD (212),
Repair Primary Heater, page 59.
23. Reconnect cable to overtemperature switches
(209).
24. Reconnect wires to lower din rail. If necessary,
install lower din rail (33).
25. Install lower din rail cover (48).
Line Voltage

The heater outputs its rated wattage at 240 VAC.
Low line voltage will reduce power available and the
heater will not perform at full capacity.

Figure 13

333024E

Repair

Repair Overtemperature Switch

1.
2.
3.
4.

Perform Shutdown, page 43.
Wait for heaters to cool.
Remove heater cover (10).
Disconnect overtemperature switches (209) from
cable (46). Test across spade terminals with
ohmmeter.
a. If the resistance
approximately 0 ohms,
the overtemperature switch needs to be
replaced. Go to step 5.
b. If the resistance approximately 0 ohms,
inspect cable (46) to ensure it is not cut
or open. Reconnect the overtemperature
switch (209) and cable (46). Disconnect
cable from TCM. Test from pin 1 to 3 and
1 to 4. If resistance is not approximately 0,
and switches are 0. Replace cable in place
of original cable.
5. If switch fails test, remove screws. Discard failed
switch. Apply a thin layer of thermal compound

110009, install new switch in same location on
housing (201), and secure with screws (213).
Reconnect cables.

is not

333024E

Repair

Replace RTD

1.
2.
3.
4.
5.
6.

7.
8.

Perform Shutdown, page 43.
Wait for heater to cool.
Remove heater cover (10).
Cut cable ties around the woven wrap with the
RTD cable (212).
Disconnect RTD cable(212) from TCM (453).
Loosen ferrule nut (N). Remove RTD (212) from
heater housing (201), then remove RTD housing
(H). Do not remove the adapter (206) unless
necessary. If adapter must be removed, ensure
that mixer (210) is out of the way when replacing
the adapter.
Remove RTD cable (212) from woven wrap.
Replace RTD (212).

a. Apply PTFE tape and thread sealant to male
pipe threads and tighten RTD housing (H)
into adapter (206).
b. Push in RTD (212) so tip contacts heater
element (208).
c. Holding RTD (212) against heater element,
tighten ferrule nut (N) 3/4 turn past
ﬁnger-tight.
9. Route wires (S) as before through woven wrap
and reconnect RTD cable (212) to the TCM.
10. Replace heater shroud (10).
11. Follow startup instructions in the operation
manual. Turn on A and B heat simultaneously to
test. Temperatures should rise at same rate. If
one is low, loosen ferrule nut (N) and tighten RTD
housing (H) to ensure RTD tip contacts element
(212) when ferrule nut (N) is retightened.

Figure 14

333024E

Repair

Repair Heated Hose

Refer to the heated hose manual 309572 for hose
replacement parts.
Check Hose Heat Connectors

1. Perform Shutdown, page 43.

5. If the FTS is not reading properly at the end of
the hose, connect FTS directly to RTD cable (C)
at the manifold.
6. If the FTS reads properly at the manifold but
not at the end of the hose, check cable (C)
connections. Verify they are tight.

Note

Whip hose must be connected.
2. Disconnect hose connector (V) at Reactor, see
Fig. 13.
3. Using an ohmmeter, check between the
connectors (V). There should be continuity.
4. If hose fails test, retest at each length of hose,
including whip hose, until failure is isolated.
Check RTD Cables and FTS

1. Perform Shutdown, page 43.
2. Disconnect RTD cable (C) at Reactor.
3. Test with an ohmmeter between pins of cable
connector C.
Note

Do not touch outer ring with test probe.

Pins

3 to 1

Result

approximately 1090
ohms
3 to 4
approximately 1090
ohms
1 to 4
0.2 - 0.4 ohms
2 to any
inﬁnity (open)
4. Retest at each length of hose, including whip
hose, until failure is located.

333024E

Heated Hose
Figure 15
Note

To assist in taking readings, order RTD
Test Kit 24N365. Kit includes two cables:
one cable with a compatible female M8
connector and another cable with a male
M8 connector. Both cables have stripped
wire at the other end for easy test probe
access.
Pins / Wire Color

Result

3 to 1 / brown to blue approximately 1090
ohms
3 to 4 / blue to black approximately 1090
ohms
1 to 4 / brown to black 0.2 - 0.4 ohms
2 to any / N/A
inﬁnity (open)

Repair

Repair Fluid Temperature Sensor
(FTS)

Installation

The Fluid Temperature Sensor (FTS) is supplied with
the system. Install FTS between main hose and
whip hose. See Heated Hose manual 309572 for
instructions.

Figure 16

Test/Removal

1. Perform Shutdown, page 43.
2. Remove tape and protective covering from FTS.
Disconnect hose cable (F).
3. If FTS is not reading properly at the end of the
hose, see Check RTD Cables and FTS, page 63.
4. If FTS fails, replace FTS.

a. Disconnect air hoses (C,L) and electrical
connectors (D).
b. Disconnect FTS from whip hose (W) and
ﬂuid hoses (A, B).
c. Remove ground wire (K) from ground screw
on underside of FTS.
d. Remove FTS probe (H) from component A
(ISO) side of hose.

333024E

Repair

Transformer Primary Check

See Electrical Schematics, page 89.
1. Check wires and transformer:
a. See Shutdown, page 43.
b. Shut off CB05.
c. Use an ohmmeter to test for continuity
between terminals 2 and 4 of CB05. If there
is no continuity, check transformer.
2. Check transformer:
a. See Shutdown, page 43.
b. Remove lower shroud.
c. Locate the two smaller (10 AWG) wires,
labeled 1 and 2, coming out of transformer.
Trace these wires back to terminal blocks
TB15 and TB16.
d. Use an ohmmeter to test for continuity
between two wires; there should be
continuity.
Transformer Secondary Check

See Electrical Schematics, page 89.
1. Check wires and transformer:
a. Disconnect 7 pin green connector from TCM.
b. Use an ohmmeter to test for continuity
between terminals 6 and 7 on the TCM 7 pin
green connector. There should be continuity.
If there is no continuity, check transformer.
c. Reconnect 7 pin green connector to TCM
2. Check transformer:
a. Remove lower shroud.
b. Locate the two larger (6 AWG) wires,
labeled 3 and 4, coming out of transformer.
Trace these wires back to TB17 and TB18.
Open circuit breaker CB01 to turn the color

333024E

indicator on the circuit breaker GREEN. Use
an ohmmeter to test for continuity between
two transformer wires in terminal blocks
TB17 and TB18; there should be continuity.
c. Close the circuit breaker CB01.

Figure 17
d. Apply incoming power to system.
e. To verify voltage on the secondary leads
of the transformer, measure between the
terminals terminals 3 and 4 on TB17 and
TB18. Verify voltage is approximately 90
VAC for 240 VAC input.
f. See the Diagnostic Run Screen on the
ADM. The Diagnostic Run Screen displays
the incoming (90 Vac) to the TCM “Hose
Voltage”. The diagnostic screen will show if
the circuit breaker has been tripped for the
incoming power to the TCM.

Repair

Replace Transformer

1.
2.
3.
4.

Perform Shutdown, page 43.
Remove four bolts (23) and shroud (10).
Remove lower dinrail cover (48).
Disconnect fan and transformer connections
from terminal blocks. Connections are on left
side labeled: V+, V-, 1, 2, 3, and 4.
5. Remove four nuts (27) holding metal transformer
cover (8) to frame. Carefully remove cover while
sliding wires through hole in cover.
6. Remove nuts (27) and transformer (17).
7. Install transformer (17) in reverse order.

Figure 18

333024E

Repair

Replace Power Supply

1. Perform Shutdown, page 43.
2. Disconnect input and output cables from
both sides of the power supply. See
Electrical Schematics, page 89.
3. Insert a ﬂat head screw driver in the mounting
tab on the bottom of the power supply to remove
from the din rail.
4. Install new power supply (535) in reverse order.

Figure 20 Surge Protector
Replace Advanced Display Module
(ADM)

1. Loosen four screws (70) on inside of electrical
enclosure door (61). Lift up and pull out to
remove ADM (88).
2. Disconnect CAN cable (475).
3. Inspect ADM (88) for damage. Replace if
necessary.

Figure 19 24 VDC Power Supply
Replace Surge Protector

1. Loosen connections on terminals 1 and 3 on
CB02.
2. Loosen connections on input to power supply
(535) on N and L connections.
3. Remove two screws (413) and surge protector
Figure 21
(505) from enclosure.
4. Install new surge protector (505) in reverse order.
Note

Wire on both the circuit breaker and power
supply are interchangeable.

333024E

Repair

Replace Motor Control Module (MCM)

1. Perform Shutdown, page 43.
2. Disconnect connectors from MCM (63).
Disconnect two power cables. See
Electrical Schematics, page 89.
3. Remove nuts (91) and MCM (63).
4. Set rotary switch. 2= E–30 and 3= E-XP2.
5. Replace MCM in enclosure.
6. Connect cables to MCM. See
Electrical Schematics, page 89.

Figure 22 Replace MCM

Replace Temperature Control Module
(TCM)

1.
2.
3.
4.
5.

Perform Shutdown, page 43.
Open electrical enclosure door (61).
Disconnect all connectors from the TCM (453).
Remove four nuts (461) and TCM (453).
Install new TCM module (453). Reassemble
parts in reverse order.

Figure 23 Replace TCM

Software Update Procedure

NOTICE

Repair kit GCA modules are shipped
pre-programmed and software loading is not
necessary. If software version upgrade is
necessary, follow the procedure in the manual
provided.

333024E

Parts

Parts
Proportioners

333024E

Parts

2
3

Apply anaerobic polyacrylate pipe sealant to all
non-swiveling pipe threads.
Apply grease to tube ﬁtting threads. Torque to
43 ft-lbs (58 N•m).
Safety and warning labels are from label sheet
(68).

333024E

Parts

Ref

1
2

Part

- - - - -

246995

4
5

16X531
24U843
24U842

24U704

16W654

8
9

24R684
261821

10
11
12
13

24U841
16W765
16W764
24U837
24U838
24U839
24U840

14
15
17

24U834
24U833
24U836
24U835
15K742

18
19

15B456
125643

119865

333024E

Description

FRAME
ENCLOSURE, electrical;
see Electrical Enclosure,
page 82
BOTTLE, assembly,
complete
BRACKET, tsl, bottle
HEATER, 10kw, 2
zone, RTD; see
Fluid Heater, page 78
HEATER, 7.5kw,
1 zone, RTD; see
Fluid Heater, page 78
MANIFOLD, ﬂuid; see
Fluid Manifold, page 80
INSULATOR, foam,
heater
COVER, transformer
CONNECTOR, wire,
6awg
COVER, heater
COVER, motor
COVER, heater, rear
TUBE, b-side, inlet
TUBE, b-side, inlet, 10kw
TUBE, b-side, outlet
TUBE, b-side, outlet,
10kw
TUBE, a-side, inlet
TUBE, a-side, inlet
TUBE, a-side, outlet
TUBE, a-side, outlet
TRANSFORMER,
4090va, 230/90
GASKET, manifold
FITTING, elbow, 3/8 npt
x #8 jic
SCREW, mch, hex
serrated; 3/8 in. x 1/4–20

Quantity
272010

272011

272012

272110

272111

272112

1
1

1
1
1

1
1
1
1

1
1
1

1
1
1
1

1
1
1

1
1

1
1
1

1
1

1
1
1

1
1

1
2

Parts

Ref

21
22
23
24
25
26
27
28
29
30
31
32
33
33a

33b
33c
33d

34
35
36
37
38
39
40
41

42★
43★
72

Part

Description

118444 SCREW, mch, slot hex
wash hd; 1/2 in. x #10–24
117683 SCREW, mch, phil pan
hd; 1.5 in. x #6–32
113796 SCREW, ﬂanged, hex hd;
3/4 in. x 1/4–20
112731 NUT, hex, ﬂanged
111800 SCREW, cap, hex hd;
7/32 in. x 5/16–18
111218 CAP, tube, square
110996 NUT, hex, ﬂange head
104859 SCREW, tapping pnhd;
5/16 in. x #10–16
103181 WASHER, lock ext
100020 WASHER, lock
115836 GUARD, ﬁnger
24U847 FAN, cooling, 120mm,
24vdc
24R685 ENCLOSURE, lower,
dinrail; includes 33a-33d
24U849
KIT, module, din rail,
heater; see Heater and
Transformer Terminal
Block Module, page 85
16W667 INSULATOR, FOAM
- - COVER, bottom, dinrail
113505
NUT, keps, hex hd
151395 WASHER, ﬂat
120685 GROMMET
114269 GROMMET, rubber
125625 TIE, cable, ﬁr tree
127277 BOLT, carriage, 1/2-13 x
3.5 l
127278 NUT, keps, hex
127282 GROMMET, rubber
16X095 CONNECTOR, power,
male, 4 pin
125871 TIE, cable, 7.5 in.
24K207 KIT, fts, rtd, single hose

Quantity
272010

272011

272012

272110

272111

272112

6
4

2
8
2

4
2
1
2

4
4
1

25
1

4
2
1
5
4

4
2
1
6
4

4
2
1
5
4

4
2
1
6
4

333024E

Parts

Ref

44★
45★
46
47
48
49
50

52
53
54
55
56
57
58

333024E

Part

Description

24R725 BRIDGE, plug-in jumper,
ut35
106569 TAPE, electrical
24T242 CABLE, over-temp, 10
kW Reactor
24P970 CABLE, over-temp, 15
kW Reactor
104765 PLUG, pipe headless
16V268 COVER, top, dinrail
15Y118 LABEL, made in the USA
24V150 PROPORTIONER,
module, E-30; see
Proportioner Module,
page 76
24V151 PROPORTIONER,
module, E-XP2; see
Proportioner Module,
page 76
24U321 KIT, asm, pair,
elite, reactor; see
Fluid Inlet Kits, page 87
24U320 KIT, assembly, pair,
std, reactor; see
Fluid Inlet Kits, page 87
16X118 MODULE, cellular, gps,
temp
24T050 CABLE, m8 4p f to m12
8p m 1.5m
16W130 CABLE, m12 5p, fem male, 2.0m
24U845 TUBE, pressure relief
191892 FITTING, elbow, street,
90 deg; 1/8 npt
116746 FITTING, barbed, plated;
1/8–27 npt x 1/4 in. hose
I.D.
16W218 LABEL, branding, e-30
16W321 LABEL, branding, e-30,
elite
16W215 LABEL, branding, e-xp2
16W322 LABEL, branding, e-xp2,
elite

Quantity
272010

272011

272012

272110

272111

272112

1
1

2
1
1
1

2
1
1

2
1
1
1

1
1
1

2
1
1
1

1
1

2
2

1
73

Parts

Ref

59★
60
61
62
63
64★
65★
67★
68
70
71
72
73
74
75
79★
81
82
83★
84★
85
88
89

Part

Description

16U530 MODULE, system surge
protector (spare)
15G349 COVER, drive, plastic
16W766 COVER, control, box
16W596 LATCH, door
24U832 MODULE, MCM
24U831 MODULE, MCM
206995 FLUID, tsl, 1 qt.
206994 FLUID, tsl 8 oz bottle
114225 TRIM, edge protection;
1.6 ft (0.48 m)
16X250 LABEL, identiﬁcation
127296 SCREW, mchn, pnh,
w/ext tooth wash; M4 x
0.7
16X129 SCREW, mach, phillips,
tooth wash; 5/16 x 8–32
117502 FITTING, reducer #5 x #8
(JIC)
117677 FITTING, reducer #6 x
#10 (JIC)
299521 CAP, 1/2-20 jic
cap-aluminum
299520 CAP, 9/16-18 JIC
cap-aluminum
261843 FLUID, oxide inhibitor
16V806 BRACKET, wall, mount
15V551 SHIELD, membrane,
ADM (10 pack)
24K409 BAR, 55 gal chem.
measure; A side
24K411 BAR, 55 gal chem.
measure. B side
127276 BOLT, carriage, 1/2-13 x
2.5 l
24U854 MODULE, ADM
16W967 FITTING, swivel, 3/4 npt
x 1 npsm
118459 FITTING, union, swivel,
3/4 in.

Quantity
272010

272011

272012

272110

272111

272112

2
1
2

1
1
1
1

2
1
2
1

1
1
1

1
4

1
2
1

1
2

2
333024E

Parts

Ref

90
91
92
93★
94
95
96★
97★

Part

Description

16W213 LABEL, branding, reactor
115942 NUT, hex, ﬂange head
15D906 SUPPRESSOR, round
snap ferrite .260
127368 SLEEVE, split, wire, 1.50
ID
127377 TIE, cable, 6 in.
16X154 LABEL, InSite
333091 MANUAL, quick guide,
startup
333092 MANUAL, quick guide,
shutdown

Quantity
272010

272011

272012

272110

272111

272112

1
1
1

▲ Replacement Warning labels, signs, tags, and

cards are available at no cost.
★ Not shown.
 Parts included in Graco Insite Kit 24T280.

333024E

2
4
1

1
1
1

2
4
1

 See Electrical Schematics, page 89.

Not available for purchase.

Parts

Proportioner Module
24V150, Module for E-30
24V151, Module for E-XP2

Torque to 190–120 in-lbs (21–24 N•m).
Lubricate threads with ISO oil or grease. Assemble pump cylinders ﬂush to one full thread under-ﬂush of
housing surface.

Apply grease to all gear teeth proportionally, motor pinion and drive housing.

Torque to 20–30 ft-lbs (27–40.6 N•m).

Crankshaft must be in line with crankshaft at other end of motor.

Torque to 70–80 ft-lbs (95–108 N•m).

Flat side faces up.

333024E

Parts
24V150
E-30

24V151
E-XP2

MOTOR, brushless, double ended, 2 HP

---

HOUSING, drive, Mark VII

257355

HOUSING, bearing

245927

HOUSING, bearing

104

287290

KIT, repair, gear

105

241279

KIT, rod, connecting

106★

245971

PUMP, displacement A

245972

PUMP, displacement A

107

114699

WASHER, thrust; copper colored

108

114672

WASHER, thrust; steel colored

110

183169

SPRING, retaining

111

183210

PIN, str, hdls

112

15C753

SCREW, machine, hex wash hd; 1.25 in. x
5/16–18

113

114666

SCREW, cap, socket head; 2.25 x 3/8–16

114

106115

WASHER, lock (hi-collar)

115★

246831

PUMP, displacement, B

246832

PUMP, displacement, B

193031

NUT, retaining

193394

NUT, retaining

118

116192

WASHER, thrust (1595)

120

116618

MAGNET

121

24P728

SWITCH, reed, M8 4-pin

122

127301

SCREW, hexhead, thread cut, 4-40 x 0.375

125

187437

LABEL, torque

126▲

192840

LABEL, warning

Ref

Part

Description

101

24U050

102
103

116

▲ Replacement Warning labels, signs, tags, and

cards are available at no cost.
★ See pump repair manual 309577 for repair kits.
 Spring (110) included in Connecting Rod Kit
241279.

333024E

1
1
2

 Gear Repair Kit includes washers (107) and

(108).
 Drive Housing Repair Kit includes housing (1),
screws (5), and washer (1) to replace one end.

Parts

Fluid Heater
24U843 — 10kW, 2–zone
24U842 — 7.5 kW, 1–zone

Torque to 120 ft-lbs (163 N•m).

Torque to 23 ft-lbs (31 N•m).

Torque to 40 ft-lbs (54 N•m).
Apply thermal paste.

Apply pipe sealant and PTFE tape to all non-swiveling threads and threads without o-rings.

6
7

Apply lithium grease lubricant to o-rings before assembling in block (1).
Remove tape from probe tip and Orientate sensor as shown. Insert probe until it bottoms on heating element.
Tighten ferrule on sensor probe one turn past ﬁnger tight or 16 ft-lbs (21.6 N•m).

333024E

Parts
Ref
201

Part
15J090

Description
HEATER, machined, 1 zone
HEATER, machined, dual zone

202

15K825
124132

O-RING

FITTING, plug, hollow, hex, 1-3/16 sae

3
5

FITTING, adapter, sae-orb x jic

2
3

203
204

15H305
121309

24U843

24U842
1

205

15H304

FITTING, plug 9/16 sae

206

ADAPTER, 9/16 x 1/8

207

15H306
120336

208

16A110

O-RING, packing
HEATER, immersion, 2550W, 230V

SWITCH, over temperature
MIXER, immersion heater

FITTING, compression

209

15B137

210

15B135

-----

211*
212*
213
214

SENSOR, RTD

124131

SCREW, machine, pnhd; 5/16 in. x #6–32
15M178 HOUSING, rupture disc

Included in 24L973 Heater RTD Repair Kit.

333024E

Parts

Fluid Manifold
24U844

1
2
3

Torque to 355–395 in.-lbs (40–44.6 N●m)
Apply sealant (113500) to threads.
Valve must be closed with handle position as
shown on drawing.

4
5

Apply PTFE tape and thread sealant to gauge
threads.
Apply grease on valve.
Apply PTFE tape or thread sealant to tapered
threads.

333024E

Parts

24U844, Fluid Manifold
Ref

401
402★
402a★
402b★
403
404
405
406
407
408
411
412

Part

255228
247824
158674
247779
102814
162453
15M669
247788
247789
112309
117556
121312

333024E

Description

MANIFOLD, ﬂuid
KIT, valve, cartridge, drain
O-RING, BUNA-N
SEAL, seat, valve
GAUGE, press, ﬂuid
FITTING, 1/4 NPSM X 1/4
NPT
SENSOR, pressure, ﬂuid
outlet
HANDLE, red
HANDLE, blue
NUT, hex, jam
NIPPLE, #8 JIC x 1/2 NPT
FITTING, elbow, 3/4 SAE
x 1/2 JIC

Qty

1
2
1
1
2
2
2
1
1
2
1
1

Ref

413
414
415▲
416
419
▲
★

Part

100840
111457
189285
150829
117557

Description

FITTING, elbow, street
O-RING, PTFE
LABEL, caution
SPRING, compression
NIPPLE, #10 JIC x 1/2
NPT

Qty

2
2
1
2
1

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.

Parts

Electrical Enclosure

333024E

Parts

Electrical Enclosure

451

Part

Description

24U087

ENCLOSURE

453

24U855

454

24U848

MODULE, TCM
FAN, cooling, 80 mm,
24VDC
SWITCH, disconnect,
door mounted
TERMINAL, ground

Ref

455

24R736

457

117666

458

120859

Qty

Part

Description

468

111218

CAP, tube, square

469

114269

GROMMET, rubber

470

127282

471

127278

GROMMET, rubber
NUT, keps, hex

472

16W925

473

16W926

1
1

GASKET, enclosure,
foam
GASKET, enclosure,
foam
CABLE, CAN power, M12
female, pigtail
CABLE, CAN,
female/female 1.0 meter
MODULE, breaker

461

115942

NUT, strain relief, M40
thread
BUSHING, strain relief,
M40 thread
KNOB, operator
disconnect
NUT, hex, flange head

462

103181

WASHER, lock external

463

124131

478▲

16X050

CABLE, 4-pin,
male/female, 1.3 meter,
molded (hose RTD)
LABEL, safety; enclosure

479▲

16X049

LABEL, safety; multi

459
460

120858
123967

464

194337

SCREW, machine, pan
head; 5/16 in. x #6–32
WIRE, grounding, door

466

113505

NUT, keps, hex head

Qty

Ref

474

24R735

475

127068

476

24U850

477

127290

4
2
2
1
2
1

1
1
1

▲ Replacement Warning labels, signs, tags, and

cards are available at no cost.
See Electrical Schematics, page 89.

333024E

Parts

System DIN Rail and Harness Module Kit
24U850, System DIN Rail and Harness Module Kit

See Electrical Schematics, page 89.

Torque to 6–8 in.-lbs (0.7–1 N●m)

Torque to 28–33 in.-lbs (3–3.8 N●m)

Torque to 23–26 in.-lbs (2.6–3 N●m)

333024E

Parts
Ref
501

Part
16U529

502

16V515

503

16U522

Description
HARNESS, breaker
module
HARNESS, hose out
MODULE, din rail, term
blk, power sup; see
System Circuit Breaker
Module, page 86

Qty

Ref
504

Part
16U526

505

16U530

1
1

Description
MODULE, din rail,
circuit breakers; see
Power Supply and
Terminal Block Module,
page 86
MODULE, sys surge
protector

Qty

Qty
6

1
1

Heater and Transformer Terminal Block Module
24U849

Ref
511

Part
24T315

512

126811

Description
RAIL, DIN; 35 mm x 7.5
mm x 7 in.
BLOCK, clamp, end

513

126383

COVER, end

514

126382

BLOCK, terminal

333024E

Qty
1
2

Ref
515

Part
120570

Description
BLOCK, terminal

516

24R758

517

24R759

BLOCK, terminal,
UT-2.5, red
BLOCK, terminal,
UT-2.5, black

1
1

Parts

System Circuit Breaker Module
16U526

Ref
521

Part
514014

522

120838

523

17A319

Description
RAIL, DIN; 35 mm x
7.5 mm x 8.625 in.
TERMINAL, end stop

Qty
1

Ref
524

Part
17A314

525

17A317

CIRCUIT, breaker, 1
pole, 50A, C Curve

Description
CIRCUIT, breaker, 2P,
20A, UL489
CIRCUIT, breaker, 2P,
40A, UL489

Qty
1
3

Power Supply and Terminal Block Module
16U522

Ref
531

Part
514014

532

120838

533

24R722

Description
RAIL, DIN; 35 mm x 7.5
mm x 8.625 in.
TERMINAL, end stop
BLOCK, terminal PE,
quad, ABB

Qty
1

Ref
534

Part
24R723

Qty
2

126453

Description
BLOCK, terminal, quad
M4, ABB
POWER SUPPLY, 24V

535

536

24R724

BLOCK, terminal, UT35

333024E

Parts

Fluid Inlet Kits
24U320, Standard
24U321, Elite

Apply sealant to all tapered pipe threads. Apply
sealant to female threads. Apply to at least the
ﬁrst four threads and approximately 1/4 turn wide.
Apply thermal paste to the stem of dial before
assembling into housing.

333024E

Parts

Ref

Part

Description

601 160327 FITTING, union adapter, 90°
602 118459 FITTING, union, swivel, 3/4 in.
603 247503 MANIFOLD, strainer, inlet
604 24U852 THERMOMETER, dial
605 24U853 GAUGE, press, ﬂuid
- - - FILTER, replacement
606★
607★ C20203 PACKING, o-ring, 1.17, ﬂuoroelastomer
608 16V879 CAP, ﬁlter
609 555808 PLUG, 1/4mp w/ hex hd
610 15D757 HOUSING, thermometer, viscon hp
613 109077 VALVE, ball 3/4 npt
614 C20487 FITTING, nipple, hex
614 624545 FITTING, tee 3/4m run x 1/4f branc
615 24U851 TRANSDUCER, pressure, temperature (includes foam)
* Optional 80 mesh ﬁlter 255082 (2 pack)
★

Quantity
24U320

2
2
2
2
2
2
2
2
2
2
1
2

24U321

2
2
2
2
2
2
2
2
2
2
2

2
2

Included in 24V020 Inlet Filter and Seal Kit, 20
mesh (2 pack).

 Included in 247503 Manifold Repair Kit.

333024E

Electrical Schematics

Electrical Schematics
Reactor 2 E-30
Reactor 2 E-XP2

To TCM

24U831
24U832

16X118

333024E

Electrical Schematics

PS-L
PS-N

CB-B
CB-A
ti22680b

333024E

Electrical Schematics

16U529

15D906

24U855

16V515

Locate near TCM.

333024E

Reactor 2 Repair Spare Parts Reference

Reactor 2 Repair Spare
Parts Reference
Recommended Common Spare Parts
Ref

106,
115
106,
115
106,
115
106,
115
606,
607
402
403
405
211,
212
----

Part

Description

15C852 E-30 Pump Repair Kit

Part of Assembly

Pump

15C851 E-XP2 Pump Repair Kit

Pump

246963 E-XP2 Wet Cup Repair Kit

Pump

246964 E-30 Wet Cup Repair Kit

Pump

24V020 Y-Strainer Filter and Gasket Kit
(pack of two each)
247824 Drain Valve Cartridge
102814 Fluid Pressure Gauge
15M669 Pressure Sensor
24L973 RTD Repair Kit

Y-Strainer
Fluid Manifold
Fluid Manifold
Fluid Manifold
Heater

24K207 Hose FTS
Hose
24N450 RTD Cable (50 ft. replacement)
Hose
24N365 RTD Cable Test Kit (To assist measureing Hose
RTDs and RTD cable resistances)

333024E

Performance Charts

Performance Charts
Use these charts to help identify the proportioner that will work most efﬁciently with each mix chamber. Flow
rates are based on a material viscosity of 60 cps.
NOTICE

To prevent system damage, do not pressurize the
system above the line for the gun tip size being used.

Proportioners For Foam
2000
(138)

AR4242
(01)
AR5252
(02)

1500
(103)

PRESSURE
psi (bar)

AR6060
(03)

1000
(69)

AR7070
(04)

E-30

500

(34) 0

333024E

(2.3)

(4.5)

(6.8)

(9.1)

(11.3)

FLOW lbs/min (kg/min)

(13.6)

(15.9)

(18.1)

Performance Charts

Proportioners For Coatings
Table 1 Fusion Air Purge, Round Pattern

3500
(241)

3000
(207)

2500

PRESSURE
psi (bar)

E-XP2

AR2020
(000)

(172)

AR2929
(00)

2000
(138)

1500
(103)

AR4242
(01)

1000
(69)

500

(34) 0

0.5

1.0

(1.9)

1.5

(3.8)

FLOW gal./min (l/min)

2.0

(5.7)

(7.6)

Table 2 Fusion Air Purge, Flat Pattern

3500

(241, 24.1)

3000

(207, 20.7)

AF2929
(FTXX38 TIP)

2500

(174, 17.4)

PRESSURE
psi (bar)

AF2020
(FTXX24 TIP)

2000

(138, 13.8)

E-XP2

AF4242
(FTXX38 TIP)

1500

(103, 10.3)

AF5252
(FTXX48 TIP)

1000

(69, 6.9)

500

(35, 3.5)

0.5

(1.9)

1.0

(3.8)

FLOW gal./min (l/min)

1.5

(5.7)

2.0

(7.6)

333024E

Performance Charts

Table 3 Fusion Mechanical Purge, Round Pattern

3500

(241, 24.1)

E-XP2

3000

(207, 20.7)

XR2323
(RTM040)

2500

(174, 17.4)

PRESSURE
psi (bar)

XR2929
(RTM040)

2000

(138, 13.8)

MR3535
(RTM040)

1500

(103, 10.3)

XR3535
(RTM055)

1000

(69, 6.9)

MR4747
(RTM055)

XR4747
(RTM055)

500

(35, 3.5)

0.5

(1.9)

1.5

(3.8)

2.0

(5.7)

FLOW gal./min (l/min)

(7.6)

Table 4 Fusion Mechanical Purge, Flat Pattern

3500

(241, 24.1)

XF2323
(FTM424)

XF1313
(FTM424)

3000

(207, 20.7)

MF2929
(FTM424)

2500

(174, 17.4)

PRESSURE
psi (bar)

MF1818
(FTM424)

2000

(138, 13.8)

XF1818
(FTM424)

1500

MF4747
(FTM638)

XF2929
(FTM424)

(103, 10.3)

XF5757
(FTM638)

XF3535
(FTM638)

1000

(69, 6.9)

E-XP2

MF5757
(FTM638)

MF3535
(FTM638)

500

(35, 3.5)

333024E

0.2

(0.7)

0.4

(1.5)

0.6

(2.3)

0.8

(3.0)

(3.8)

1.2

(4.5)

FLOW gal./min (l/min)

1.4

(5.3)

1.6

(6.0)

1.8

(6.8)

2.0

(7.6)

Technical Specifications

Technical Speciﬁcations
Reactor 2 E-30 and E-XP2 Proportioning System

Maximum Fluid Working Pressure

E-30
E-XP2

Maximum Fluid Temperature

E-30
E-XP2

Maximum Flow Rate

E-30
E-XP2

Maximum Heated Hose Length

Length

U.S.

Metric

2000 psi
3500 psi

14 MPa, 140 bar
24.1 MPa, 241 bar

190°F
190°F

88°C
88°C

30 lb/min
2 gpm

13.5 kg/min
7.6 lpm

310 ft

94 m

0.0272 gal.
0.0203 gal.

0.1034 liter
0.0771 liter

20° to 120°F

-7° to 49°C

Output per Cycle

ISO and RES

E-30
E-XP2

Operating Ambient Temperature Range

Temperature

Line Voltage Requirement

Nominal 200–240 VAC, 1 Phase,
50/60 Hz
Nominal 200–240 VAC, 3 phase,
DELTA, 50/60 Hz
Nominal 350–415 VAC, 3 phase,
WYE, 50/60 Hz

195–265 VAC
195–265 VAC
340–455 VAC

Heater Power

(at 230 VAC rated voltage)

E-30 10 kW
E-30, 15 kW
E-XP2 15 kW

10,200 Watts
15,300 Watts
15,300 Watts

333024E

Technical Specifications

Sound Pressure

Sound Pressure measured per ISO-9614–2.

E-30

87.3 dBA

E-XP2

79.6 dBA

Sound Power

E-30

93.7 dBA

E-XP2

86.6 dBA

Measured from 3.1 ft (1 m), at
1000 psi (7 MPa, 70 bar), 3 gpm
(11.4 lpm)
Measured from 3.1 ft (1 m), at
3000 psi (21 MPa, 207 bar), 1 gpm
(3.8 lpm)
Measured from 3.1 ft (1 m), at
1000 psi (7 MPa, 70 bar), 3 gpm
(11.4 lpm)
Measured from 3.1 ft (1 m), at
3000 psi (21 MPa, 207 bar), 1 gpm
(3.8 lpm)
Fluid Inlets

Component A ISO) and
Component B (RES)
Fluid Outlets

Component A (ISO)
Component B (RES)

3/4 NPT(f) with 3/4 NPSM(f) union
#8 (1/2 in.) JIC, with #5 (5/16 in.) JIC adapter
#10 (5/8 in.) JIC, with #6 (3/8 in.) JIC adapter

Fluid Circulation Ports

Size
Maximum Pressure
Dimensions

250 psi

1/4 NPSM(m)

1.75 MPa, 17.5 bar

Width
Height
Depth

26.3 in.
63 in.
15 in.

668 mm
1600 mm
381 mm

Weight

315 lb
350 lb
320 lb
355 lb
345 lb
350 lb

143 kg
159 kg
145 kg
161 kg
156 kg
159 kg

E-30, 10 kW
E-30, 15 kW
E-30, 10 kW Elite
E-30, 15 kW Elite
E-XP2
E-XP Elite
Wetted Parts

Material

333024E

Aluminum, stainless steel, zinc plated carbon steel, brass,
carbide, chrome, chemically resistant o-rings, PTFE, ultra-high
molecular weight polyethylene

Notes

333024E

Graco Extended Warranty for Reactor® 2
Components
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.

Graco Part Number

24U050
24U051
24U831
24U832
24U855
24U854
All other Reactor 2 parts

Description

Warranty Period

Electric Motor

36 Months or 3 Million Cycles

Motor Control Module
Motor Control Module
Heater Control Module
Advanced Display Module

36 Months or 3 Million Cycles
36 Months or 3 Million Cycles
36 Months or 3 Million Cycles
36 Months or 3 Million Cycles
12 Months

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 hereunder must be brought within the latter of two (2) years of the date of
sale, or one (1) year the warranty period expires.

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
All written and visual data contained in this document reﬂects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
For patent information, see www.graco.com/patents.
Original Instructions. This manual contains English. MM 333024

Graco Headquarters: Minneapolis
International Ofﬁces: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com
Revision E, February 2015

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Keywords                        : MM 333024; 333024E; 333024EN-E; 333024EN; 333024; Reactor 2 E-30 and E-XP2 Proportioning System; Repair-Parts; Reactor 2
Creator Tool                    : PScript5.dll Version 5.2.2
Modify Date                     : 2015:03:12 14:52:25-05:00
Create Date                     : 2015:02:24 10:45:08-06:00
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Format                          : application/pdf
Title                           : 333024E - Reactor 2 E-30 and E-XP2 Proportioning System, Repair-Parts, English
Description                     : 333024E - Reactor 2 E-30 and E-XP2 Proportioning System, Repair-Parts, English
Rights                          : 2014, Revision E, February 2015
Creator                         : Emil Meindl
Subject                         : MM 333024, 333024E, 333024EN-E, 333024EN, 333024, Reactor 2 E-30 and E-XP2 Proportioning System, Repair-Parts, Reactor 2
Page Count                      : 100
Author                          : Emil Meindl

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Graco 333024E Reactor 2 E 30 And Xp2 Proportioning System Users Manual System, Repair Parts, English

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