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Graco 259079 Operation Manuals

Graco 259079 Operation Manuals

Reactor e-30i series; reactor e-xp2i series; electric, heated, integrated plural component proportioning system with integrated generator
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Operation
Reactor® E-30i and E-XP2i
Electric, Heated, Integrated Plural Component Proportioning System With Integrated Generator. 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.
3A1705E
EN

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Summary of Contents for Graco 259079

  • Page 1 Operation 3A1705E Reactor® E-30i and E-XP2i Electric, Heated, Integrated Plural Component Proportioning System With Integrated Generator. 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.

  • Page 2: Table Of Contents

    Dimensions ............93 Connect Remote Display Module ....41 Grounding ........... 41 Performance Charts..........96 Supply Wet Cups With Throat Seal Liquid Notes ..............97 (TSL) ..........42 Technical Specifications........98 Advanced Display Module (ADM) Operation..........43 Graco Standard Warranty........102 3A1705E...

  • Page 3: Warnings

    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.
  • Page 4 Warnings WARNING SKIN INJECTION HAZARD High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment. •...
  • Page 5 Warnings WARNING PRESSURIZED ALUMINUM 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.
  • Page 6 Warnings WARNING BATTERY HAZARD The battery may leak, explode, cause burns, or cause an explosion if mishandled. • Only use the battery type specified for use with the equipment. See Technical Data. • Battery maintenance must only be performed or supervised by personnel knowledgeable of batteries and the required precautions.

  • Page 7: Important Two-Component Material Information

    Important Two-Component Material Information Important Two-Component Material Information Isocyanate Conditions Moisture Sensitivity of Isocyanates Cross-contamination can result in cured Spraying or dispensing materials containing material in fluid lines which could cause serious isocyanates creates potentially harmful mists, injury or damage equipment. To prevent vapors, and atomized particulates.

  • Page 8: Changing Materials

    Important Two-Component Material Information Foam Resins with 245 fa Blowing Changing Materials Agents Changing the material types used in your equipment requires special attention to avoid equipment damage Some foam blowing agents will froth at temperatures and downtime. above 90°F (33°C) when not under pressure, especially if agitated.

  • Page 9: Proportioner Models

    240 V, 60 (Watts) cle (A+B) Pressure (4000 (5000 Watts) Hz* gal. (liter) psi (MPa, Watts) bar) 0.0272 2000 (14, 259079 50 Amps 240 V (1) 7,700 30 (13.5) (0.1034) 140) 0.0272 2000 (14, 259080 32 Amps 240 V (1) 11,700 30 (13.5)

  • Page 10: Systems

    Systems Approvals Model Approvals: 259079 Conforms to ANSI/UL Std. 73 Certified to CAN/CSA Std. C22.2 No. 68 259080 259081 Conforms to ANSI/UL Std. 499 Certified to CAN/CSA Std. C22.2 No. 88 Systems Remote Heated Hose Part Proportioner Display 50 ft (15 m) 10 ft (3 m)

  • Page 11: Accessories

    Accessories Systems with Air Compressor Remote Heated Hose Air Com- Part Proportioner Display pressor 50 ft (15 m) 10 ft (3 m) Model Part Module Kit AP9089 259089 24K240 246050 Fusion™ AP 246101 ✓ AP9090 259090 24K240 246050 Fusion™ AP 246101 ✓...

  • Page 12: Supplied Manuals

    The following manuals are for accessories used with The following manuals are shipped with the Reactor. Refer to these manuals for detailed equipment the Reactor. information. Manuals are available at www.graco.com Manuals are also available at www.graco.com. Component manuals in English: Manual Description System Manuals 3A1705...

  • Page 13: Typical Installation, With Circulation

    Typical Installation, with circulation Typical Installation, with circulation Figure 1 * Shown exposed for clarity. Wrap with tape during operation. Reactor Proportioner Fluid Supply Lines Heated Hose Feed Pumps Fluid Temperature Sensor (FTS) Agitator Heated Whip Hose Desiccant Dryer Fusion Spray Gun Gun Fluid Manifold (part of gun) Gun Air Supply Hose Recirculation Lines...

  • Page 14: Typical Installation, Without Circulation

    Typical Installation, without circulation Typical Installation, without circulation Figure 2 * Shown exposed for clarity. Wrap with tape during operation. Reactor Proportioner Fluid Supply Lines Heated Hose Feed Pumps Fluid Temperature Sensor (FTS) Agitator Heated Whip Hose Desiccant Dryer Fusion Spray Gun Bleed Lines Gun Air Supply Hose Gun Fluid Manifold (part of gun)

  • Page 15: Component Identification

    Component Identification Component Identification (FM) Front View Heated Hose Electrical Connectors Figure 3 Main Power Switch Component A Pressure Relief Outlet Component A Pump Component B Pressure Relief Outlet Component B Pump (behind Electrical Drive Gear Housing Enclosure) Electrical Enclosure Proportioner Control Panel, page 18 Electric Motor Pallet...
  • Page 16 Component Identification Low Power Module (LPTCM) Cable Back View Connections, page 26 (not included with Figure 4 all models) Circulation Pump ISO Pump Lubricant Reservoir Electrical Cord Strain Relief Motor Control Module (MCM), page 23 Y-strainer (includes pressure gauge and Sight Glass temperature gauge) Component A Control Valve...

  • Page 17: Generator

    Component Identification Generator Generator Power Distribution Box Figure 5 Glow Plugs Air Filter Heat Exchanger Coolant Expansion Bottle Battery (not supplied) Heat Exchanger Diesel Fuel Filter Heat Exchanger Coolant Fill Bottle 12V Charge Alternator Oil Drain Engine Coolant Expansion Bottle Oil Filter Engine Oil Fill...

  • Page 18: Proportioner Control Panel

    Component Identification Proportioner Control Panel Advanced Display Module (ADM), page 19 Engine Control Module, page 24 Component A Feed Pump Air Outlet Component B Feed Pump Air Outlet Agitator Air Outlet Gun Air Outlet Component A Feed Pump Air Regulator Component B Feed Pump and Agitator Air Regulator Gun Air Regulator...

  • Page 19: Advanced Display Module (Adm)

    Component Identification Advanced Display Module (ADM) NOTICE To prevent damage to the softkey buttons, do not press buttons with sharp objects such as pens, plastic cards, or fingernails. Call Button Function Component Identification — Front Figure 8 Cancel Cancels a selection or Call Button Function...
  • Page 20 Component Identification USB Module Status LEDs (CL) Component Identification — Back Conditions Figure 9 Flat Panel Mount (VESA 100) Green Flashing - Data recording in progress Model and Serial Number USB Port and Status LEDs Yellow Solid - Downloading information to USB CAN Cable Connection Green and Yellow Flashing - ADM is busy, USB Module Status LEDs...
  • Page 21 Component Identification ADM Display Details Alarm/Deviation The current system error is displayed in the middle of Power Up Screen the menu bar. There are four possibilities: The following screen appears when the ADM is Icon Function powered up. It remains on while the ADM runs through No Icon No information or no error has occurred initialization and establishes communication with other...
  • Page 22 Component Identification Icons Icons Softkeys Icon Function Icon Function Component A Start Proportioner Start and Stop Proportioner in Jog Mode Component B Stop Proportioner Estimated Supply Material Turn on specified heat zone. Hose Temperature Park component A pump Jog Mode Speed Enter Jog Mode.

  • Page 23: Motor Control Module (Mcm)

    Component Identification Motor Control Module (MCM) Optional Accessory Connection: Feed Motor Control Module Pump Shut Down Kit Figure 10 Pressure Transducer B (Blue) side Token and Rotary Switch Access Cover Pressure Transducer A (Red) side Module Status LEDs see Module Status Motor Brush Wear and Over-Temperature LEDs (CN) Conditions, page 20 Sensor Connection...

  • Page 24: Engine Control Module

    Component Identification Engine Control Module Icon Description Function Start Engine NOTICE Auto Auto mode (not To prevent damage to the softkey buttons, do not used) press buttons with sharp objects such as pens, plastic cards, or fingernails. Stop all system processes.

  • Page 25: Load Center

    Component Identification Load Center Related ON-State Color Component Description Fuel shutoff Fuel Shutoff Green solenoid on the Solenoid (FS) engine is open. Starter is Starter (ST) cranking. Glow Plugs Glow plugs are Green (GL) heating. Radiator Fan Radiator fan is Green (RF) A-side (red)

  • Page 26: Temperature Control Modules

    Component Identification Temperature Control Modules Located inside the Electrical Enclosure (DB). High Power Temperature Control Module Low Power Module (LPTCM) Cable (HPTCM) Cable Connections Connections Only used with E-XP2i and E-30i models with booster heat. Figure 12 Figure 14 Figure 13 Figure 15 Not used Over-Temperature Switch Connection...
  • Page 27 Component Identification Adjust Rotary Switch HPTCM A and B Rotary Switch Settings Setting Zone The rotary switch setting indicates which zone the temperature control module will control in the system. Heated Hose The HPTCM uses an 8-position rotary switch. The LPTCM uses a 16-position rotary switch.

  • Page 28: Circuit Breakers

    Component Identification Circuit Breakers Ref. Size Component CB01 30 A High Power Temperature Control Module (HPTCM) CB02 20 A Motor Control Module (MCM) CB03 Two Motor Fans, Cabinet Fan, Power Supply, and CB08 Coolant Circulation Pump CB07 CB04* 30 A Auxiliary Power (Air CB06 Compressor)
  • Page 29 Component Identification CB04 be substituted to accommodate larger loads or a sub-panel. The total auxiliary equipment loads added to the configuration must be limited to the system’s available auxiliary current. See Proportioner Models, page 9, for available auxiliary current at 240V, 60Hz. See the Reactor repair manual for optional circuit breakers and their current ratings.

  • Page 30: Overview

    Overview Overview The system uses two coolant loops to use heat exchanger (HE), radiator (ER), and back to the released from the engine to heat the A and B engine. Coolant in the proportioner coolant loop component material to the target temperatures (black) captures heat from the engine coolant loop defined on the ADM (PD).
  • Page 31 Overview The proportioner coolant loop circulates coolant For models with a booster heater, the A and B through secondary heat exchangers (HE) located material enters the booster heater after the material on the back of the proportioner to heat the A is pressurized in the proportioning pumps to heat the and B component material before the material is material higher than 140°F (60°C).
  • Page 32 Overview Coolant only flows through the secondary heat exchangers when the heat exchanger control valves (VA, VB) are open and the A and B component temperatures are below the target temperatures set on the ADM. See Fig. 24. When the control valves (VA, VB) close, the A and B material has reached target temperature.

  • Page 33: Setup

    Setup Setup e. Connect pilot air lines (A3 and A4) between the air compressor and air tank. Secure water drain lines (A5 and A6) to the NOTICE frame and drain outlets. Proper system setup, startup, and shutdown 2. Install hose rack, if ordered. See manual 3A1903 procedures are critical to electrical equipment for detailed instructions.
  • Page 34 Setup 3A1705E...

  • Page 35: Trailer Setup Guidelines

    Setup Trailer Setup Guidelines 2. Provide radiator exhaust for Reactor. Use a 400 (258,064 mm ) minimum louver. 3. Provide air duct to connect radiator exhaust to louver. 4. Provide a 400 in. ( 258,064 mm ) minimum fresh Route exhaust system away from combustible air intake louver near the generator.

  • Page 36: Install Wall (Optional)

    Setup Install Wall (optional) 3. Remove fuel tank from the pallet. a. Remove the mounting screws, supports, and Install a wall between the proportioner and generator spacers. b. Disconnect inlet and outlet fuel lines from the • Temperature condition the trailer space where fuel tank.
  • Page 37 Setup 15 in. (381 mm) 1 ft min (0.3m) 1.25 in. 1.25 in. (31.75 mm) 6 in. min (406.4 mm) (31.75 mm) Wall (IW) Installation Guidelines Figure 27 3A1705E...

  • Page 38: Connect Battery

    Setup Connect Battery 3. Cover battery terminals with plastic caps (PC) attached to supplied battery cables. 4. Verify battery was connected properly by pressing OFF on the engine control module (PE) to “wake up” the controller screen. Do not Improper battery installation or maintenance attempt to start the engine until all Setup steps may result in electric shock, chemical burns, are complete.

  • Page 39: Electrical Connections

    Setup Electrical Connections 5. Connect air lines to proportioner. Ensure components are properly connected to correct location. Connect air compressor, breathing air, and auxiliary power electrical connections to the specified circuit breakers. See Circuit Breakers, page 28. 1. Remove one or more knock-outs on side of electrical enclosure, as required, and route wires through for air compressor, breathing air, and auxiliary equipment.

  • Page 40: Connect Pressure Relief Lines

    Setup Connect Pressure Relief Lines coded: red for component A (ISO), blue for component B (RES). Fittings are sized to prevent connection errors. Note Manifold hose adapters (HA, HB) allow Do not operate Reactor without all covers and use of 1/4 in. and 3/8 in. ID fluid hoses. shrouds in place.

  • Page 41: Close Gun Fluid Manifold Valves A And

    Setup Close gun fluid manifold valves A and or vehicle chassis or, if stationary, to true earth ground. Remove bolt and braided cable from pallet. Install grounding cable terminated with a ring terminal (cable and terminal not supplied) under braided cable. Reinstall bolt and torque to minimum 25 ft-lbs (34 N∙m).

  • Page 42: Supply Wet Cups With Throat Seal Liquid

    • Component B (Resin) Pump: Check felt washers Liquid (TSL) in packing nut/wet-cup (S) daily. Keep saturated with Graco Throat Seal Liquid (TSL), Part No. 206995, to prevent material from hardening on displacement rod. Replace felt washers when worn or contaminated with hardened material.

  • Page 43: Advanced Display Module (Adm)

    Advanced Display Module (ADM) Operation Advanced Display Module (ADM) Operation When main power is turned on by turning the main power switch (MP) to the ON position, the splash screen will be displayed until communication and initialization is complete. Perform the following tasks to fully setup your system. 1.

  • Page 44: Setup Mode

    Advanced Display Module (ADM) Operation Setup Mode The ADM will start in the Run screens at the Home screen. From the Run screens, press access the Setup screens. The system defaults with no password, entered as 0000. Enter the current password then press .
  • Page 45 Advanced Display Module (ADM) Operation Setup Screens Navigation Diagram Figure 35 3A1705E...

  • Page 46: Advanced Setup Screens

    Advanced Display Module (ADM) Operation Advanced Setup Screens Advanced setup screens enable users to set units, adjust values, set formats, and view software information for each component. Press to scroll through the Advanced setup screens, Once in the desired Advanced setup screen, press to access the fields and make changes.

  • Page 47: System

    Advanced Display Module (ADM) Operation System Add Recipe Use this screen to set the activation pressure for the 1. Press and then use to select a Pressure Imbalance Alarm and Advisory, enable or recipe field. Press to enter a recipe name disable diagnostic screens, enable drum alarms, set (maximum 16 characters).

  • Page 48: Run Mode

    Advanced Display Module (ADM) Operation Run Mode The ADM will start in the Run screens at the “Home” screen. Press to navigate through the Run Mode screens. See Run Screens Navigation Diagram, page 44. From the Run screens, press to access the Setup screens. 3A1705E...
  • Page 49 Advanced Display Module (ADM) Operation Run Screens Navigation Diagram Figure 36 3A1705E...
  • Page 50 Advanced Display Module (ADM) Operation Home — System Off Home — System With Error This is the home screen when the system is off. Active errors are shown in the status bar. The error This screen displays actual temperatures, actual code, alarm bell, and description of the error will pressures at the fluid manifold, jog speed, coolant scroll in the status bar.
  • Page 51 Advanced Display Module (ADM) Operation Maintenance Events Use this screen to view daily and lifetime cycles or This screen shows the date, time, event code, and gallons that have been pumped and gallons or liters description of all events that have occurred on remaining in the drums.
  • Page 52 Advanced Display Module (ADM) Operation Diagnostic • Booster B Chemical • Booster A PCB — temperature control module Use this screen to view information for all system temperature components. • Booster B PCB — temperature control module temperature • Hose PCB — temperature control module temperature •...
  • Page 53 Advanced Display Module (ADM) Operation Troubleshooting Recipes This screen displays the last ten errors that Use this screen to select an enabled recipe. Use the occurred on the system. Use the up and down up and down arrows to highlight a recipe and press arrows to select an errors and press to view to load.
  • Page 54 Advanced Display Module (ADM) Operation System Events Use the table below to find a description for all system events. All events are logged in the USB log files. Event Code Description Recipe Selected Heat On A Heat On B Heat On Hose Pump On Jog On USB Drive Inserted...

  • Page 55: Startup

    Startup Startup To prevent serious injury, only operate Reactor with all covers and shrouds in place. 6. Start the generator. NOTICE Proper system setup, startup, and shutdown Press start button twice on the engine procedures are critical to electrical equipment control module.
  • Page 56 Startup 8. Check coolant color. 11. Open the main air shutoff valve. Use a flashlight to inspect the color of the coolant through sight glass (SG). The mesh filter should be visible inside the sight glass and the coolant should be green. If there are a lot of air bubbles, then the coolant level may be low.
  • Page 57 Startup Open fluid inlet valves (FV). Check for leaks. This equipment is used with heated fluid which can cause equipment surfaces to become very hot. To avoid severe burns: • Do not touch hot fluid or equipment. • Do not turn on hose heat without fluid in hoses.

  • Page 58: Temporary Manual Hose Temperature Control

    Temporary Manual Hose Temperature Control Temporary Manual Hose 2. Insert the RTD sensor probe between the two hoses where the scuff guard ends. Temperature Control 3. Lower the hose temperature setpoint on the system ADM screen by (20°F (-6°C). Push probe If T6DH error code appears from a break in the into the hose bundle at least 3 in.

  • Page 59: Fluid Circulation

    Fluid Circulation Fluid Circulation Circulation Through Reactor 3. Set PRESSURE RELIEF/SPRAY valves (SA, NOTICE SB) to PRESSURE RELIEF/CIRCULATION Do not circulate fluid containing a blowing agent without consulting with your material supplier regarding fluid temperature limits. To circulate through gun manifold and preheat hose, see Circulation Through Gun Manifold, page 60.

  • Page 60: Circulation Through Gun Manifold

    Jog Mode Circulation Through Gun Manifold 3. Follow procedures from Startup, page 55. NOTICE 4. Turn main power switch on Do not circulate fluid containing a blowing agent 5. Set temperature targets. See Targets, page 50. without consulting with your material supplier regarding fluid temperature limits.

  • Page 61: Spraying

    Spraying Spraying 4. Adjust the gun air regulator on the proportioner control panel to desired gun air pressure. Do not exceed 130 psi (0.2 MPa, 2 bar). 5. Set PRESSURE RELIEF/SPRAY valves (SA, The Fusion AP gun is shown. SB) to SPRAY 1.

  • Page 62: Spray Adjustments

    Spraying 12. Open gun fluid inlet valves A and B. 15. Equipment is ready to spray. Spray Adjustments Flow rate, atomization, and amount of overspray are affected by four variables. • Fluid pressure setting. Too little pressure results in an uneven pattern, coarse droplet size, low flow, and poor mixing.

  • Page 63: Shutdown

    Shutdown Shutdown NOTICE 8. Turn main power switch OFF. 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.

  • Page 64: Pressure Relief Procedure

    Pressure Relief Procedure Pressure Relief Procedure 4. Route fluid to waste containers or supply tanks. Turn PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION This equipment stays pressurized until pressure . Ensure gauges drop to 0. 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...

  • Page 65: Flushing

    Flushing Flushing • To flush feed hoses, pumps, and heaters separately from heated hoses, set PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE To prevent fire and explosion, flush equipment only RELIEF/CIRCULATION . Flush through bleed in a well-ventilated area. Do not spray flammable lines (N).

  • Page 66: Maintenance

    Refill Proportioner Coolant Loop, page 70. See Refill Engine Coolant Loop, page 71. Wet Cup Engine Maintenance Check the wet cup daily. Keep it 2/3 full with Graco Throat Seal Liquid (TSL ) or compatible solvent. Do ® The engine instructions that accompany your not overtighten packing nut/wet cup.

  • Page 67: Flush Inlet Strainer Screen

    Maintenance Flush Inlet Strainer Screen 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.

  • Page 68: Pump Lubrication System

    Maintenance Pump Lubrication System 4. When the reservoir is flushed clean, fill with fresh lubricant. Check the condition of the ISO pump lubricant daily. 5. Thread the reservoir onto the cap assembly and Change the lubricant if it becomes a gel, its color place it in the bracket.

  • Page 69: Drain Coolant

    Maintenance Drain Coolant LED Component LED Color Manual valve switch (MV) Red A Side Control Valve B Side Control Valve Blue To avoid burns, do not perform maintenance on Bypass Valve Green the coolant system until the coolant system has reached ambient temperature.

  • Page 70: Refill Proportioner Coolant Loop

    Maintenance Refill Proportioner Coolant Loop 5. To drain engine coolant loop: a. Remove the engine coolant loop (RC) cap. Note b. Remove engine guards as shown. Let the Air needs to be purged from the proportioner guards rest on the engine to access the drain coolant loop when it is filled with new coolant valve.

  • Page 71: Refill Engine Coolant Loop

    Maintenance 3. Replace cap. Only use coolant solutions that are compatible with the system. See Coolant Specifications, page 71. 4. Press start button twice on the engine 1. Perform Shutdown, page 63. control module. 2. Remove the engine radiator coolant cap 5.

  • Page 72: Errors

    Errors Errors View Errors When an error occurs the error information screen displays the active error code and description. To diagnose the active error, see Troubleshoot Errors, page 73. The error code, alarm bell, and active errors will scroll in the status bar. For a list of the ten most recent errors see Troubleshooting, page 53.

  • Page 73: Troubleshoot Errors

    Errors Troubleshoot Errors to diagnose the error. Press to return to the previous screen. See Error Codes and Troubleshooting, page 74 for causes and solutions to each error code. To troubleshoot the error: 1. Press the soft key for help with the active error. 3.

  • Page 74: Troubleshooting

    Troubleshooting Troubleshooting See Troubleshooting, page 53 for the ten most recent errors that have occurred on the system. See Troubleshoot Errors, page 73 to diagnose errors that have occurred on the system. See Errors, page 72 for information about errors that See Error Codes and Troubleshooting for error can occur on the system.
  • Page 75 Troubleshooting Error Error Type Name Cause Solution Code Location A4CM MCM ALARM High MCM MCM is drawing too If problem continues Current much current from the replace MCM. See System system. Repair manual. A4DA Boost A ALARM High Heater Short circuit in booster Check wiring for touching Current heater wiring.
  • Page 76 Troubleshooting Error Error Type Name Cause Solution Code Location CACA Boost A ALARM Communication Module does not have Insert a system token into Error software or dial is set to the missing GCA module wrong position. and cycle the power. Wait until the red light on the module to stop flashing before removing the token.
  • Page 77 Troubleshooting Error Error Type Name Cause Solution Code Location DADX MCM ALARM Pump Runaway Flow rate is too large Mix chamber too large for system selected, use mix chamber rated for system. Make sure the system has chemical and the feed pumps are operating correctly.
  • Page 78 Troubleshooting Error Error Type Name Cause Solution Code Location L1AX ALARM Low Chemical Tanks low on material. Fill tanks with material. Level A L1BX Low Chemical Level B MBN0 MCM ADVI- Motor Brush Brushes have worn Replace Brushes. See SORY Wear down and need System Repair manual.
  • Page 79 Troubleshooting Error Error Type Name Cause Solution Code Position P7AX ALARM Pressure Pressure difference Ensure the material flow is Imbalance A High between A and B material equally restricted on both is greater than the material lines. defined value. Pressure imbalance is Ensure that the pressure defined too low.
  • Page 80 Troubleshooting Error Error Type Name Cause Solution Code Position T2AE Heat DEVIATION Low Temperature Coolant circulation pump Check for 240VAC on pump. Exchanger Hx A not working. If there is the correct voltage, replace circulation pump. Air lock in circulation Check for coolant flow in pump.
  • Page 81 Troubleshooting Error Error Type Name Cause Solution Code Position T3NM ADVISORY High Motor Motor is operating Run the system at a Temperature outside of pressure lower duty cycle or with a flow curve. The system smaller mix chamber. See is running at a lower Performance Charts, page setpoint to preserve motor life.
  • Page 82 Troubleshooting Error Error Type Name Cause Solution Code Position T4DH Hose ALARM High Chemical Bad High Power Replace HPTCM. See Temperature Temperature Control System Repair manual. Module. T4DE Heat ALARM High Temperature Broken Fan. Check fan relay (K4) and Exchanger Coolant Outlet fuse (30 Amp ATO “F3”) on load center board.
  • Page 83 Troubleshooting Error Error Type Name Cause Solution Code Position T6AE Heat ALARM RTD Fault A The module is reading Check port on module and Exchanger infinite resistance. wiring to RTD. T6BE Heat RTD Fault B Bad RTD. Switch the RTD with another Exchanger and see if the error message follows the RTD.
  • Page 84 Troubleshooting Error Error Type Name Cause Solution Code Position T8DA Boost A ALARM Temperature Not Bad heater rod (boost). Measure resistance, 23 – 26 Rising Ω, of heater rod, replace if reading open. T8DB Boost B Bad hose heater. Measure hose resistance, replace if reading open.
  • Page 85 Troubleshooting Error Error Type Name Cause Solution Code Position WMCE MCM ALARM Load Center Fault Bad Connection between Check connection and MCM (Port 2) and load cables. center board. Bad load center. Replace load center. See System Repair manual. WSCX ADM ADVISORY Invalid CAN Duplicate node on CAN Verify LPTCM are set to A...

  • Page 86: Usb Data

    USB Data USB Data USB Logs Event codes include both error codes (alarms, deviations, and advisories) and record only events. Note Actions Taken includes setting and clearing event conditions by the system, and acknowledging error The ADM can read/write to FAT (File conditions by the user.

  • Page 87: System Configuration Settings

    This log powered up. The volume units will be the same units will help Graco troubleshoot system errors. that were used in the Job Log. The following data is stored in this file: System Configuration Settings...

  • Page 88: Custom Language File

    5. The USB flash drive window automatically opens. The following rules must be followed in order for the If it does not, open USB flash drive from within installation process to succeed. Windows® Explorer. 6. Open GRACO folder. 7. Instructions continue on next page. 3A1705E...

  • Page 89: Upload Procedure

    9. Open DOWNLOAD folder. than one system, there will be more than one 10. Open DATAxxxx folder. folder within the GRACO folder. Each folder is labeled with the corresponding serial number of 11. Open DATAxxxx folder labeled with the highest the ADM.

  • Page 90: Appendix A: Engine Control Module

    Appendix A: Engine Control Module Appendix A: Engine Control Module Run Screens There are seven run screens on the engine control module: • Line-to-neutral voltage • Line-to-line voltage • Frequency • Engine Speed • Engine lifetime counter • Battery voltage Press to scroll through the run screens.
  • Page 91 Appendix A: Engine Control Module Mode Icons An icon is displayed in the mode icon area of the display to indicate what mode the unit is currently in. Icon Description Details Engine is at rest and the unit is in stop mode. Stopped Auto Engine is at rest and the unit is in auto mode.
  • Page 92 Appendix A: Engine Control Module Alarms There are two types of alarms that can occur on the system. Alarms are indicated by an icon the Run and Information screens. Warning When present on system, a warning alarm will not stop the generator. Icon Description Details...

  • Page 93: Dimensions

    Dimensions Dimensions Top View Figure 43 Side View Figure 44 3A1705E...
  • Page 94 Dimensions Top View: System with Compressor and Hose Rack Side View: System with Compressor and Hose Rack Accessories Accessories Figure 45 Figure 47 Front View Figure 46 3A1705E...
  • Page 95 Dimensions Pallet Mounting Dimensions Figure 48 3A1705E...

  • Page 96: Performance Charts

    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. Proportioners For Foam 2000 (138) AR4242 (01) 1500 AR5252 (02) (103)

  • Page 97: Notes

    Notes Notes 3A1705E...

  • Page 98: Technical Specifications

    Technical Specifications Technical Specifications E-30i Models Metric U.S. Maximum Fluid Working Pressure Pressure 2000 psi 14 MPa, 140 bar Maximum Fluid Temperature E-30i 140°F 60°C E-30i with booster heater 180°F 82°C Maximum Output Output 30 lb/min 13.5 kg/min Maximum Heated Hose Length Length 310 ft 94 m...
  • Page 99 Technical Specifications Recommended Air Compressors Champion® BR-5, Base Mount Specifications 5 HP, 240 V, 1 Phase, 60 Hz, 21 cfm Required Features Belt guard aftercooler Pilot valve unloader Quincy PLT5–5B, Base Mount Specifications 5 HP, 240 V, 1 Phase, 60 Hz Required Features Belt guard aftercooler Pilot valve unloader...
  • Page 100 Technical Specifications E-XP2i Models U.S. Metric Maximum Fluid Working Pressure Pressure 3500 psi 24.1 MPa, 241 bar Maximum Fluid Temperature E-XP2i 180°F 82°C Maximum Output Output 2 gpm 7.6 lpm Maximum Heated Hose Length Length 310 ft 94 m Output per Cycle A and B 0.0203 gal.
  • Page 101 Technical Specifications Recommended Air Compressors Champion® BR-5, Base Mount Specifications 5 HP, 240 V, 1 Phase, 60 Hz, 21 cfm Required Features Belt guard aftercooler Pilot valve unloader Quincy PLT5–5B, Base Mount Specifications 5 HP, 240 V, 1 Phase, 60 Hz Required Features Belt guard aftercooler Pilot valve unloader...

  • Page 102: Graco Standard Warranty

    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.

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