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

Graco Reactor 2 E-30 Repair And Parts Manual

Proportioning system
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Repair-Parts
Reactor 2 2 2 E-30
Reactor
Reactor
Proportioning System
Proportioning
Proportioning
Electric, Heated,
Heated, Plural
Plural Component
Electric,
Electric,
Heated,
Plural
polyurea coatings.
coatings. For
For professional
polyurea
polyurea
coatings.
For
hazardous locations.
locations.
hazardous
hazardous
locations.
Important Safety
Safety Instructions.
Important
Important
Safety
this manual.
manual. Save
Save these
this
this
manual.
Save
E-30 and
and E-XP2
E-30
and
System
System
Component Proportioning
Proportioning System.
Component
Proportioning
professional use
use only.
only. Not
professional
use
only.
Instructions. Read
Read all all all warnings
Instructions.
Read
these instructions.
instructions.
these
instructions.
PROVEN QUALITY. LEADING TECHNOLOGY.
E-XP2
E-XP2
System. For
For spraying
System.
For
Not approved
approved for
for use
Not
approved
for
warnings and
and instructions
instructions in in in
warnings
and
instructions
spraying polyurethane
polyurethane foam
spraying
polyurethane
use in in in explosive
explosive atmospheres
atmospheres or or or
use
explosive
atmospheres
333024L
EN
foam and
and
foam
and

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Summary of Contents for Graco Reactor 2 E-30

  • Page 1 Repair-Parts Reactor 2 2 2 E-30 E-30 and and E-XP2 E-XP2 Reactor Reactor E-30 E-XP2 333024L Proportioning System System Proportioning Proportioning System Electric, Heated, Heated, Plural Plural Component Component Proportioning Proportioning System. System. For For spraying spraying polyurethane polyurethane foam foam and Electric, Electric,...

  • Page 2: Table Of Contents

    Install Pump ..........57 Technical Specifications........106 Repair Drive Housing ........57 Notes ............. 108 Repair Electric Motor........60 Repair Circuit Breaker Module ...... 61 Graco Extended Warranty for Reactor® 2 Replace Fluid Inlet Sensor......62 Components ........109 333024L...

  • 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 gun, hose leaks, or ruptured components will pierce skin. This may Get immediate immediate surgical surgical look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical 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 Technical Data Data in all equipment manuals.

  • 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 11 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 11 Model Model...

  • Page 11: Approvals

    Integrated PowerStation, Tier 4 Final, 20 cfm 979202 Integrated PowerStation, Tier 4 Kit Number Number Number Description 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) 333024L...

  • Page 12: Supplied Manuals

    Manual Description Manual Manual Description 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 Manuals Related Related Manuals The following manuals are for accessories used with the Reactor.

  • Page 13: Troubleshooting

    Otherwise, manually navigate to Error Description Error Error Description Description http://help.graco.com and search for the active Alarms Alarms Alarms A parameter critical to error. the process has reached a level requiring the system to stop.
  • Page 14 Online Online Troubleshooting Troubleshooting Troubleshooting See www.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, with 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 A7DB Heater B Unexpected Shorted TCM If error cannot be cleared or Current B regenerates consistently, replace module. A7DH Hose Unexpected Shorted TCM If error cannot be cleared or Current Hose...
  • 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 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...
  • Page 22 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution 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.
  • Page 23 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution P1FB Low Inlet Inlet pressure Ensure that inlet pressure to the Pressure B lower than pump is sufficient. defined value. Ensure that the low pressure alarm Value defined too high.
  • Page 24 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution 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.
  • Page 25 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution 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.
  • Page 26 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution 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.
  • Page 27 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution 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...
  • Page 28 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. If recirculating, decrease flow or decrease temperature setpoint.
  • Page 29 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution T2DH Hose Cold chemical in Recirculate heated chemical back Temperature unheated portion to drum in cold conditions before Hose of system passed startup.
  • Page 30 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 machine is powered on. Cutback not operating •...
  • Page 31 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 32 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. 333024L...
  • Page 33 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution 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...
  • Page 34 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution T4EB Heater B High Overtemperature Heater was delivered too much Temperature switch sensed a power, causing the overtemperature Switch B fluid temperature switch to open.
  • Page 35 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 •...
  • Page 36 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution 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.
  • Page 37 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution T8DA Heater A Bad RTD or bad Swap A and B heater output cables Temperature RTD placement and RTD cables and see if issue Rise A against heater.
  • Page 38 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution V1CM Low Voltage Loose/bad Check wiring for loose connection or connection or tripped circuit breaker. tripped circuit breaker. Low incoming Measure voltage at circuit breaker line voltage.
  • Page 39 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. V3MB High Voltage B Incoming line Ensure incoming system power is voltage is too wired properly.
  • Page 40 Troubleshooting Error Location Type Description Cause Solution Error Error Location Location Type Type Description Description Cause Cause Solution Solution V4MH High Voltage Incoming line Ensure incoming system power is Hose voltage is too wired properly. Verify voltage at each high. circuit breaker is between 195 and 264 VAC.
  • Page 41 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 42 Troubleshooting Problem Problem Problem Cause Cause Cause Solution Solution Solution Fluid leak in pump packing nut Worn throat seals. Replace. See pump manual. area. No pressure on one side. Fluid leaking from heater inlet Check if heater and PRESSURE rupture disk (372). RELIEF/SPRAY valve (SA or SB) are plugged.
  • Page 43 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 44 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 Faulty FTS connections.
  • Page 45 Troubleshooting Problem Cause Solution Problem Problem Cause Cause Solution Solution Hoses near Reactor are warm, but Shorted connection or failed hose With power off, check the hose hoses downstream are cold. heating element. resistance with and without the whip hose attached. With the whip hose attached, the reading should be less than 3 ohm.
  • Page 46 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 47 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 48: Pressure Relief Procedure

    Pressure Relief Procedure Pressure Relief Relief Procedure Procedure Pressure 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 49: Shutdown

    Shutdown 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 50 Shutdown 8. Close all fluid supply valves. 9. Engage gun piston safety lock then close fluid inlet valves A and B. Fusion Probler Fusion Fusion Probler Probler 333024L...

  • Page 51: 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 52: Repair

    Repair 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).

  • Page 53: 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 54: 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. 2. Perform Pressure Relief Procedure, page 3. Disconnect the flow meter cable. 4.

  • Page 55: 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 56 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 57: 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 58 Repair 7. Perform Pressure Relief Procedure, page NOTICE NOTICE 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 59 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 60: Repair Electric Motor

    Repair Repair Electric Electric Motor Motor Repair Repair Electric Motor 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. 1. Remove the system frame from the floor and L-brackets.

  • Page 61: Repair Circuit Breaker Module

    Repair Repair Circuit Circuit Breaker Breaker Module 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, Figure 6 trip breaker, reset, and retest.

  • Page 62: Replace Fluid Inlet Sensor

    Repair Replace Fluid Fluid Inlet Inlet Sensor Sensor Replace 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.

  • Page 63: Replace Fans

    Repair Replace Fans Fans Replace Replace Fans Replace Replace Electrical Replace Electrical Electrical Enclosure Enclosure Enclosure Fan 1. Perform Shutdown, page 49 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.
  • Page 64 Repair Replace Replace Replace Transformer Transformer 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 65: Repair Primary Heater

    Repair Repair Primary Primary Heater Heater Repair Repair Primary Heater 8. Wait for heater to cool. Replace Replace Replace Heater Heater Element Heater Element Element 9. Remove four bolts (23) and shroud (10). 1. Press to stop the pumps. 2. Turn off heat zones. 3.
  • Page 66 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 67 Repair Repair Repair Repair Overtemperature Overtemperature Overtemperature Switch Switch 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.
  • Page 68 Repair Replace Replace 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 69: Repair Heated Hose

    Repair Repair Heated Heated Hose Hose Repair Repair Heated Hose 3. For Series A only: Disconnect hose connector (D) at Reactor. Refer to the heated hose manual 309572 for hose replacement parts. Check Hose Hose Heat Heat Power Power Connectors Connectors Check Check...
  • Page 70 Repair Check Check Check RTD RTD Cables Cables Cables and 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 Pins...
  • Page 71 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 Temperature °C °C °C (°F) (°F) (°F) -40 (-40) -30 (-22) -20 (-4) -10 (14) 1000...

  • Page 72: (Fts)

    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 Heated Hose manual 309572 for instructions.
  • Page 73 Repair Transformer Transformer Transformer Primary Primary Check Primary Check Check indicator on the circuit breaker GREEN. Use an ohmmeter to test for continuity between Electrical Schematics, page two transformer wires in terminal blocks TB17 and TB18; there should be continuity. 1.
  • Page 74 Repair Replace Replace Replace Transformer Transformer Transformer 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. Connections are on left side labeled: V+, V-, 1, 2, 3, and 4. 5.

  • Page 75: Replace Power Supply

    Repair Replace Power Power Supply Supply Replace Replace Power Supply 1. Perform Shutdown, page 2. Disconnect input and output cables from both sides of the power supply. See Electrical Schematics, page 3. Insert a flat head screw driver in the mounting tab on the bottom of the power supply to remove Figure 21 Surge Protector from the din rail.

  • 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: Parts

    Parts Parts Parts Parts Proportioners Proportioners Proportioners 333024L...
  • Page 78 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). 333024L...
  • Page 79 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 92 246995 BOTTLE, assembly, complete...
  • Page 80 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 125643 FITTING, elbow, 3/8 npt x #8 jic 119865 SCREW, mch, hex serrated;...
  • 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 16X095 CONNECTOR, power, male, 4 pin 42◊ 125871 TIE, cable, 7.5 in. 43◊...
  • 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 16W218 LABEL, branding, e-30 16W321 LABEL, branding, e-30, elite 16W215 LABEL, branding, e-xp2 16W322 LABEL, branding, e-xp2, elite...
  • 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 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,...
  • Page 84 Parts Proportioner Module Module Proportioner Proportioner Module 24V150, Module Module for for E E E - - - 30 24V150, 24V150, Module 24V151, 24V151, 24V151, Module Module Module for for E E E - - - XP2 Torque to 190–210 in-lb (21–24 N•m). Lubricate threads with ISO oil or grease.
  • Page 85 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 105†✖❖ 241279 KIT, rod, connecting 106◊❖ 245971 PUMP, displacement, B-side 245972 PUMP, displacement, B-side 107‡...
  • Page 86 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 87 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 88 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). 333024L...
  • Page 89 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 90 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 91 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 419‡ 17Y235 FITTING, 3/4 ORB x #10 402◊ 247824 KIT, valve, cartridge, drain 117557 FITTING, 1/2 NPT x #10 402a◊...
  • Page 92 Parts Electrical Enclosure Enclosure Electrical Electrical Enclosure 333024L...
  • Page 93 Parts Electrical Enclosure Enclosure Electrical Electrical Enclosure Description Description Part Part Part Description Description Part Part Part Description Description 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...
  • Page 94 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 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)
  • Page 95 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 96 blk, power sup; see 16U530 MODULE, sys surge System Circuit Breaker protector Module, page 96...
  • Page 96 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 97 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 98 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† - - - FILTER, replacement 607†‡...

  • Page 99: Electrical Schematics

    Electrical Schematics Electrical Schematics Schematics Electrical Electrical Schematics Reactor 2 E-30 Reactor 2 E-XP2 To TCM 24U831 24U832 ti22679c 333024L...
  • Page 100 Electrical Schematics PS-L PS-N CB-B CB-A ti22680b 333024L...
  • Page 101 Electrical Schematics 16U526 16V515 ELEC ENCL GND STUD TO HTD HOSE ti35626a ti35627a Locate near TCM. Heated hose wire termination enclosure (series B only). 333024L...

  • Page 102: 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 103: 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 104 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 105 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) MR3 535 psi (bar) (RTM040)

  • Page 106: 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 107 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 Power...

  • Page 108: Notes

    Notes Notes Notes Notes 333024L...

  • Page 109: 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 110 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:...

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