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Graco Reactor E-XP1 Troubleshooting Manual
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Graco Reactor E-XP1 Troubleshooting Manual

Error code trouble shooting
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Reactor Error Code Trouble Shooting Guide
Rev 2.6 (02/2014)
Page 1

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Summary of Contents for Graco Reactor E-XP1

  • Page 1 Reactor Error Code Trouble Shooting Guide Rev 2.6 (02/2014) Page 1...
  • Page 2 Read, understand and follow all instruction manuals and warning labels supplied with all equipment. Only trained and qualified personnel should perform repairs on the equipment. To access the latest manuals in your preferred language go to “www.graco.com” and use the “Search” function.
  • Page 3 Reactor Error Code Trouble Shooting Guide Rev 2.6 (02/2014) Page 3...
  • Page 4 Reactor Error Code Trouble Shooting Guide Table of Contents HEAT CONTROL ERROR LIST E01 - High Fluid temperature E02 - High Current E03 - No current E04 - Missing t/c thermocouple E05 - Power module over temperature E06 - Control module to power module communications error E09 - Missing display E99 - Display communications error MOTOR CONTROL ERROR LIST - E and H Series...
  • Page 5 Reactor Error Code Trouble Shooting Guide (Return to Table Of Contents) E01: High Fluid temperature Note: The display that is showing the E01 error is the zone that is seeing the error.  Check to see if you really do have high a temperature, by using an external temperature-sensing device.
  • Page 6 Reactor Error Code Trouble Shooting Guide One of the over temperature switches (Ref # 308) picked up a high fluid temp greater than 230° F (110°C). At 190° F (88°C) the contacts close again.  Check continuity of the over temperature switches by removing the J1/SENSOR B connector from the temperature control module socket.
  • Page 7 Reactor Error Code Trouble Shooting Guide Primary Heaters / Heater Elements 6.0 kW – 1500w (30-35 ohms) x 2 each per side = 15–17.5 ohms combined. 10.2 kW – 2550w (18-21 ohms) x 2 each per side = 9-10.5 ohms combined. 8.0 kW –...
  • Page 8 Reactor Error Code Trouble Shooting Guide Rev 2.6 (02/2014) Page 8...
  • Page 9 Reactor Error Code Trouble Shooting Guide Heater modules failed to turn off any heat zone, causing a run-away condition.  Exchange zone module with another one. Turn zone on and check for error. If error moves to another zone, replace the faulty module. (When there is a high current error, the LED on that zone’s module will turn red while the error is displayed.
  • Page 10 Reactor Error Code Trouble Shooting Guide  One of the over temperature switches failed in the “open” position. Open circuit in the over temperature wiring harness, or switch “B” jumper is loose or open on a dual zone heater systems. ...
  • Page 11 Reactor Error Code Trouble Shooting Guide (Return to Table Of Contents) E02: High Current Note: The display that is showing the E02 error is the zone that is seeing the error. Causes: Electrical short in the heater module. o Hold down actual temperature key for each zone to view current output when the heat module is on.
  • Page 12 Reactor Error Code Trouble Shooting Guide current error, the LED on that zone’s module will turn red while the error is displayed. 2) For Hose zone, electrical short in the hose heat transformer o Check continuity of transformer windings, and if shorted to ground. o Perform the hose heat transformer primary and secondary check.
  • Page 13 Reactor Error Code Trouble Shooting Guide (Return to Table Of Contents) E03: No Zone Current Note: The display that is showing the E03 error is the zone that is seeing the error. Causes: Tripped circuit breaker in the electrical cabinet. o For HOSE, check 183CB HOSE, and 178 CB HOSE.
  • Page 14 Reactor Error Code Trouble Shooting Guide 3) Hose heat transformer not functioning. Set Hose Zone target key below current actual temperature and turn on the Hose Zone only. (not “A” or “B”) o Perform transformer secondary check.  Measure 90 – 100 VAC between T1 on183CB-HOSE and T2 on POD HOSE of Hose Heater Module.
  • Page 15 Reactor Error Code Trouble Shooting Guide 238CR 5) Single phasing in a three phase system o Verify line voltage between all 3 legs of power. L1 to L2, L2 to L3, and L1 to L3. Note: If the customers incoming power has a Wild Leg/High Leg it must be installed on the L3 terminal.
  • Page 16 Reactor Error Code Trouble Shooting Guide E04: Fluid Temperature Sensor (FTS), or “A” or “B” (Return to Table Of Contents) Thermocouple not Connected. Note: The display that is showing the E04 error is the zone that is seeing the error. Causes: 1) E04 on the “A”...
  • Page 17 Reactor Error Code Trouble Shooting Guide 2) E04 on the hose heat display = While the unit was powered on, the Fluid Temperature Sensor (FTS) lost communication with the temperature control module.  Check the electrical connections at the temperature control module. o Looking at plug J1/ SENSOR B on the temperature control module, check and see if pins 10, 11 &...
  • Page 18 Reactor Error Code Trouble Shooting Guide  Check the FTS with an ohmmeter. o Locate the FTS. o With the main power off, unplug the FTS and measure the pins on the FTS.  Pins 1 to 2 10 Ohms ...
  • Page 19 Reactor Error Code Trouble Shooting Guide (Return to Table Of Contents) E05: Control Module Over Temperature Cause: o The control module has an on-board temperature sensor. Heat is turned off if the module temperature exceeds 185°F (85°C) to prevent damage to the circuit board. (See also High Motor Temp section under E27).
  • Page 20 Reactor Error Code Trouble Shooting Guide E09: Heater and Display Communication Malfunction (Return to Table Of Contents) Cause: Communications between the heater control module and the display is not functioning. When communication is lost, the display will show E09.  Check all wiring between the display and the heater control module. o Pay close attention to the wire crimping on plug J5/DISPLAY C of temperature control module.
  • Page 21 Reactor Error Code Trouble Shooting Guide (Return to Table Of Contents) E21: No Component A Transducer Causes: 1) Faulty pressure transducer 24K999. 2) Faulty connection on J3/J5 of motor control board. Rev 2.6 (02/2014) Page 21...
  • Page 22 Reactor Error Code Trouble Shooting Guide 3) Checking for a E21 error o Check transducer A connection at J3, (E-20/E-XP1, H-series) or J5, (E-30/E-XP2) on motor control board. o Clean the plug and socket of transducer connection by unplugging and spraying commercially available contact cleaner and reconnecting.
  • Page 23 Reactor Error Code Trouble Shooting Guide (Return to Table Of Contents) E22: No Component B Transducer Causes: 1) Faulty pressure transducer 24K999. 2) Faulty connection on J8/J3 of motor control board. 3) Checking for a E22 error o Check transducer B connection at J8, (E-20/E-XP1, H-series) or J3, (E-30/E- XP2), on motor control board.
  • Page 24 Reactor Error Code Trouble Shooting Guide E23: High Pressure (Return to Table Of Contents) Causes: 1) Jumper wire on plug J10 (E-20/E-XP1) or J7 (E-30/E-XP2) pin 7 to pin 10 on the motor control board is loose or has become disconnected. o On the current units without the over pressure switches Check the jumpers and the wiring.
  • Page 25 Reactor Error Code Trouble Shooting Guide 2) The Reactor motor control board is receiving a signal from the “A” or “B” pressure transducer that is above 3000 psi for (E-20, E-30, H-25, H-40, H-50), or above 4500 psi for (E-XP1, E-XP2, H-XP2, H-XP3). o Clean the plug and socket of transducer connection by unplugging and spraying commercially available contact cleaner and reconnecting.
  • Page 26 Reactor Error Code Trouble Shooting Guide 4) Material cavitation A or B side.  Verify feed supply pumps or ball valves are not off.  That the material drums are not empty.  That the filter strainers are not restricted. ...
  • Page 27 Reactor Error Code Trouble Shooting Guide (Return to Table Of Contents) E24: Pressure Imbalance There is a pressure imbalance between the “A” and “B” fluids that is higher than allowed by the motor control board. Available control settings are between 100 – 999 psi, or 7 –...
  • Page 28 Reactor Error Code Trouble Shooting Guide 1a) One of the pressure transducers has failed. o The digital display on a Reactor always shows the higher of the two pressures. As soon as the higher analog pressure drops below the lower analog pressure the digital display will switch to the new highest reading.
  • Page 29 Reactor Error Code Trouble Shooting Guide  Run the unit to build up pressure (1000 – 1200 psi) with the motor ON key. When the machine then stalls at set pressure, press the motor OFF key to clear the E24 warning, but don’t depressurize the unit. Rev 2.6 (02/2014) Page 29...
  • Page 30 Reactor Error Code Trouble Shooting Guide  Check the analog gauges to see which pressure is higher. And then check and see if the pump display pressure matches. If it does, that would indicate that the motor control board is “Seeing” that transducer. ...
  • Page 31 Reactor Error Code Trouble Shooting Guide  The last test is to determine if the pressure transducer has failed or if the socket on the pressure control board has gone bad.  Swap the transducer plug-ins on the motor control board. (J3 & J8 for the E-20 &...
  • Page 32 Reactor Error Code Trouble Shooting Guide o If we can determine what chemical “A” or “B” is coming out of the gun, then we can focus on the missing chemical side. This will immediately save us time by checking the side that is lacking chemical or is the cause of our problem.
  • Page 33 Reactor Error Code Trouble Shooting Guide 2c) If “B” (RESIN) side is lacking at the gun, and “B” side fluid gauge reading is higher than the “A” side, this is an indication of restriction on the “B” side, anywhere from the gun mix chamber back to the fluid outlet manifold.
  • Page 34 Reactor Error Code Trouble Shooting Guide (Return to Table Of Contents) E25: High Line Voltage Cause: 1) Supply voltage too high. Check voltage requirements in technical data section of the manual. Verify input voltage is correct to motor control board for your system. (Return to Table Of Contents) E26: Low Line Voltage Cause:...
  • Page 35 Reactor Error Code Trouble Shooting Guide E27: High Motor Temperature (Return to Table Of Contents) Causes: 1) Motor temperature too high. o Reduce fluid pressure, gun mix chamber size, or move the Reactor to a cooler location. Allow one hour for cooling before re-setting. 2) Cooling fan is not operating properly.
  • Page 36 Reactor Error Code Trouble Shooting Guide Motor Control Board, H-Series  The E27 error should be gone. o If the E27 error is gone and the motor is truly not overheated then the problem is likely in the motor/motor wire harness assembly. You can verify this by measuring the resistance between the 2 yellow wires that go to pins 1 &...
  • Page 37 Reactor Error Code Trouble Shooting Guide (Return to Table Of Contents) E28: High Motor Current (E-Series Only) Causes: 1) Failed motor or motor electrical component. 2) Something in the drive system broken (locked up pump, broken gear, etc.) not allowing the motor to rotate, causing high current. 3) Possible short in the motor control board.
  • Page 38 Reactor Error Code Trouble Shooting Guide (Return to Table Of Contents) E29: Brush Wear (E-Series Only) Causes: 1) Normal brush wear, causing the brush sensor to come in contact with the motor commutator. o Replace the brushes p/n-234037. 2) The spade plug inside the motor housing is twisted and making contact with the commutator side of the brush sensor assembly, causing a false alarm.
  • Page 39 Reactor Error Code Trouble Shooting Guide (Return to Table Of Contents) E30: Momentary Loss of Communication Causes: o Communications between the display and the motor control board or the motor control board has been momentarily lost. Normally, when communication is lost, the corresponding display will show E99. The corresponding control board will register E30 (The red LED will flash 30 times).
  • Page 40 Reactor Error Code Trouble Shooting Guide  Capacitor check procedure o Remove the Reactor from power source and wait 15 minutes to allow the capacitor to drain the stored energy through the motor circuit. Locate the large blue capacitor in the lower cabinet, upper right hand corner. Perform a general inspection of the capacitor for shape distortion, cracks, or leakage.
  • Page 41 Reactor Error Code Trouble Shooting Guide (Return to Table Of Contents) E31: Reversing Switch Failure/High Cycle Rate H-Series Only)  Exceeded 65 cpm H-40, H-50, H-XP3  Exceeded 30 cpm H-25, H-XP2 Causes: Too large a flow rate o mix chamber too large for system selected o Fluid pressure too high for mix chamber and system selected.
  • Page 42 Reactor Error Code Trouble Shooting Guide (Return to Table Of Contents) E99: Loss of Communication Causes: 1) Communications between the display and the motor control board or the temperature control board has been lost. When communication is lost, the corresponding display will show E99. ...
  • Page 43 Reactor Error Code Trouble Shooting Guide (Return to Table Of Contents) Recommend Start-up Technician Tool Set 1. Extech AC/DC True RMS Clamp Meter P/N EX830 or equivalent. 2. Pocket Thermometer 3. Craftsman Tool Set P/N 37154 or equivalent. 4. Craftsman Plier Set P/N 45419 or equivalent. 5.
  • Page 44 Reactor Error Code Trouble Shooting Guide 6. Chain Wrench 12” 7. Strap Wrench 8. Adjustable Wrenches 6 – 10 – 12” 9. Pipe Wrench 10 – 18” 10. Wire Strippers 11. Ball Peen Hammer 4 – 12 oz 12. Dead Blow Hammer (soft face) Rev 2.6 (02/2014) Page 44...