Graco Reactor 2 E-30 Repair And Parts Manual
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Graco Reactor 2 E-30 Repair And Parts Manual

Proportioning proportioning system
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Repair, Parts
Reactor 2 2 2 E E E - - - 30
Reactor
Reactor
Proportioning
Proportioning System
Proportioning
Electric, heated,
heated, plural
plural component
Electric,
Electric,
heated,
plural
coatings.
coatings.
coatings. For
For professional
For
professional
professional use
(classified)
(classified) locations.
(classified)
locations.
locations.
Important
Important Safety
Important
Safety Instructions
Safety
Read all warnings and instructions in this manual before using the
equipment. Save these instrustions.
30 and
and E E E - - - XP2
XP2
30
and
XP2
System
System
component proportioning
proportioning system.
component
proportioning
use
use only.
only. Not
only.
Not approved
Not
approved for
approved
Instructions
Instructions
PROVEN QUALITY. LEADING TECHNOLOGY.
system. For
For spraying
spraying polyurethane
system.
For
spraying
for use
for
use in in in explosive
use
explosive atmospheres
explosive
333024S
polyurethane foam
foam and
and polyurea
polyurethane
foam
and
atmospheres or or or hazardous
atmospheres
hazardous
hazardous
EN
polyurea
polyurea

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Summary of Contents for Graco Reactor 2 E-30

  • Page 1 Repair, Parts Reactor 2 2 2 E E E - - - 30 30 and and E E E - - - XP2 Reactor Reactor Proportioning Proportioning Proportioning System System System 333024S Electric, heated, heated, plural plural component component proportioning proportioning system.

  • Page 2: Table Of Contents

    Repair Electric Motor........58 Technical Specifications........110 Repair Circuit Breaker Module ...... 59 Notes ............. 112 Replace Fluid Inlet Sensor......60 Replace Flow Meter ........60 Graco Extended Warranty for Reactor® 2 Replace Pressure Transducers ..... 61 Components ........113 333024S...

  • Page 3: Warnings

    Warnings 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 symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings.
  • Page 4 Warnings WARNING WARNING WARNING SKIN SKIN SKIN INJECTION INJECTION INJECTION HAZARD HAZARD 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 surgical treatment treatment.
  • Page 5 Warnings WARNING WARNING WARNING THERMAL THERMAL THERMAL EXPANSION EXPANSION HAZARD EXPANSION HAZARD 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.
  • Page 6 Warnings WARNING WARNING WARNING EQUIPMENT EQUIPMENT EQUIPMENT MISUSE MISUSE HAZARD MISUSE HAZARD 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.

  • Page 7: Important Isocyanate Information

    Important Isocyanate Information Important Isocyanate Isocyanate Information Information Important Important Isocyanate Information Isocyanates (ISO) are catalysts used in two component materials. Isocyanate Conditions Conditions Isocyanate Isocyanate Conditions Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and atomized particulates.
  • Page 8 Important Isocyanate Information Material Self Self - - - Ignition Ignition Moisture Sensitivity Sensitivity of of of Isocyanates Isocyanates Material Material Self Ignition Moisture Moisture Sensitivity Isocyanates Exposure to moisture (such as humidity) will cause ISO to partially cure, forming small, hard, abrasive crystals that become suspended in the fluid.

  • Page 9: Models

    Models Models Models Models Reactor 2 2 2 E E E - - - 30 30 and and E E E - - - 30 30 Elite Elite Reactor Reactor Elite All elite systems include fluid inlet sensors, ratio monitoring, and Xtreme-Wrap 50 ft (15 m) heated hose. For part numbers, see Accessories, page E E E - - - 30...
  • Page 10 Models Reactor 2 2 2 E E E - - - XP2 XP2 and and E E E - - - XP2 XP2 Elite Elite Reactor Reactor Elite All elite systems include fluid inlet sensors and Xtreme-Wrap 50 ft (15 m) heated hose. For part numbers, see Accessories, page Model Model...

  • Page 11: Approvals

    Integrated PowerStation, Tier 4 Final, 20 cfm 979202 Integrated PowerStation, Tier 4 Kit Number Number Description Number Description Description Final, 35 cfm 24U315 Air Manifold Kit (4 outlets) 24U314 Wheel and Handle Kit 16X521 Graco InSite Extension cable, 24.6 ft (7.5 m) 333024S...

  • Page 12: Supplied Manuals

    Reactor 2 E-30 and E-XP2 Component Manuals Manuals in in in English English Component Component Manuals English Operation 333091 Reactor 2 E-30 and E-XP2 Startup System Manuals Manuals System System Manuals Quick Guide 333023 Reactor 2 E-30 and E-XP2 Operation 333092...

  • Page 13: Troubleshooting

    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. Or, manually navigate to help.graco.com and search for the active error. To avoid injury due to unexpected machine...
  • Page 14 Online Online Troubleshooting Troubleshooting Troubleshooting See help.graco.com for more detail on troubleshooting errors. NOTE: NOTE: 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, including date, time, and description.
  • Page 15 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution A4DA Heater A High Current A Short circuit in Check wiring for touching wires. heater wiring. Bad Heater. Confirm resistance of heater. Heater resistance should be 18–21 Ω...
  • Page 16 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution A8DA Heater A No Current A Tripped circuit Visually check circuit breaker for a breaker. tripped condition. Loose/broken Check heater wiring for loose wires. connection.
  • Page 17 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution CACM MCM Commu- Cross threaded CAN cables carry 24 V dc power and nication Error CAN cable. communication between modules. A cross threaded CAN cable connector may cause problems with communication and/or power to modules.
  • Page 18 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution CACT TCM Commu- Cross threaded CAN cables carry 24 V dc power and nication Error CAN cable. communication between modules. A cross threaded CAN cable connector may cause problems with communication and/or power to modules.
  • Page 19 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution DADX Pump Flow rate is too Mix chamber too large for system Runaway large. selected. Use mix chamber rated for system. Ensure the system has chemical and the feed pumps are operating correctly.
  • Page 20 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution F9DX High Machine is Mix chamber is too large for set Pressure/Flow operating above pressure. Cutback pressure/flow Set pressure is too high for given mix rating.
  • Page 21 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution K8NM Locked Rotor Software bug. A bug exists in older motor control Motor software that may falsely trigger this error code when there is neither a locked rotor, nor mechanical issues or damage to the proportioner motor.
  • Page 22 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution P0AX Pressure Pressure difference Ensure material flow is equally Imbalance A between A and B restricted on both material lines. High material is greater than the defined value.
  • Page 23 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution P2FA Low Inlet Inlet pressure lower Ensure that inlet pressure to the pump Pressure A than defined value. is sufficient. Value defined too Ensure that the low pressure alarm high.
  • Page 24 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution P6AX Pressure Loose/bad Check to ensure the pressure Sensor Error connection. transducer is properly installed and all wires are properly connected. Bad sensor.
  • Page 25 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution P7AX Pressure Pressure difference Ensure material flow is equally Imbalance A between A and B restricted on both material lines. High material is greater than the defined value.
  • Page 26 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution R1D0 Low Ratio/Low Damaged A-side Inspect the A-side (ISO) pump for Flow (A-side) (ISO) pump. damage. If necessary, replace the pump. Fluid leak between Inspect the fluid lines for leaking the A-side pump...
  • Page 27 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution T2DA Heater A Flow is too high at Use a smaller mix chamber that Temperature current setpoint. is rated for the unit in use. recirculating, decrease flow or decrease temperature setpoint.
  • Page 28 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution T2FA Inlet fluid Recirculate fluid through heaters until Temperature temperature is inlet fluid temperature is above defined Inlet A below the defined error level.
  • Page 29 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution T3NM Motor Cooling fan on • Ensure fan is always running when Temperature back of motor not machine is powered on. Cutback operating properly.
  • Page 30 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution T4DA Heater A High Bad RTD or bad Swap A and B heater output cables Temperature RTD placement and RTD cables and see if issue against heater.
  • Page 31 (Wrapping replacement insulation over the whole hose bundle is not sufficient for proper hose temperature control.) Replacement insulation is available from Graco or a hardware store. T4DH Hose High Increase hose setpoint so it is closer...
  • Page 32 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution T4EA Heater A High Overtemperature Heater was delivered too much Temperature power, causing the overtemperature switch sensed a Switch A fluid temperature switch to open.
  • Page 33 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution T4NM High High ambient Ensure ambient temperature is below Temperature temperature. 120° F (49° C) before using the Motor system. Cooling fan is not •...
  • Page 34 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution T6DH Hose Sensor Error Disconnected or Expose each hose RTD connection shorted RTD cable to check and retighten any loose Hose in hose or bad FTS.
  • Page 35 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution T6NM Sensor Error Disconnected Verify wiring between the motor or loose motor Motor temperature sensor and the module. temperature cable. Failed motor Measure resistance between pins temperature 1 and 3 on motor temperature...
  • Page 36 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution T8DH Hose Started spraying Wait until operating temperature has Temperature been reached before spraying or before heater Rise Hose reached operating recirculating.
  • Page 37 208 VAC wye (star). Contact Graco Technical Assistance. V3MB High Voltage B Incoming line Ensure incoming system power is voltage is too high.
  • Page 38 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution WBC0 Software Incorrect software Insert a system token into the ADM module and cycle the power. Wait Version Error version. until the upload is complete before removing the token.
  • Page 39 Troubleshooting System System System Before performing any troubleshooting procedures: 1. Relieve Pressure. See Pressure Relief Procedure, page 2. Turn main power switch OFF. 3. Allow equipment to cool. Problem Problem Problem Cause Cause Cause Solution Solution Solution Reactor ADM does not turn on. No power.
  • Page 40 Troubleshooting Hose Heat Heat System System Hose Hose Heat System Before performing any troubleshooting procedures: 1. Relieve Pressure. See Pressure Relief Procedure, page 2. Turn main power switch OFF. 3. Allow equipment to cool. Problem Cause Solution Problem Problem Cause Cause Solution Solution...
  • Page 41 Troubleshooting Problem Cause Solution Problem Problem Cause Cause Solution Solution Hose temperature exceeds A and/or B heaters are overheating Check primary heaters for either setpoint. material. a RTD problem or a failed element attached to RTD, see Electrical Schematics, page 103.
  • Page 42 Troubleshooting Problem Cause Solution Problem Problem Cause Cause Solution Solution Hose does not heat. FTS failed. Check FTS, see Repair Fluid Temperature Sensor (FTS), page FTS not installed correctly. FTS should be installed close to end of hose in same environment as gun.
  • Page 43 Troubleshooting Primary Heater Heater Primary Primary Heater Before performing any troubleshooting procedures: 1. Relieve Pressure. See Pressure Relief Procedure, page 2. Turn main power switch OFF. 3. Allow equipment to cool. Problems Problems 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.
  • Page 44 Troubleshooting Flow Meter Meter Flow Flow Meter Before performing any troubleshooting procedures: 1. Relieve Pressure. See Pressure Relief Procedure, page 2. Turn main power switch OFF. 3. Allow equipment to cool. Problems Problems Problems Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Problem Problem Problem...

  • Page 45: Pressure Relief Procedure

    Pressure Relief Procedure Pressure Relief Relief Procedure Procedure Pressure Pressure Relief Procedure 4. Close gun fluid inlet valves A and B. Follow the Pressure Relief Procedure whenever you see this symbol. 5. Shut off feed pumps and agitator, if used. 6.

  • Page 46: Shutdown

    Shutdown Shutdown Shutdown Shutdown 5. Press to deactivate the system. NOTICE NOTICE NOTICE Proper system setup, startup, and shutdown procedures are critical to electrical equipment reliability. The following procedures ensure steady 6. Turn off the air compressor, air dryer, and voltage.
  • Page 47 Shutdown 8. Close all fluid supply valves. 10. Engage gun piston safety lock then close fluid inlet valves A and B. Fusion Fusion Fusion Probler Probler Probler 9. Set PRESSURE RELIEF/SPRAY valves to SPRAY to seal out moisture from the drain line. 333024S...

  • Page 48: Flushing

    Flushing Flushing Flushing Flushing To flush feed hoses, pumps, and heaters separately from heated hoses, set PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION . Flush through bleed lines (N). To avoid fire and explosion: • Flush equipment only in a well-ventilated area. •...

  • Page 49: Repair

    Repair Repair Repair Repair 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. 1. Close the fluid inlet valve on the y-strainer inlet Repairing this equipment requires access to parts and shut off the appropriate feed pump.

  • Page 50: Change Pump Lubricant

    Repair Change Pump Pump Lubricant Lubricant Change Change Pump Lubricant 5. Thread the reservoir onto the cap assembly and place it in the bracket. Check the condition of the ISO pump lubricant daily. 6. Manually prime the ISO pump. Plug the small Change the lubricant if it becomes a gel, its color vent hole (H) between the tube grommets while darkens, or it becomes diluted with isocyanate.

  • Page 51: Clean Flow Meter

    Repair Clean Flow Flow Meter Meter Clean Clean Flow Meter 9. Reinstall the gears. a. Place the gear with the magnets (MG) on the 1. Perform Shutdown, page left pin of the housing. Perform Pressure Relief Procedure, page 3. Disconnect the flow meter cable. 4.

  • Page 52: Clean E-Xp2 Flow Meter

    Repair Clean E E E - - - XP2 XP2 Flow Flow Meter Meter Clean Clean Flow Meter 9. Reinstall the gears. a. Place the gear with the magnets (G) on the 1. Perform Shutdown, page left pin of the housing. Perform Pressure Relief Procedure, page 3.

  • Page 53: Remove Pump

    Repair Remove Pump Pump Remove Remove Pump 8. Route fluid to waste containers or supply tanks. Turn PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION . Ensure gauges drop to 0. Pump rod and connecting rod move during operation. Moving parts can cause serious injury such as pinching or amputation.
  • Page 54 Repair 11. Loosen locknut (G) by hitting firmly with a 12. Disconnect fluid inlet (C) and outlet (D). Also non-sparking hammer. Unscrew pump far disconnect steel outlet tube from heater inlet. enough to expose rod retaining pin. Push 13. Push retaining wire clip (E) up. Push pin (F) retaining wire clip up.

  • Page 55: Install Pump

    Repair Install Pump Pump Install Install Pump 7. Start threading pump into bearing housing (M). When pin holes align, insert pin. Pull retaining wire clip down. Note 8. Continue threading pump into bearing housing Steps 1–5 apply to pump B. To reconnect (M) until top threads are +/- 1/16 in.
  • Page 56 Repair Perform Pressure Relief Procedure, page 13. Disconnect pump inlet and outlet lines. Remove screws (113), washers (115), and bearing 8. Remove the system frame from the floor and housing (103). L-brackets. NOTICE NOTICE NOTICE Do not drop gear cluster (104) when removing drive housing (102).
  • Page 57 Repair Installation Installation Installation 4. Push drive housing (102) onto motor (101). Install screws (112) and washers (114). 1. Apply heavy duty extreme pressure grease Note liberally to washers (107, 108, 118), all gears, and inside drive housing (102). If bearing housing (103), connecting rod (105), or pump (106) were removed, 2.

  • Page 58: Repair Electric Motor

    Repair Repair Electric Electric Motor Motor Repair Repair Electric Motor 6. Remove four screws (25) holding motor (101) to bracket. Lift motor off unit. Removal Removal Removal NOTICE NOTICE NOTICE Be careful not to drop or damage the motor. The motor is heavy and may require two people to lift.

  • Page 59: Repair Circuit Breaker Module

    Repair Repair Circuit Circuit Breaker Breaker Module Module Repair Repair Circuit Breaker Module 1. See Before Beginning Repair, page 2. Using an ohmmeter, check for continuity across circuit breaker (top to bottom). If no continuity, Circuit Breakers Breakers Circuit Circuit Breakers trip breaker, reset, and retest.

  • Page 60: Replace Fluid Inlet Sensor

    Repair Replace Fluid Fluid Inlet Inlet Sensor Sensor Replace Flow Flow Meter Meter Replace Replace Fluid Inlet Sensor Replace Replace Flow Meter NOTE: For E-30 Elite models only. NOTE: NOTE: NOTE: For elite models only. NOTE: NOTE: 1. Perform Shutdown, page 1.

  • Page 61: Replace Pressure Transducers

    Repair Replace Pressure Pressure Transducers Transducers Replace Replace Pressure Transducers 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.

  • Page 62: Replace Fans

    Repair Replace Fans Fans Replace Replace Fans Replace Replace Electrical Replace Electrical Electrical Enclosure Enclosure Enclosure Fan 1. Perform Shutdown, page 46 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 Shutdown system to avoid electric shock.
  • Page 63 Repair Replace Replace Replace Transformer Transformer Fan Transformer 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.

  • Page 64: Repair Primary Heater

    Repair Repair Primary Primary Heater Heater Repair Repair Primary Heater 7. Relieve pressure. Pressure Relief Procedure, page 8. Wait for heater to cool. Replace Replace Replace Heater Heater Heater Element Element Element 9. Remove four bolts (23) and shroud (10). 1.
  • Page 65 Repair 13. Remove nuts (27) and transformer cover 20. Install new heater element (208), holding mixer (8). Cover transformer with plastic sheet or (210) so it does not block RTD port. cardboard. 21. Secure heater to frame with bolts (23). 14.
  • Page 66 Repair Repair Repair Repair Overtemperature Overtemperature Switch Overtemperature Switch Switch 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.
  • Page 67 Repair Replace Replace Replace RTD 8. 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). 1. Perform Shutdown, page c.

  • Page 68: Repair Heated Hose

    Repair Repair Heated Heated Hose Hose Repair Repair Heated Hose 4. Disconnect system wires from terminal block. 5. Use and ohmeter to check between the hose Refer to your heated hose manual for replacement wires. There should be continuity. hose parts. 6.
  • Page 69 Repair Check Check Check RTD RTD Cables Cables and Cables and FTS 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. 1. Perform Shutdown, page 2.
  • Page 70 Repair RTD Resistance Resistance Resistance vs. vs. Temperature Temperature Temperature RTD or or or FTS FTS Resistance Resistance Resistance Ohms Ohms Ohms RTD or or or FTS FTS Temperature Temperature °C Temperature °C (°F) °C (°F) (°F) -40 (-40) -30 (-22) -20 (-4) -10 (14) 1000...

  • Page 71: Repair Fluid Temperature Sensor

    Repair Repair Fluid Fluid Temperature Temperature Sensor Sensor (FTS) (FTS) Repair Repair Fluid Temperature Sensor (FTS) Installation Installation Installation The Fluid Temperature Sensor (FTS) is supplied with the system. Install FTS between main hose and whip hose. See your heated hose manual for instructions. Figure 15 4.

  • Page 72: Calibration Procedure

    Repair Calibration Procedure Procedure Calibration Calibration Procedure 3. Wait while the system measures the hose resistance. NOTICE NOTICE NOTICE To prevent damage to the heated hose, a hose calibration is required if any of the following conditions are true: • The hose has never been calibrated before. •...

  • Page 73: Transformer Primary Check

    Repair Transformer Primary Primary Check Check Transformer Transformer Primary Check 4. Accept or cancel the hose calibration. NOTE: A temperature estimate will be displayed NOTE: NOTE: Electrical Schematics, page 103. if the system was able to measure the hose wire resistance.

  • Page 74: Transformer Secondary Check

    Repair Transformer Secondary Secondary Check Check Transformer Transformer Secondary Check 2. Check transformer: a. Remove lower shroud. Electrical Schematics, page 103. b. Locate the two larger (6 AWG) wires, 1. Check wires and transformer: labeled 3 and 4, coming out of transformer. Trace these wires back to TB17 and TB18.

  • Page 75: Replace Transformer

    Repair Replace Transformer Transformer Replace Replace Transformer 4. Install new power supply (535) in reverse order. 1. Perform Shutdown, page 2. Remove four bolts (23) and shroud (10). 3. Remove lower dinrail cover (48). 4. Disconnect fan and transformer connections from terminal blocks.

  • Page 76: Replace Motor Control Module (Mcm)

    Repair Replace Motor Motor Control Control Module Module (MCM) (MCM) Replace Temperature Temperature Control Control Module Module Replace Replace Motor Control Module (MCM) Replace Replace Temperature Control Module (TCM) (TCM) (TCM) 1. Perform Shutdown, page 1. Perform Shutdown, page 2. Disconnect connectors from MCM (63). Disconnect two power cables.

  • Page 77: (Adm)

    Repair Replace Advanced Advanced Display Display Module Module Software Update Update Procedure Procedure Replace Replace Advanced Display Module Software Software Update Procedure (ADM) (ADM) (ADM) NOTICE NOTICE NOTICE 1. Loosen four screws (70) on inside of electrical Repair kit GCA modules are shipped enclosure door (61).

  • Page 78: Update Adm Software

    Repair Update ADM ADM Software Software Update Update Software NOTE: When the ADM display turns on, you may NOTE: NOTE: see the following screens: First: First: First: Software is checking which modules will take the available updates. 1. Turn the main power switch OFF. Second: Second: Second:...

  • Page 79: Parts

    Parts Parts Parts Parts Proportioners Proportioners Proportioners 333024S...
  • Page 80 Parts Apply anaerobic polyacrylate pipe sealant to all non-swiveling pipe threads. Apply grease to tube fitting threads. Torque to 43 ft-lb (58 N•m). Safety labels are from label sheet (68). 333024S...
  • Page 81 Parts Part Description Quantity Part Part Description Description Quantity Quantity 272010 272010 272010 272011 272011 272011 272012 272012 272012 272110 272110 272110 272111 272111 272111 272112 272112 272112 - - - FRAME - - - ENCLOSURE, electrical; Electrical Enclosure, page 96 246995 BOTTLE, assembly, complete...
  • Page 82 Parts Part Description Quantity Part Part Description Description Quantity Quantity 272010 272010 272010 272011 272011 272011 272012 272012 272012 272110 272110 272110 272111 272111 272111 272112 272112 272112 119865 SCREW, mch, hex serrated; 3/8 in. x 1/4–20 118444 SCREW, mch, slot hex wash hd;...
  • Page 83 Parts Part Description Quantity Part Part Description Description Quantity Quantity 272010 272010 272010 272011 272011 272011 272012 272012 272012 272110 272110 272110 272111 272111 272111 272112 272112 272112 43◊ 24K207 KIT, fts, rtd, single hose 44◊ 24R725 BRIDGE, plug-in jumper, ut35 45◊...
  • Page 84 Parts Part Description Quantity Part Part Description Description Quantity Quantity 272010 272010 272010 272011 272011 272011 272012 272012 272012 272110 272110 272110 272111 272111 272111 272112 272112 272112 60★ 287292 COVER, drive, plastic 16W766 COVER, control, box 16W596 LATCH, door 24U832 MODULE, MCM 24U831...
  • Page 85 Parts Part Description Quantity Part Part Description Description Quantity Quantity 272010 272010 272010 272011 272011 272011 272012 272012 272012 272110 272110 272110 272111 272111 272111 272112 272112 272112 92‡ 15D906 SUPPRESSOR, round snap ferrite .260 93◊ 127368 SLEEVE, split, wire, 1.50 127377 TIE, cable, 6 in.
  • Page 86 Parts Proportioner Module Module Proportioner Proportioner Module 24V150, Module Module for for E E E - - - 30 24V150, 24V150, Module 24V151, Module Module for for E E E - - - XP2 24V151, 24V151, Module Torque to 190–210 in-lb (21–24 N•m). Lubricate threads with ISO oil or grease.
  • Page 87 Parts 24V150 24V151 Part Description E-30 E-XP2 24U050 MOTOR, brushless, double ended, 2 hp 102* 17W869 KIT, drive housing 103✖❖ 257355 HOUSING, bearing 245927 HOUSING, bearing 104‡ 287290 KIT, repair, gear 241279 105†✖❖ KIT, rod, connecting 106◊❖ 245971 PUMP, displacement, B-side 245972 PUMP, displacement, B-side 107‡...
  • Page 88 Parts Fluid Heater Heater Fluid Fluid Heater 24U843 24U843 24U843 — — — 10kW, 10kW, 2–zone 10kW, 2–zone 2–zone 24U842 24U842 24U842 — — — 7.5 7.5 kW, kW, 1–zone 1–zone 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).
  • Page 89 Parts Description Part 24U843 24U842 15J090 HEATER, machined, 1 zone 15K825 HEATER, machined, dual zone 124132 O-RING 15H305 FITTING, plug, hollow, hex, 1-3/16 sae 121309 FITTING, adapter, sae-orb x jic 15H304 FITTING, plug 9/16 sae 15H306 ADAPTER, 9/16 x 1/8 120336 O-RING, packing 16A110...
  • Page 90 Parts Flow Meter Meter Flow Flow Meter 25N930 25N930 25N930 Torque to 90–100 in-lbs (11 N•m). Torque to 15–25 in-lbs (2 N•m). 333024S...
  • Page 91 Parts 25N930 25N930 25N930 Part Description Part Part Description Description Qty. Qty. Qty. - - - HOUSING, 3/4" orb, w/ pins, sub-assembly 25C298 GEAR, magnets, sd/matrix 15V690PKG GEAR, oval, metering element 17Y063PKG GASKET, meter 131971PKG O-RING, 031, fx75 17Y062PKG CAP, meter 108787 SCREW, cap, sch 110163PKG...
  • Page 92 Parts E E E - - - XP2 XP2 Flow Flow Meter Meter Flow Meter 25P388 25P388 25P388 Torque to 396–420 in-lbs (44–47 N•m). Torque to 15–25 in-lbs (2–3 N•m). 333024S...
  • Page 93 Parts 25P388 25P388 25P388 Part Description Part Part Description Description Qty. Qty. Qty. 18A877 HOUSING, high pressure meter 25C298 GEAR, magnets, sd/matrix 15V690 GEAR, oval, metering element 166623 PACKING, o-ring 192387 PIN, dowel 109114 SCREW, cap, sch 18A878 CAP, high pressure meter 25E134 BOARD, assy reactor ratio monitor 110163...
  • Page 94 Parts Fluid Manifold Manifold Fluid Fluid Manifold 24U844 24U844 24U844 Apply PTFE tape and thread sealant to gauge Torque to 355–395 in.-lbs (40–44.6 N●m) threads. Apply sealant (113500) to threads. Apply grease on valve. Valve must be closed with handle position as Apply PTFE tape or thread sealant to tapered shown on drawing.
  • Page 95 Parts 24U844, Fluid Fluid Manifold Manifold 24U844, 24U844, Fluid Manifold Part Description Part Description Part Part Description Description Part Part Description Description 401† 255228 MANIFOLD, fluid 150829 SPRING, compression 402◊ 247824 KIT, valve, cartridge, drain 419‡ 17Y235 FITTING, 3/4 ORB x #10 402a◊...
  • Page 96 Parts Electrical Enclosure Enclosure Electrical Electrical Enclosure 333024S...
  • Page 97 Parts Electrical Enclosure Enclosure Electrical Electrical Enclosure Description Description Part Part 24U087 ENCLOSURE 111218 CAP, tube, square 24U855 114269 MODULE, TCM GROMMET, rubber 127282 24U848 FAN, cooling, 80 mm, GROMMET, rubber 24VDC 127278 NUT, keps, hex 24R736 SWITCH, disconnect, 16W925 GASKET, enclosure, door mounted foam...
  • Page 98 Parts System DIN DIN Rail Rail and and Harness Harness Module Module Kit System System Rail Harness Module 24U850, 24U850, 24U850, System System System DIN DIN Rail Rail Rail and and Harness Harness Module Harness Module Kit Module Electrical Schematics, page 103.
  • Page 99 Parts Description Description Part Part 16U529 HARNESS, breaker 16U526 MODULE, din rail, module circuit breakers; see Power Supply and 16V515 HARNESS, hose out Terminal Block Module, 16U522 MODULE, din rail, term page 100 blk, power sup; see 16U530 MODULE, sys surge System Circuit Breaker protector Module, page 100...
  • Page 100 Parts System Circuit Circuit Breaker Breaker Module Module System System Circuit Breaker Module 16U526 16U526 16U526 Part Description Part Description 514014 RAIL, DIN; 35 mm x 17A314 CIRCUIT, breaker, 2P, 7.5 mm x 8.625 in. 20A, UL489 120838 TERMINAL, end stop 17A317 CIRCUIT, breaker, 2P, 40A, UL489...
  • Page 101 Parts Fluid Inlet Inlet Kits Kits Fluid Fluid Inlet Kits 24U320, 24U320, 24U320, Standard Standard Standard 25N920, 25N920, 25N920, Elite Elite 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.
  • Page 102 Parts Part Description Quantity Part Part Description Description Quantity Quantity 24U320 24U320 24U320 25N920 25N920 25N920 160327 FITTING, union adapter, 90° 118459 FITTING, union, swivel, 3/4 in. 603‡ 247503 MANIFOLD, strainer, inlet 24U852 THERMOMETER, dial 24U853 GAUGE, press, fluid - - - 606†...

  • Page 103: Electrical Schematics

    Electrical Schematics Electrical Schematics Schematics Electrical Electrical Schematics Reactor 2 E-30 Reactor 2 E-XP2 To TCM 24U831 24U832 ti22679c 333024S...
  • Page 104 Electrical Schematics PS-L PS-N CB-B CB-A ti22680b 333024S...
  • Page 105 Electrical Schematics 16U526 16V515 ELEC ENCL GND STUD TO HTD HOSE ti35626a ti35627a Locate near TCM. Heated hose wire termination enclosure (series B only). 333024S...

  • Page 106: Reactor 2 Repair Spare Parts Reference

    Reactor 2 Repair Spare Parts Reference Reactor 2 2 2 Repair Repair Spare Spare Parts Parts Reference Reference Reactor Reactor Repair Spare Parts Reference Recommended Common Common Spare Spare Parts Parts Recommended Recommended Common Spare Parts Part Part Part Description Description Description Part...

  • Page 107: Performance Charts

    Performance Charts Performance Charts Charts Performance 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 NOTICE NOTICE To prevent system damage, do not pressurize the system above the line for the gun tip size being used.
  • Page 108 Performance Charts Proportioners For For Coatings Coatings Proportioners Proportioners Coatings Table Table Table 1 1 1 Fusion Fusion Fusion Air Air Purge, Purge, Round Purge, Round Pattern Round Pattern Pattern 3500 (241) 3000 (207) 2500 E-XP2 AR2 020 (172) (000) PRESSURE AR2 929 2000...
  • Page 109 Performance Charts Table 3 3 3 Fusion Fusion Mechanical Mechanical Purge, Purge, Round Round Pattern Pattern Table Table Fusion Mechanical Purge, Round Pattern 3500 (241, 24.1) E-XP2 3000 (207, 20.7) (RTM040) 2500 (174, 17.4) XR2 929 (RTM040) 2000 PRESSURE (138, 13.8) psi (bar) MR3 535 (RTM040)

  • Page 110: Technical Specifications

    Technical Specifications Technical Specifications Specifications Technical Technical Specifications Reactor Reactor 2 2 2 E E E - - - 30 Reactor 30 and and E E E - - - XP2 XP2 Proportioning Proportioning Proportioning System System System U.S. U.S. U.S.
  • Page 111 Technical Specifications Sound Sound Pressure Sound Pressure, Pressure Sound Pressure measured per ISO-9614–2. Measured from 3.1 ft (1 m), 87.3 dBA E-30, at 1000 psi (7 MPa, 70 bar), 3 gpm (11.4 lpm) E-XP2, Measured from 3.1 ft (1 79.6 dBA m), at 3000 psi (21 MPa, 207 bar), 1 gpm (3.8 lpm) Sound...

  • Page 112: Notes

    Notes Notes Notes Notes 333024S...

  • Page 113: Components

    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.
  • Page 114 Information For the latest information about Graco products, visit www.graco.com. To place place an an order, order, contact your Graco Distributor or call to identify the nearest distributor. place order, Phone: 612-623-6921 or or or Toll Toll Free: Free: 1-800-328-0211 Fax:...

This manual is also suitable for:

Reactor 2 e-xp2Reactor 2 e-30 eliteReactor 2 e-xp2 elite e-xp2E-xp2 elite

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