Graco Reactor 2 E-30 Operation - Repair - Parts
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Graco Reactor 2 E-30 Operation - Repair - Parts

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

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Summary of Contents for Graco Reactor 2 E-30

  • Page 1 Repair, Parts Reactor 2 E-30 and E-XP2 333024N Proportioning System Electric, heated, plural component proportioning system. For spraying polyurethane foam and polyurea coatings. For professional use only. Not approved for use in explosive atmospheres or hazardous (classified) locations. Important Safety Instructions. Read all warnings and instructions in this manual before using the equipment.

  • Page 2: Table Of Contents

    Repair Drive Housing ........59 Performance Charts.......... 110 Repair Electric Motor........62 Technical Specifications........113 Repair Circuit Breaker Module ...... 63 Replace Fluid Inlet Sensor......64 Graco Extended Warranty for Reactor® 2 Replace Flow Meter ........64 Components ........115 333024N...

  • 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 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 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 spray without tip guard and trigger guard installed. •...
  • Page 5 Warnings WARNING THERMAL EXPANSION HAZARD Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure due to the thermal expansion. Over-pressurization can result in equipment rupture and serious injury. • Open a valve to relieve the fluid expansion during heating. •...
  • Page 6 Warnings WARNING EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. • Do not operate the unit when fatigued or under the influence of drugs or alcohol. • Do not exceed the maximum working pressure or temperature rating of the lowest rated system component.

  • Page 7: Important Isocyanate Information

    Important Isocyanate Information Important Isocyanate Information Isocyanates (ISO) are catalysts used in two component materials. Isocyanate Conditions Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and atomized particulates. • Read and understand the fluid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific hazards and precautions related to isocyanates.
  • Page 8 Important Isocyanate Information Material Self-Ignition Moisture Sensitivity of Isocyanates Exposure to moisture (such as humidity) will cause ISO to partially cure, forming small, hard, abrasive crystals that become suspended in the fluid. Eventually a film will form on the surface and the ISO Some materials may become self-igniting if applied will begin to gel, increasing in viscosity.

  • Page 9: Models

    Models Models Reactor 2 E-30 and E-30 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 11 E-30 Model E-30 Elite Model Model 10 kW...
  • Page 10 Models Reactor 2 E-XP2 and E-XP2 Elite All elite systems include fluid inlet sensors and Xtreme-Wrap 50 ft (15 m) heated hose. For part numbers, see Accessories, page 11 Model E–XP2 Model E–XP2 Elite Model 15 kW 15 kW Proportioner ★ 272012 272112 Maximum Fluid Working...

  • Page 11: Approvals

    979201 Integrated PowerStation, Tier 4 Final, 20 cfm 979202 Integrated PowerStation, Tier 4 Kit Number 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) 333024N...

  • Page 12: Supplied Manuals

    Manual Description 333023 Reactor 2 E-30 and E-XP2 Operation 333091 Reactor 2 E-30 and E-XP2 Startup Quick Guide 333092 Reactor 2 E-30 and E-XP2 Shutdown Quick Guide Related Manuals The following manuals are for accessories used with the Reactor. Manuals are available at www.graco.com.

  • Page 13: Troubleshooting

    QR code with your smartphone to be sent tower (optional). directly to online troubleshooting for the active error code. Otherwise, manually navigate to Error Description http://help.graco.com and search for the active Alarms A parameter critical to error. the process has reached a level requiring the system to stop.
  • Page 14 Error Codes Online Troubleshooting See help.graco.com for more detail on troubleshooting errors. 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 A1NM Low Motor Fluid not in No fluid in the pump can cause a low Current system. motor current error. Verify: • Fluid is in pumps. • Inlet valves are open. An outlet restriction does not exist. System cannot build pressure.
  • Page 16 Troubleshooting Error Location Type Description Cause Solution A4DB Heater B High Current B Short circuit in Check wiring for touching wires. heater wiring. Bad Heater. Confirm resistance of heater. Heater resistance should be 9-12 Ω for 10 kW systems and 6-8 Ω for 15 kW systems.
  • Page 17 Troubleshooting Error Location Type Description Cause 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. A8DB Heater B No Current B Tripped circuit Visually check circuit breaker for a breaker.
  • Page 18 Troubleshooting Error Location Type Description Cause 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 19 Troubleshooting Error Location Type Description Cause 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 20 Troubleshooting Error Location Type Description Cause 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. No material in pumps.
  • Page 21 Troubleshooting Error Location Type Description Cause 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. chamber. Reference the pressure/flow performance chart in the operation manual and decrease the mix chamber size or set pressure accordingly.
  • Page 22 Troubleshooting Error Location Type Description Cause Solution H3MH Hose High Line frequency is Ensure line frequency of incoming Frequency above 65 Hz power is between 45 and 65 Hz. Hose 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...
  • Page 23 Troubleshooting Error Location Type Description Cause Solution P0AX Pressure Pressure Ensure material flow is equally Imbalance A difference restricted on both material lines. High between A and B material is greater than the defined value. Pressure Ensure that the pressure imbalance imbalance is value, on the System Setup screen, is at an acceptable maximum pressure...
  • Page 24 Troubleshooting Error Location Type Description Cause Solution P1FB Low Inlet Inlet pressure Ensure that inlet pressure to the Pressure B lower than pump is sufficient. defined value. Value defined too Ensure that the low pressure alarm high. level defined on the System Setup screen is acceptable.
  • Page 25 Troubleshooting Error Location Type Description Cause Solution P4FA High Inlet The A-side (ISO) Replace the A-side (ISO) pump inlet Pressure pump inlet ball or ball and seat. (A-side) seat is damaged. The A-side To avoid thermal expansion, condition (ISO) material the A-side (ISO) material drum to the is expanding same ambient temperature as the...
  • Page 26 Troubleshooting Error Location Type Description Cause Solution P6FA Pressure Inlet sensors not If inlet sensors are not installed, inlet Sensor Error installed. sensors should be disabled on the Inlet A System Setup screen. Loose/bad Check to ensure inlet sensor is connection.
  • Page 27 Troubleshooting Error Location Type Description Cause Solution P7BX Pressure Pressure Ensure material flow is equally Imbalance B difference restricted on both material lines. High between A and B material is greater than the defined value. Pressure Ensure that the pressure imbalance imbalance is value, on the System Setup screen, is at an acceptable maximum pressure...
  • Page 28 Troubleshooting Error Location Type Description Cause Solution R4D0 High Damaged B-side Inspect the B-side (RES) pump for Ratio/Low (RES) pump. damage. If necessary, replace the Flow (B-side) pump. Fluid leak Inspect the fluid lines for leaking between the B-side chemical (RES). B-side pump and the meter.
  • Page 29 Troubleshooting Error Location Type Description Cause 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. If recirculating, decrease flow or decrease temperature setpoint. Loose or missing Reconnect or install jumper.
  • Page 30 Troubleshooting Error Location Type Description Cause Solution T2DH Hose Cold chemical in Recirculate heated chemical back Temperature unheated portion to drum in cold conditions before Hose startup. of system passed hose FTS at startup. Flow is too high at Use a smaller mix chamber that current setpoint.
  • Page 31 Troubleshooting Error Location Type Description Cause Solution T3NM Motor Cooling fan on • Ensure fan is always running when Temperature back of motor machine is powered on. Cutback not operating • Ensure fan is blowing air toward properly. the motor (inward). •...
  • Page 32 Troubleshooting Error Location Type Description Cause 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. follows. If so, replace RTD. Flow too high Use a smaller mix chamber that is for temperature rated for the unit in use.
  • Page 33 6 ft (2 m) of the control. A-side hose. If not, replace missing insulation over the individual hoses. (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. 333024N...
  • Page 34 Troubleshooting Error Location Type Description Cause Solution T4DH Hose High Setting the A Increase hose setpoint so it is closer Temperature or B setpoint to A and B setpoints. Hose much higher than hose setpoint can cause fluid more than 27° F (15° C) over hose temperature setting to reach...
  • Page 35 Troubleshooting Error Location Type Description Cause Solution T4EB Heater B High Overtemperature Heater was delivered too much Temperature switch sensed a power, causing the overtemperature Switch B switch to open. RTD is not reading fluid temperature above 230° F properly. After the heater cools (110°...
  • Page 36 Troubleshooting Error Location Type Description Cause Solution T4NM High High ambient Ensure ambient temperature is below Temperature temperature. 120° F (49° C) before using the Motor system. Cooling fan is • Check to see that the motor fan is not operating moving.
  • Page 37 Troubleshooting Error Location Type Description Cause Solution T6DH Hose Sensor Error Disconnected Expose each hose RTD connection Hose or shorted RTD to check and retighten any loose cable in hose or connector. Measure hose RTD bad FTS. cable and FTS continuity. See Repair Heated Hose, page Order RTD Test kit 24N365 for measurement.
  • Page 38 Troubleshooting Error Location Type Description Cause Solution T6NM Sensor Error Disconnected Verify wiring between the motor Motor or loose motor temperature sensor and the module. temperature cable. Failed motor Measure resistance between pins 1 and 3 on motor temperature temperature sensor.
  • Page 39 Troubleshooting Error Location Type Description Cause Solution T8DB Heater B Bad RTD or bad Swap A and B heater output cables Temperature RTD placement and RTD cables and see if issue Rise B against heater. follows. If so, replace RTD. Loose heater Check for loose heater element wires wires or...
  • Page 40 264 VAC. Generator is set If the generator is wired in a high-leg to a high-leg delta delta configuration and is consistently configuration. causing this error, change generator configuration to 208 VAC wye (star). Contact Graco Technical Assistance. 333024N...
  • Page 41 If the generator is wired in a high-leg to a high-leg delta delta configuration and is consistently configuration. causing this error, change generator configuration to 208 VAC wye (star). Contact Graco Technical Assistance. V3MH High Voltage Incoming line Ensure incoming system power is Hose voltage is too wired properly.
  • Page 42 Troubleshooting Error Location Type Description Cause Solution WMI0 TCM Fan Error Fan inside TCM Check for debris in the TCM fan and is not operating clear with forced air if necessary. properly. WSUX Configuration A valid Inset a system token into the ADM Error USB configuration file and cycle power.
  • Page 43 Troubleshooting 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 Reactor ADM does not turn on. No power. Turn main power switch ON. Failed 24 V power supply.
  • Page 44 Troubleshooting 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 Hose heats but heats slower Ambient temperature is too cold. Relocate hoses to a warmer area than usual or it does not reach or recirculate heated fluid through...
  • Page 45 Troubleshooting Problem Cause 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 106. Faulty FTS connections. Verify that all FTS connections are snug and that pins of connectors are clean.
  • Page 46 Troubleshooting Problem Cause 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. Verify FTS installation, Repair Fluid Temperature Sensor (FTS), page Loose hose electrical connections.
  • Page 47 Troubleshooting 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 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 48 Troubleshooting 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 Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Problem Cause Solution...

  • Page 49: Pressure Relief Procedure

    Pressure Relief Procedure Pressure Relief Procedure 3. Shut off feed pumps and agitator, if used. 4. Route fluid to waste containers or supply tanks. Turn PRESSURE RELIEF/SPRAY valves (SA, Follow the Pressure Relief Procedure SB) to PRESSURE RELIEF/CIRCULATION whenever you see this symbol. .

  • Page 50: Shutdown

    Shutdown Shutdown 4. Press to park the Component A Pump. The park operation is complete when green dot goes out. Verify the park operation is complete before moving to next step. 5. Press to deactivate the system. Shutdown system to avoid electric shock. All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.
  • Page 51 Shutdown 8. Close all fluid supply valves. 9. Engage gun piston safety lock then close fluid inlet valves A and B. Fusion Probler 333024N...

  • Page 52: 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 53: Repair

    Repair Repair 1. Close the fluid inlet valve on the y-strainer inlet and shut off the appropriate feed pump. This prevents material from being pumped while cleaning the screen. 2. Place a container under the strainer base to catch drain off when removing the strainer plug (C). Repairing this equipment requires access to parts 3.

  • Page 54: Change Pump Lubricant

    Repair 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 55: Clean Flow Meter

    Repair 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. 2. Perform Pressure Relief Procedure, page 3. Disconnect the flow meter cable. 4. Disconnect the heated hose from the flow meter. Remove the flow meter.

  • Page 56: Clean E-Xp2 Flow Meter

    Repair Clean E-XP2 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. 2. Perform Pressure Relief Procedure, page 3. Disconnect the flow meter cable. 4.

  • Page 57: Remove Pump

    Repair 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 58 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 59: Install Pump

    Repair 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. (2 mm) of pump A, proceed to step 6.
  • Page 60 Repair 7. Perform Pressure Relief Procedure, page NOTICE 8. Remove the system frame from the floor and Do not drop gear cluster (104) when removing L-brackets. drive housing (102). Gear cluster may stay engaged in motor front end bell or drive housing.
  • Page 61 Repair 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 62: Repair Electric Motor

    Repair Repair Electric Motor Removal NOTICE Be careful not to drop or damage the motor. The motor is heavy and may require two people to lift. 1. Remove the system frame from the floor and L-brackets. Installation 1. Place motor on unit. Thread motor cables into conduit as before.

  • Page 63: Repair Circuit Breaker Module

    Repair Repair Circuit Breaker Module new circuit breaker. Insert wires and tighten down all screws. 1. See Before Beginning Repair, page 2. Using an ohmmeter, check for continuity across circuit breaker (top to bottom). If no continuity, trip breaker, reset, and retest. If still no continuity, Figure 6 Circuit Breakers replace breaker as follows:...

  • Page 64: Replace Fluid Inlet Sensor

    Repair Replace Fluid Inlet Sensor Note For Elite models only. 1. Perform Shutdown, page 2. Perform Pressure Relief Procedure, page 3. Disconnect inlet sensor cable from the fluid inlet assembly. Inspect cable for damage and replace if necessary. See Electrical Schematics, page 106.

  • Page 65: Replace Fans

    Repair Replace Fans Replace Electrical Enclosure Fan 1. Perform Shutdown, page 50 2. Open electrical enclosure door (401). Loosen four nuts (421) and remove fan (404). 3. Install new fan (404) in reverse order of Shutdown system to avoid electric shock. To avoid disassembly so that the fan blows out of the burns, do not perform maintenance on the fan until electrical enclosure.
  • Page 66 Repair Replace Transformer Fan 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 67: Repair Primary Heater

    Repair Repair Primary Heater 8. Wait for heater to cool. Replace Heater Element 9. Remove four bolts (23) and shroud (10). 1. Press to stop the pumps. 2. Turn off heat zones. 3. Flush pump. 10. Remove screw (20) and lower din rail cover (48). 4.
  • Page 68 Repair 13. Remove nuts (27) and transformer cover burnt, ash-like material adhered to element, or (8). Cover transformer with plastic sheet or sheath shows pitting marks. cardboard. 20. Install new heater element (208), holding mixer 14. Disconnect overtemperature switches (209) from (210) so it does not block RTD port.
  • Page 69 Repair Repair Overtemperature Switch 110009, install new switch in same location on housing (201), and secure with screws (213). 1. Perform Shutdown, page Reconnect cables. 2. Wait for heaters to cool. 3. Remove heater cover (10). 4. Disconnect overtemperature switches (209) from cable (46).
  • Page 70 Repair Replace RTD a. Apply PTFE tape and thread sealant to male pipe threads and tighten RTD housing (H) 1. Perform Shutdown, page into adapter (206). 2. Wait for heater to cool. b. Push in RTD (212) so tip contacts heater element (208).

  • Page 71: Repair Heated Hose

    Repair Repair Heated Hose 3. For Series A only: Disconnect hose connector (D) at Reactor. Refer to your heated hose manual for replacement hose parts. Check Hose Heat Power Connectors 1. Perform Shutdown, page Note Whip hose must be connected. 2.

  • Page 72: Fts

    Repair Check RTD Cables and FTS 1. Perform Shutdown, page 2. Disconnect RTD cable (C) at Reactor. 3. Test with an ohmmeter between pins of cable connector C. Note Do not touch outer ring with test probe. Pins Result Heated Hose 3 to 1 RTD Resistance Figure 16...
  • Page 73 Repair RTD Resistance vs. Temperature RTD or FTS Resistance Ohms RTD or FTS Temperature °C (°F) -40 (-40) -30 (-22) -20 (-4) -10 (14) 1000 0 (32) 1039 10 (50) 1078 20 (68) 1117 30 (86) 1155 40 (104) 1194 50 (122) 1232 60 (140)
  • Page 74 Repair Repair Fluid Temperature Sensor (FTS) Installation The Fluid Temperature Sensor (FTS) is supplied with the system. Install FTS between main hose and whip hose. See Heated Hose manual 309572 for instructions. Figure 17 a. Disconnect air hoses (C,L) and electrical connectors (D).

  • Page 75: Calibration Procedure

    Repair Calibration Procedure 3. Wait while the system measures the hose resistance. 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 76: Transformer Primary Check

    Repair Transformer Primary Check 4. Accept or cancel the hose calibration. NOTE: A temperature estimate will be displayed Electrical Schematics, page 106. if the system was able to measure the hose wire resistance. 1. Check wires and transformer: a. See Shutdown, page b.

  • Page 77: Transformer Secondary Check

    Repair Transformer Secondary Check Electrical Schematics, page 106. 1. Check wires and transformer: a. Disconnect 7 pin green connector from TCM. b. Use an ohmmeter to test for continuity between terminals 6 and 7 on the TCM 7 pin green connector. There should be continuity. If there is no continuity, check transformer.

  • Page 78: Replace Power Supply

    Repair Replace Power Supply Replace Surge Protector 1. Loosen connections on terminals 1 and 3 on CB02. 2. Loosen connections on input to power supply (535) on N and L connections. 1. Perform Shutdown, page 3. Remove two screws (413) and surge protector (505) from enclosure.

  • Page 79: Replace Motor Control Module (Mcm)

    Repair Replace Motor Control Module (MCM) Replace Temperature Control Module (TCM) 1. Perform Shutdown, page 1. Perform Shutdown, page 2. Disconnect connectors from MCM (63). Disconnect two power cables. See 2. Open electrical enclosure door (61). Electrical Schematics, page 106. 3.

  • Page 80: Replace Advanced Display Module

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

  • Page 81: Update Adm Software

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

  • Page 82: Parts

    Parts Parts Proportioners 333024N...
  • Page 83 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 and warning labels are from label sheet (68). 333024N...
  • Page 84 Parts Part Description Quantity 272010 272011 272012 272110 272111 272112 FRAME - - - ENCLOSURE, electrical; - - - Electrical Enclosure, page 99 246995 BOTTLE, assembly, complete 16X531 BRACKET, tsl, bottle 24U843 HEATER, 10kw, 2 zone, RTD; see Fluid Heater, page 91 24U842 HEATER, 7.5kw, 1 zone, RTD;...
  • Page 85 Parts Part Description Quantity 272010 272011 272012 272110 272111 272112 125643 FITTING, elbow, 3/8 npt x #8 jic 119865 SCREW, mch, hex serrated; 3/8 in. x 1/4–20 118444 SCREW, mch, slot hex wash hd; 1/2 in. x #10–24 117683 SCREW, mch, phil pan hd;...
  • Page 86 Parts Part Description Quantity 272010 272011 272012 272110 272111 272112 16X095 CONNECTOR, power, male, 4 pin 42◊ 125871 TIE, cable, 7.5 in. 43◊ 24K207 KIT, fts, rtd, single hose 44◊ 24R725 BRIDGE, plug-in jumper, ut35 45◊ 106569 TAPE, electrical 46‡ 24T242 CABLE, over-temp, 10 kW Reactor...
  • Page 87 Parts Part Description Quantity 272010 272011 272012 272110 272111 272112 16W218 LABEL, branding, e-30 16W321 LABEL, branding, e-30, elite 16W215 LABEL, branding, e-xp2 16W322 LABEL, branding, e-xp2, elite 59◊ 16U530 MODULE, system surge protector (spare) 60★ 287292 COVER, drive, plastic 16W766 COVER, control, box 16W596...
  • Page 88 Parts Part Description Quantity 272010 272011 272012 272110 272111 272112 127276 BOLT, carriage, 1/2-13 x 2.5 l 24U854 MODULE, ADM 16W967 FITTING, swivel, 3/4 npt x 1 npsm 118459 FITTING, union, swivel, 3/4 in. 16W213 LABEL, branding, reactor 115942 NUT, hex, flange head 92‡...
  • Page 89 Parts Proportioner Module 24V150, Module for E-30 24V151, Module for E-XP2 Torque to 190–210 in-lb (21–24 N•m). Lubricate threads with ISO oil or grease. Assemble pump cylinders flush to one full thread under-flush of housing surface. Apply grease to all gear teeth proportionally, motor pinion and drive housing. Torque to 20–30 ft-lb (27–40.6 N•m).
  • Page 90 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 114699...
  • Page 91 Parts Fluid Heater 24U843 — 10kW, 2–zone 24U842 — 7.5 kW, 1–zone Torque to 120 ft-lbs (163 N•m). Torque to 23 ft-lbs (31 N•m). Torque to 40 ft-lbs (54 N•m). Apply thermal paste. Apply pipe sealant and PTFE tape to all non-swiveling threads and threads without o-rings. Apply lithium grease lubricant to o-rings before assembling in block (1).
  • Page 92 Parts Description Part 24U843 24U842 15J090 HEATER, machined, 1 zone HEATER, machined, dual zone 15K825 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 93 Parts Flow Meter 25N930 Torque to 90–100 in-lbs (11 N•m). Torque to 15–25 in-lbs (2 N•m). 333024N...
  • Page 94 Parts 25N930 Part Description 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 SCREW, thd forming, pnh 25E134PKG BOARD, assembly, ratio monitor - - -...
  • Page 95 Parts E-XP2 Flow Meter 25P388 Torque to 396–420 in-lbs (44–47 N•m). Torque to 15–25 in-lbs (2–3 N•m). 333024N...
  • Page 96 Parts 25P388 Part Description 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 SCREW, thd forming, pnh 18A879...
  • Page 97 Parts Fluid Manifold 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 98 Parts 24U844, Fluid Manifold Part Description Part Description 401† 255228 MANIFOLD, fluid 419‡ 17Y235 FITTING, 3/4 ORB x #10 402◊ 247824 KIT, valve, cartridge, drain 117557 FITTING, 1/2 NPT x #10 402a◊ 158674 O-RING, BUNA-N 402b◊ 247779 SEAL, seat, valve 102814 GAUGE, press, fluid Replacement Warning labels, signs, tags,...
  • Page 99 Parts Electrical Enclosure 333024N...
  • Page 100 Parts Electrical Enclosure Description Description Part Part 24U087 ENCLOSURE 113505 NUT, keps, hex head 111218 24U855 MODULE, TCM CAP, tube, square 114269 24U848 FAN, cooling, 80 mm, GROMMET, rubber 24VDC 127282 GROMMET, rubber 24R736 SWITCH, disconnect, 127278 NUT, keps, hex door mounted 16W925 GASKET, enclosure, foam...
  • Page 101 Parts System DIN Rail and Harness Module Kit 24U850, System DIN Rail and Harness Module Kit Electrical Schematics, page 106. Torque to 6–8 in.-lbs (0.7–1 N●m) Torque to 28–33 in.-lbs (3–3.8 N●m) Torque to 23–26 in.-lbs (2.6–3 N●m) 333024N...
  • Page 102 Parts Description Description Part Part 16U529 HARNESS, breaker 16U526 MODULE, din rail, module circuit breakers; see 16V515 HARNESS, hose out Power Supply and Terminal Block Module, 16U522 MODULE, din rail, term page 103 blk, power sup; see 16U530 MODULE, sys surge System Circuit Breaker protector Module, page 103...
  • Page 103 Parts System Circuit Breaker Module 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 17A319 CIRCUIT, breaker, 1 pole, 50A, C Curve Power Supply and Terminal Block Module 16U522...
  • Page 104 Parts Fluid Inlet Kits 24U320, Standard 25N920, 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 105 Parts Part Description Quantity 24U320 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† FILTER, replacement 607†‡ 128061 PACKING, o-ring 608‡ 16V879 CAP, filter 609‡...

  • Page 106: Electrical Schematics

    Electrical Schematics Electrical Schematics Reactor 2 E-30 Reactor 2 E-XP2 To TCM 24U831 24U832 ti22679c 333024N...
  • Page 107 Electrical Schematics PS-L PS-N CB-B CB-A ti22680b 333024N...
  • Page 108 Electrical Schematics 16U526 24U855 16V515 ELEC ENCL GND STUD TO HTD HOSE ti35626a ti35627a Locate near TCM. Heated hose wire termination enclosure (series B only). 333024N...

  • Page 109: Reactor 2 Repair Spare Parts Reference

    Reactor 2 Repair Spare Parts Reference Reactor 2 Repair Spare Parts Reference Recommended Common Spare Parts Part Description Part of Assembly 106, E-30 Pump Repair Kit Pump 15C852 106, 15C851 E-XP2 Pump Repair Kit Pump 106, 246963 E-XP2 Wet Cup Repair Kit Pump 106, 246964...

  • Page 110: 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. NOTICE To prevent system damage, do not pressurize the system above the line for the gun tip size being used.
  • Page 111 Performance Charts Proportioners For Coatings Table 1 Fusion Air Purge, Round Pattern 3500 (241) 3000 (207) 2500 E-XP2 AR2020 (172) (000) PRESSURE AR2929 2000 (00) psi (bar) (138) 1500 (103) AR4242 (01) 1000 (69) (34) (1.9) (3.8) (5.7) (7.6) FLOW gal./min (l/min) Table 2 Fusion Air Purge, Flat Pattern 3500 (241, 24.1)
  • Page 112 Performance Charts Table 3 Fusion Mechanical Purge, Round Pattern 3500 (241, 24.1) E-XP2 3000 (207, 20.7) XR2323 (RTM040) 2500 (174, 17.4) XR2929 (RTM040) PRESSURE 2000 (138, 13.8) psi (bar) MR3535 (RTM040) 1500 MR4747 (103, 10.3) (RTM055) XR3535 (RTM055) XR4747 1000 (RTM055) (69, 6.9) (35, 3.5)

  • Page 113: Technical Specifications

    Technical Specifications Technical Specifications Reactor 2 E-30 and E-XP2 Proportioning System U.S. Metric Maximum Fluid Working Pressure E-30 2000 psi 14 MPa, 140 bar E-XP2 3500 psi 24.1 MPa, 241 bar Maximum Fluid Temperature E-30 190°F 88°C E-XP2 190°F 88°C...
  • Page 114 Technical Specifications Sound Pressure measured per ISO-9614–2. Sound Pressure, Measured from 3.1 ft (1 m), E-30, 87.3 dBA 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 Power E-30, Measured from 3.1 ft (1 m),...

  • Page 115: Graco Extended Warranty For Reactor

    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 116 Graco Information For the latest information about Graco products, visit www.graco.com. To place an order, contact your Graco Distributor or call to identify the nearest distributor. Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505 All written and visual data contained in this document reflects the latest product information available at the time of publication.

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