Graco REACTOR E-20 Repair Manual
  1. Manuals
  2. Brands
  3. Graco Manuals
  4. Paint Sprayer
  5. REACTOR E-20
  6. Repair manual

Graco REACTOR E-20 Repair Manual

Reactor e series; reactor e-xp series electric, heated, plural component proportioner
Hide thumbs Also See for REACTOR E-20:
Table of Contents

Advertisement

Quick Links

Repair - Parts
Electric, Heated, Plural Component
Proportioner
For spraying polyurethane foam and polyurea coatings.
Not for use in explosive atmospheres.
Important Safety Instructions:
Read all warnings and instructions in this manual. Save these
instructions.
See page 2 for Table of Contents and page 3 for List of Models.
Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2003, Graco Inc. is registered to I.S. EN ISO 9001
309574L
TI3764a-1

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the REACTOR E-20 and is the answer not in the manual?

Questions and answers

Related Manuals for Graco REACTOR E-20

Summary of Contents for Graco REACTOR E-20

  • Page 1 Read all warnings and instructions in this manual. Save these instructions. See page 2 for Table of Contents and page 3 for List of Models. TI3764a-1 Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441 Copyright 2003, Graco Inc. is registered to I.S. EN ISO 9001...

  • Page 2: Table Of Contents

    E29: Brush Wear ......19 Graco Information ......74...

  • Page 3: Models

    Models Models E SERIES Full Maximum Load Flow Output per Fluid Working Part No., Voltage Peak System Heater lb/min Cycle (A + B) Pressure psi Series Model (phase) Amps* Watts** Watts (kg/min) gal. (liter) (MPa, bar) 246025, D E-20 230V (1) 11,100 6,000 20 (9)

  • Page 4: Manual Conventions

    Manual Conventions Manual Conventions Warning Caution WARNING CAUTION A caution alerts you to possible equipment damage or destruction if you do not follow instructions. A warning alerts you to possible serious injury or Note death if you do not follow instructions. Symbols, such as fluid injection (shown), alert you to a A note indicates additional helpful information.

  • Page 5: Related Manuals

    Related Manuals Related Manuals The following manuals are for accessories used with the Order Part No. 15B381 for a compact disk of Fusion ™ manual translated in several languages. Reactor Order Part No. 15B535 for a compact disk of Reactor manuals translated in several languages.

  • Page 6: Warning

    Warning 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. Get immediate surgical treatment. • Do not point the gun at anyone or at any part of the body.
  • Page 7 Misuse can cause serious injury or death. • For professional use only. • Use equipment only for its intended purpose. Call your Graco distributor for information. • Read manuals, warnings, tags, and labels before operating equipment. Follow instructions. • Check equipment daily. Repair or replace worn or damaged parts immediately.

  • Page 8: Before Beginning Repair

    Before Beginning Repair Before Beginning Flushing Repair WARNING WARNING Read warnings, page 6. Flush equipment only in a well-ventilated area. Do not spray flammable fluids. Do not turn on heaters while flushing with flammable sol- Repairing this equipment requires access to parts vents.

  • Page 9: Pressure Relief Procedure

    Pressure Relief Procedure Pressure Relief 4. Turn PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF. Route fluid to waste con- Procedure tainers or supply tanks. Ensure gauges drop to 0. 1. Relieve pressure in gun and perform gun shutdown procedure. See gun manual. 2.

  • Page 10: Temperature Control Diagnostic Codes

    Temperature Control Diagnostic Codes Temperature Control Diagnostic Codes Temperature control diagnostic codes E01 through E05 These alarms turn off heat. Turn main power OFF appear on temperature display. then ON to clear. Code Code Name Alarm Zone Corrective Action page High fluid temperature Individual High hose current...

  • Page 11: E02: High Hose Current

    Temperature Control Diagnostic Codes E02: High hose current E03: No hose current Check transformer. If transformer has “lollipops” 1. Check tap connection at transformer, see operation located in front, refer to E03 (lollipops). If the manual. transformer does not include the “lollipops,” refer to E03 (no lollipops).
  • Page 12 Temperature Control Diagnostic Codes 3. With the main power off, the hose plugged in, and c. Check for continuity between Pin 3 on the J13 wire harness from the connector J13 still removed harness, and the bottom of the right 20-amp from the temperature control board: hose breaker.

  • Page 13: E04: Fluid Temperature Sensor (Fts) Or "A" Or "B" Thermocouple Not Connected

    Temperature Control Diagnostic Codes 4. Check 50A (806) and 20A (817A) circuit breakers, If you do not measure line voltage, the Temperature page 32. Control Board is bad – replace the Temperature Control Board. 5. Test current sensor continuity, page 46. 8.

  • Page 14: E05: Board Overtemperature

    Temperature Control Diagnostic Codes a. Remove plug J1 (Green 14-pin terminal block) 2. Check cable connections between all hose lengths. from the temperature control board and make 3. Check temperature sensor connection at J1 on tem- sure all pins are securely connected. perature control board, page 38.

  • Page 15: Motor Control Diagnostic Codes

    Motor Control Diagnostic Codes Motor Control Diagnostic Codes Motor control diagnostic codes E21 through E29 appear Alarms can also be cleared, except for code 23, on pressure display. by pressing There are two types of motor control codes: alarms and warnings.

  • Page 16: E21: No Component A Transducer

    Motor Control Diagnostic Codes E21: No component A without removing the existing pressure transducers from the fluid manifold. transducer a. Unplug the “A” transducer from the Motor con- trol board socket (page 36) and replace with 1. Check transducer A connection at J3 on the motor “test”...
  • Page 17 Motor Control Diagnostic Codes 2. Run the unit to build up some pressure (1000 – If the gauge readings are not equal. 1200 psi). Shut down the unit, clear the alarm and 1. Clear the error and balance the pressures using the power back up.

  • Page 18: E25: High Line Voltage

    Motor Control Diagnostic Codes E25: High line voltage If the E27 error code is still there, double check if pins 1 and 2 are jumpered properly. If jumpered properly, then it would appear that the problem is with in the motor Supply voltage too high.

  • Page 19: E29: Brush Wear

    Communication Diagnostic Codes E29: Brush Wear 3. Check wiring. The yellow brush sensor wire coming out of the brush may be routed online with the com- mutator wiring (thick red wire), causing a false CAUTION alarm. Reroute the yellow wire coming out of the Prolonged operation of motor after a brush wear brush, away from the commutator wiring.

  • Page 20: Troubleshooting

    Troubleshooting Troubleshooting PROBLEM CAUSE SOLUTION Reactor does not operate. No power. Plug in power cord. Turn main power ON Turn circuit breakers ON, page 32. Red stop button circuit open. Check button connections. See page 50 and electrical diagrams. Motor does not operate. Loose connections.
  • Page 21 Troubleshooting PROBLEM CAUSE SOLUTION No display. Main power OFF. Turn main power ON Loose display cable. Check cable connections, page 50. Both display boards failed. Check boards, replace; page 50. No temperature display. Loose display cable. Check cable connections, page 50. Failed temperature control board.
  • Page 22 Troubleshooting PROBLEM CAUSE SOLUTION No heat in A or B zones. Circuit breaker(s) tripped. Reset breaker CB3 or CB4, page 32. Heat turned off. Press zone keys. Temperature control alarm. Check temperature displays for diag- nostic code, page 10. Defective heater. Replace, page 40.
  • Page 23 Troubleshooting PROBLEM CAUSE SOLUTION No hose heat. Loose hose electrical connections. Check connections. Repair as neces- sary. Circuit breakers tripped. Reset breakers (CB1 or CB2), page Hose zone not turned on. Press zone key. A and B temperature setpoints too Check.

  • Page 24: Repair

    Repair Repair Pump Removal 5. Shut off both feed pumps. Close both fluid inlet ball WARNING valves (B). Pump rod and connecting rod move during operation. Moving parts can cause serious injury such as pinch- ing or amputation. Keep hands and fingers away from connecting rod during operation.
  • Page 25 Repair Steps 7-9 apply to pump A. See F . 4. To discon- Steps 10 and 11 apply to pump B. See F . 5. nect pump B, go to steps 10 and 11. 10. Disconnect fluid inlet (C) and outlet (D). Also discon- 7.

  • Page 26: Pump Installation

    Repair Pump Installation 2. Continue screwing pump into housing until fluid out- let (D) is aligned with steel tube and top threads are +/- 1/16 in. (2 mm) of bearing face (N). Steps 1-5 apply to pump B. See F .
  • Page 27 Repair Steps 6-12 apply to pump A only. See F . 7. 9. Connect component A outlet tube loosely at pump and at heater. Line up tube, then tighten fittings securely. 6. Ensure star-shaped locknut (G) is screwed on pump with flat side up.

  • Page 28: Drive Housing

    Repair Drive Housing Removal The A side drive housing includes cycle counter switch (321). If replacing this housing, remove pins (P) and switch. Reinstall pins and switch on new drive housing. Switch wires connect to J10 1. Turn main power OFF .
  • Page 29 Repair 306B 306A Crankshaft must be in line with crankshaft at other end of motor. TI3152A . 8. Drive Housing 309574L...

  • Page 30: Motor Brushes

    Repair Motor Brushes 5. Loosen terminal screw (R). Pull away brush lead (L), being careful motor lead terminal (T) remains in place. Remove and discard brush (B). Brush Removal Replace brushes worn to less than 1/2 in. (13 mm). Brushes wear differently on each side of motor;...
  • Page 31 Repair 2. Slide terminal (L) under terminal screw (R). Make 4. Install spring clip (C) and push in until hooks (H) sure motor lead terminal (T) is still connected at catch slots in housing. Incorrect installation may jam screw. Tighten screw. clip 01227-2 01227-6...

  • Page 32: Circuit Breaker Module

    Repair Circuit Breaker Module 3. Using an ohmmeter, check for continuity across cir- cuit breaker (top to bottom). If no continuity, trip breaker, reset, and retest. If still no continuity, replace breaker as follows: 1. Turn main power OFF . Disconnect power a.

  • Page 33: Electric Motor

    Repair Electric Motor c. Unplug 3-pin connector J7 from board. d. Thread cables through top of cabinet to free Removal motor. 1. Turn main power OFF . Disconnect power CAUTION Motor is heavy. Two people may be required to lift. supply.

  • Page 34: Motor Control Board

    Repair Motor Control Board 8. Set DIP switch (SW2) on new board. See below for factory settings. See F . 10 for location on board. Motor control board has one red LED (D11 for WARNING 245980, D7 for 245981). Power must be on to check.
  • Page 35 Repair 245980 Motor Control, for E-20 and E-XP1 DIP Switch (SW2) Settings Model E-20 J3 (A) J8 (B) TI3178b-3 Model E-XP1 TI3178b-4 TI3153A-1 245981 Motor Control, for E-30 and E-XP2 DIP Switch (SW2) Settings Model E-30 J5 (A) TI3178b-2 J3 (B) Model E-XP2 TI3178b-1 Apply 110009 thermal heatsink...

  • Page 36: Transducers

    Repair Transducers 4. Disconnect transducer cables at board; see F . 10, page 35. Reverse A and B connections and check if diagnostic code follows, page 16. 5. If transducer fails test, thread cable through top of 1. Turn main power OFF .
  • Page 37 Repair 2. Relieve pressure, page 9. 3. Check fuses (F) at left of breaker module, F . 12. 1. Turn main power OFF . Disconnect power Replace if blown. If good, continue with step 4. supply. 4. Refer to electrical diagrams. Disconnect fan wires from fuses (F).

  • Page 38: Temperature Control Board

    Repair Temperature Control Board 2. Relieve pressure, page 9. 3. Refer to electrical diagrams. Temperature control board is on left side inside cabinet. Temperature control board has seven green LEDs. Power must be on to check. See F . 10 for 4.

  • Page 39: 245979 Temperature Control Board

    Repair 245979 Temperature Control Board Apply 110009 thermal heatsink compound to mating surfaces. TI2572a . 13. Temperature Control Board 309574L...

  • Page 40: Heater

    Repair Heater Heater Element 1. Turn main power OFF . Disconnect power supply. 2. Relieve pressure, page 9. WARNING Read warnings, page 7. Wait for heaters to cool before repairing. 3. Wait for heaters to cool. 4. See F . 14. Remove tape and wire connector (63, not shown), and disconnect heater element wires (W) from heater wire harness.
  • Page 41 Repair Thermocouple c. Apply PTFE tape and thread sealant to male threads and tighten thermocouple housing (H) into tube (201). 1. Turn main power OFF . Disconnect power d. Push in thermocouple (211) so tip (T) contacts supply. heater element (207), avoiding mixer (202). 2.
  • Page 42 Repair Overtemperature Switch 3. Wait for heaters to cool. 4. Disconnect one leadwire from overtemperature switch (208), F . 15. Test across switch with ohm- 1. Turn main power OFF . Disconnect power meter. Resistance must be approximately 0 ohms. supply.

  • Page 43: Heated Hose

    Repair Heated Hose Refer to the heated hose manual 309572 for hose replacement parts. Check Hose Connectors 1. Turn main power OFF . Disconnect power supply. 2. Relieve pressure, page 9. Whip hose must be connected. TI2726a 3. Disconnect hose electrical connector (D) at Reac- tor, F .

  • Page 44: Fluid Temperature Sensor (Fts)

    Repair Fluid Temperature Sensor 2. Connect whip hose ground wire (K) to ground screw on underside of FTS. (FTS) 3. Install FTS in reverse order of removal. Leave slack (G) in cables as stress relief, to prevent cable failure. Test/Removal 4.
  • Page 45 Repair 5. Carefully measure the voltage at the white Ander- son connector for the hose. You should not get a 4. Turn on heat zone by pressing voltage reading. If you do get a voltage reading, the SCR on the circuit board has been damaged and the board needs to be replaced.
  • Page 46 Repair Wire Harness Check Test Hose Continuity c. Connector pin 5 (P5) and T3 on 50A hose circuit breaker (806). (380 V Only) In-rush Current Limiter Test 1. Turn main power OFF . Disconnect power 1. Ensure all harnesses, cables and connectors are supply.
  • Page 47 Repair Detail B: Circuit Breaker Module and Hose Heat Wire Harness T1 T2 817A To J1 Connector, pins 5 and 6 J13 on Temperature Control Board TI4335A TI3470b Part No. 15B352 Transformer (Models E-30 and E-XP2) shown . 19. Transformer Continuity Tests 309574L...
  • Page 48 Repair Transformer Primary Check Transformer Secondary Check 1. Ensure that all harnesses, cables, and connectors 1. Ensure that all harnesses, cables, and connectors are properly connected. Connect hose. are properly connected. Connect hose. 2. Disconnect wire harness (C1) from wire harness 2.
  • Page 49 Repair Replace Transformer 2. Open Reactor cabinet. 3. Remove bolts holding transformer to cabinet floor. Use this procedure to replace transformer. Slide transformer forward. 4. Unplug 2-pin wire harness connector (C) from wire harness coming from temperature control board. 1. Turn main power OFF .

  • Page 50: Display Module

    Repair Display Module If replacing both displays, label temperature dis- play cables TEMP and pressure display cables PUMP before disconnecting. Temperature and Pressure Displays 7. Disconnect cable connectors J1 and J13 from back of temperature display (401) or pressure display CAUTION (402).
  • Page 51 Repair Apply medium strength thread sealant. TI2574A Detail of Membrane Switches and Display Boards Pressure Display Temperature Display 402c 402a 402b 401c 401a 401b TI3172a . 21. Display Module 309574L...
  • Page 52 Repair Red Stop Button 2. Relieve pressure, page 9. 3. Refer to electrical diagrams. CAUTION 4. Put on static conductive wrist strap. Before handling board, put on a static conductive wrist strap to protect against static discharge which can 5. Remove screws (409, 410) and cover (404), F .

  • Page 53: Parts

    Parts Parts Reactor Assembly (Model E-XP1 Shown) 57, 38 TI3764a-1 23, 38 TI3764a 41, 102 7, 12, 41 113, 119 13, 26, 35 109, 111, 112 TI3765a-2 66, 66a 309574L...
  • Page 54 Parts 29, 42 Not Shown 122* * In-rush current limiter 288359 is only included on 380V machines. See page 58 for fuse information. TI2606a (380V models only) 29, 42 TI2605A 39, 73 309574L...

  • Page 55: Reactor Assembly

    Reactor Assembly Reactor Assembly Common Parts See pages 56 through 58 for parts that vary by model. Ref. Ref. Part No. Description Part No. Description 15B775 COVER, wire access 245954 FRAME; page 59 246895 COVER, heater, back HEATER; page 56 and 58 15B798 COVER, heater, front MODULE, proportioner;...

  • Page 56: Parts That Vary By Model

    Reactor Assembly Parts that Vary by Model Use the tables on this and the next 2 pages to find parts that vary by model. Find the ref. no. of part in left column, and Reactor model in top row. Intersection is correct part no. See page 55 for parts common to all models.
  • Page 57 Reactor Assembly Reactor Models Ref. 246024 246025 246026 246028 246029 246030 246031 246032 246033 246034 246035 246036 No. Description E-XP1 E-20 E-30 E-XP2 E-XP1 E-20 E-30 E-XP2 E-XP1 E-20 E-30 E-XP2 ▲ LABEL, warning 198278 198278 198278 198278 198278 198278 CABLE, harness, 15B385 15B385 15B385 15B385...
  • Page 58 Reactor Assembly Reactor Assembly Parts Continued Reactor Models Reactor Models 248657 248658 248659 248657 248658 248659 E-30 E-30 E-30 E-30 E-30 E-30 Ref. w/15.3 w/15.3 w/15.3 Ref. w/15.3 w/15.3 w/15.3 No. Description No. Description BRACKET, heater HEATER; pages 245963 24962 245962 BRACKET, heater 15C733 15C733 15C733 59, 35...
  • Page 59 Reactor Assembly Reactor Frame Fluid Heater 245954 Frame 245962 10.2 kW Heater, for E-30 and E-XP1 Reactor Ref. No. 86 not included with heater. Order separately, see page 57. TI2512b TI2513A Ref. Ref. Part No. Description Part No. Description 246204 FRAME 15B134 HOUSING...
  • Page 60 Reactor Assembly 245963 7.65 kW Heater, for E-XP2 and E-30, 245975 6 kW Heater, for E-20 Reactor with 15.3kW of heat, Reactor (2 required) Ref. No. 86 not included with heater. Order separately, see page 57. Ref. No. 86 not included with heater. Order separately, see page 57.
  • Page 61 Reactor Assembly Proportioner Module 245956 Module, for E-20 and E-XP1 245957 Module, for E-30 245959 Module, for E-XP2 *308 **310 310** 306B *307 306A Detail of Cycle Counter Switch Flat side faces up. TI2511A TI3250a 309574L...
  • Page 62 Reactor Assembly 245956 Module, for E-20 and E-XP1 245957 Module, for E-30 245959 Module, for E-XP2 Ref. Ref. Part No. Description Part No. Description 114686 SCREW, cap, socket-hd; 5/16-18 x 245965 MOTOR; 245956 3-1/4 in. (83 mm); 245957, 245959 245966 MOTOR;...
  • Page 63 Reactor Assembly Display 245974 Display TI2574A 402c 402a 402b 401c 401a 401b TI3172a Ref. Ref. Part No. Description Part No. Description 15B293 GASKET 245978 DISPLAY, pressure; includes 15B292 COVER 401a-401c 15B291 PLATE 401a 246130 . BOARD, circuit 246287 HARNESS, wire, red stop button 401b 246478 .
  • Page 64 Reactor Assembly Temperature Control 245979 Temperature Control Apply 110009 thermal heatsink compound to mating surfaces. TI2575A-1 Ref. Part No. Description 15B779 HEAT SINK 246194 BOARD, temperature control 117683 SCREW, 6-32 x 1-1/2 in. (38 mm) 117526 SPACER 104590 SCREW, machine; 6-32 x 3/8 in. (10 309574L...
  • Page 65 Reactor Assembly Motor Control 245980 Motor Control, for E-20 and E-XP1 TI3153A Apply 110009 thermal heatsink compound to mating surfaces. Ref. Part No. Description 15B297 HEAT SINK 246195 BOARD, motor control 107156 SCREW, machine; 6-32 309574L...
  • Page 66 Reactor Assembly 245981 Motor Control, for E-30 and E-XP2 Apply 110009 thermal heatsink compound to mating surfaces. Motor harness (609) plugs in here. TI2576A Ref. Part No. Description 15B297 HEAT SINK 246196 BOARD, motor control 104590 SCREW, machine; 6-32 x 3/8 in. (10 mm) 117526 SPACER 117683...
  • Page 67 Reactor Assembly Fluid Manifold 246154 Fluid Manifold Apply 113500 thread lock (blue). Torque to 355-395 in-lb (40.1-44.6 N•m). Apply PTFE tape or thread sealant to tapered threads. Torque to 175-195 in-lb (19.8-22.0 N•m). Lubricate ends of spring when assembling. Assemble valves (702) and handles (709) with handles facing away from each other. Assemble seat (707) with lapped seat facing valve (702).
  • Page 68 Reactor Assembly Circuit Breaker Modules 230V, 3 Phase Circuit Breaker Modules For wiring and cable connections, refer to electri- cal diagrams supplied. See page 71 for parts list. Part No. 246087 (E-20, E-30, E-XP1) 803, 814, Ref. No. 92 not included with module. Order separately, see page 57.
  • Page 69 Reactor Assembly 230V, 1 Phase Circuit Breaker Modules For wiring and cable connections, refer to electri- cal diagrams supplied. See page 71 for parts list. Part No. 246090 (E-20, E-30, E-XP1) 803, 814, Ref. No. 92 not included with module. 1880 Order separately, see page 57.
  • Page 70 Reactor Assembly 380V, 3 Phase Circuit Breaker Modules For wiring and cable connections, refer to electri- cal diagrams supplied. See page 71 for parts list. Part No. 246096 (E-20, E-30, E-XP1) Ref. No. 92 not included with module. 803, Order separately, see page 57. 814, 1880 Part No.
  • Page 71 Reactor Assembly Circuit Breaker Modules Parts List Breaker Modules 246087 246090 246096 230V, 3 θ 230V, 1 θ 380V, 3 θ Ref. 246087 (E-30 246089 246090 (E-30 246092 246096 (E-30 246098 230V, 3 θ 230V, 3 θ 230V, 1 θ 230V, 1 θ...

  • Page 72: 248669 Conversion Kit

    Reactor Assembly 248669 Conversion Kit Ref. Convert and phase E-XP2 to an E-30 with 15.3kW of Part No. Description heat by changing pump lowers, bearings, and changing 118463 ELBOW, swivel; 3/4 npt(m) x 1 in. npt(f) the Motor Control DIP settings to that of an E-30. For 245927 HOUSING, bearing removal and installation of pump lowers and bearings,...

  • Page 73: Technical Data

    Technical Data Technical Data Category Data Maximum Fluid Working Pressure Models E-20 and E-30: 2000 psi (14 MPa, 140 bar) Model E-XP1: 2500 psi (17.2 MPa, 172 bar) Model E-XP2: 3500 psi (24.1 MPa, 241 bar) Maximum Fluid Temperature 190°F (88°C) Maximum Output Model E-20: 20 lb/min (9 kg/min) Model E-30: 30 lb/min (13.5 kg/min)

  • Page 74: 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 manual is also suitable for:

Reactor e-xp2Reactor e-30Reactor 246024Reactor 246025Reactor e-xp1Reactor 246028 ... Show all

Table of Contents

Save PDF