Graco 3A1705J manual

Operation Reactor® E-30i and E-XP2i 3A1705J EN Electric, Heated, Integrated Plural Compo nent Proportioning System Wit h Integrated Generator. For spraying polyurethane foam and polyurea coatings. For professional use o nly. Not approved for use in explosive atmospheres or hazardous locations. Importan t Safety Instru ctions Read all warnin gs and[...]

Contents Wa rni ng s ....................................................... ...... 3 Important Two -Component Mate rial In fo rm ati on ............................................. 7 Pr opo rt i on er Mo del s ............................................. 9 Sy ste ms ........................................................ ..... 10 Ac ces sor ie [...]

Warnings Warnings The following warnings are for the setup , use, grounding, main tenance and re pair of thi s equipment. The exclamation p oint symbol alert s you to a general warni ng and the hazard symbol refer s to p rocedure-sp ecific risks. When th ese symbols appear in the body of th is manual refer back to the se Warnings. P roduct-speci?[...]

Warnings WARNING SKIN INJECTION HAZARD High-pressure flui d from dispensi ng device, hose le aks, or ruptured comp o nents will p ierce skin. This may look like just a cut, but it is a serious inju ry that can result in amputat ion. Get immediate surgi cal treatment . • Engage trigg er lo ck when not dispensing. • Do not point dis pensing devi[...]

Warnings WARNING PRESSURIZED ALUMINUM HAZARD Use of fluids that are i ncompatible wit h aluminum in pressuri zed equipment can cause serious chemical r eaction and eq uipment rupt ure. Failure to follow this warning c an resul t in death, serious inj ury, or property damage. • Do not use 1,1 ,1-tr ichloroet hane, methylene chlori de, other halog[...]

Warnings WARNING BATTERY HAZARD The battery may lea k, explode, cause burns, or c ause an explosion if mi shandled. • Only use the battery ty pe specified for use with the equi pment. See Technical Data . • Battery mai ntenance must only be performed or supervised by personnel kn owledgea ble of batteries and the required pre cautions. Keep un[...]

Important Two-C omponent Material Infor mation Important Two-Component Material Information Isocyanate Conditions Spraying or di spensing mat erials co ntainin g isocyanates cr eates potenti ally harmfu l mists, vapors, and atomized parti culates. Read materi al manufact urer’s war nings and material MSDS to know specifi c hazards and precaution[...]

Important Two-C omponent Material Informatio n Foam Resins wi th 245 fa Blowing Agents Some foam blow ing agen ts will fr oth at tempera tures above 90°F (3 3°C) when not und er pressure, especially i f agitated. To reduce frothing , minimize preheating i n a circulation syste m. Changing Mate rials Changing the mater ial types used in your equip[...]

Proportioner Mo dels Proportioner Models E-30i Series Includes: Part Available Auxiliary Current at 240 V, 60 Hz*  Booster Heat (4000 Watts) Air Compressor (5000 Watts) Voltage (phase) Total System Load † (Watts) Max Flow Rate lb/mi n (kg/min) Approxi- mate Out- put per Cy - cle (A+B) gal. (liter) Maximum Fluid Working Pressure psi (MPa, bar) [...]

Systems Approvals Model Approvals: 259079 Conforms to ANSI/UL Std. 73 Certi fied to CAN/CSA Std. C22.2 No. 68 259080 259081 Conforms to ANS I/UL Std. 499 Cer tified to CAN/CSA S td. C22.2 No. 88 Systems Heated Hos e Gun Part Maximum Fluid Working Pressure psi (MPa, bar) Proportio ner Remote Displ ay Module Kit 50 ft (15 m) 10 ft (3 m ) Model Part[...]

Accessories Systems with A ir Compressor Heated Hose Gun Part Maximum Fluid Workin g Pressure psi (MPa, bar) Proportioner Air Compressor Remote Display Module Kit 50 ft (15 m) 10 ft (3 m) Model Part AP9089 2000 (13.8, 1 38) 259089 ✓ 24K240 246050 Fusion™ AP 246101 AP9090 2000 (13.8 , 138) 259090 ✓ 24K240 246050 Fusio n™ AP 246101 AP9091 350[...]

Supplied Manual s Supplied Manuals The following manuals are shipped with th e Reactor. Refer to these manuals for det ailed equi pment information. Manuals are als o available at www .graco.com . Manual Descript ion 3A1705 Reactor E-30i and E-XP2i, Operatio n 16K761 Reactor E-30i a nd E-XP2i, Startup Instructions 16K913 Reactor E- 30i and E-XP2i, [...]

Typical Install ation, w ith circulation Typical Insta llation, w ith circulatio n S M B D G K M R J G H K L J R A F C* P E Figure 1 * Shown exposed for clarity. Wrap with tape during opera tion. A Reactor Proportione r BH e a t e d H o s e CF l u i d Temperature Sensor (F TS) D Heated Whip Hose E Fus ion Spray Gun F Gun Air Supply Hose GF e e d Pu[...]

Typical Install ation, without circulation Typical Installation, without circulation G K M J G H K L J A F B C* P E D N S N Figure 2 * Shown exposed for clarity. Wrap wit h tape durin g operation. A Rea ctor Proportioner B Hea ted Hos e CF l u i d Temperature Sensor (FTS) D H e a t e dW h i pH o s e E Fus ion Spray Gun F Gun Air Supply Ho se GF e e[...]

Component Ident i fi cation Component Ide ntification GG PC DG EM PA PB PT MP DB GB SB GA SA BA BB FA FB HC SC HA HB (FM) Front V iew Figure 3 BA Compon ent A Pressure Re lief Outlet BB Compo nent B Pressure Relief Out let DG Driv e Gear Housing DB Electrical Enclosure EM Electric Motor FA Comp onent A Flui d Manifold I nlet FB Comp onent B Flui [...]

Component Ident i fi cation MM LM HM EC LR HE VA VB HE SG CP FH VC FV FF FF Back Vi ew Figure 4 CP Circul ation Pump EC Elect r i c a lC o r dS t r a i nR e l i e f FF Y-str ainer (incl udes pressure gauge and tempe rature gauge) FH Booster Fluid Hea ter (not incl uded wit h all models) FV Fluid Inl et Valve (A si de shown) HE Heat Exchangers (hea[...]

Component Ident i fi cation Generator BE HB HF RC FP OD FH EX EA FS FT GD EE DF AF OF ED EB HE ER OL ST RF TR GL FJ FD OS WS Figure 5 AF Air Filter BE Batt ery (not suppl ied) DF Diesel Fuel Filter EA 12V C harge Alternator EB Engi ne Coolant Expansion Bot tle EE Engine ED Eng ine Oil Dips tick ER Radiator EX Exhaust FD Fue l Shutoff So lenoid FH [...]

Component Ident i fi cation Proportioner Control Panel PE PF* PG* PH* PJ* PD PK PL PM PR PP PN ti17151a Figure 6 PD Advanced Displ ay Module (ADM), p age 19 PE Engine Control Mod ule, page 24 PF* Component A Feed Pump Air Out let PG* Component B Feed Pump Air Outlet PH* Agitator Air Outlet PJ* Gun Air Outlet PK Component A Feed Pump Air Regulat or[...]

Component Ident i fi cation Advanced Disp lay Module (ADM) NOTICE To prevent d amage to the softkey bu ttons, do n ot press buttons wi th sharp obj ects such as pen s, plastic cards, or finge rnails. A H G C B D E F D Component Identi fication — Front Figure 8 Call out Button Func tion A Power On/O ff Powers system on and off. B System Status [...]

Component Ident i fi cation CS CR CP CN CM CL CK CJ Compone nt Identi fication — Back Figure 9 CJ Flat Panel Mount (VESA 100) CK Model an d Serial Numb er CL USB Port and Status L EDs CM CAN Cable Connection CN Module Status LEDs CP Accessory Cable Conn ection CR Token Access Cover CS Batter y Access Cover System Status Indicator (B) Cond ition[...]

Component Ident i fi cation ADM Display Details Power Up Screen The following screen appears when the ADM is powered up. It remains on while the ADM runs through initialization and establishes communication with other modules in the system. Menu Bar The menu bar appears at the top of each screen. (The following image is only an example.) Date and [...]

Component Ident i fi cation Icons Icons Icon Function Component A Component B Estimated Supply Mater ial Hose Temperature Jog Mode Speed Engine Coolan t Temperature Pressure Cycle Counter (press and hold) Advisory. See Errors, page 51 for more information. Deviation. See Errors, page 51 for more information Alarm. See Errors, page 51 for more info[...]

Component Ident i fi cation Motor Control Module (MCM) MB MA 1A 10 1B 2 3 12 MC 5 13 6 7 11 8 9 Motor Control Mo dule Figure 10 MA Token and Rotary Switch Access Cover MB Module Statu s LEDs see Module Status LEDs (CN) Conditions, page 20 MC Warning Label 1A, 1B CAN Communication Connecti ons 2 Heat Excha nger Control V ave Output ( to load center[...]

Component Ident i fi cation Engine Contro l Module NOTICE To prevent damage to the softkey but tons, do not press buttons wi th sharp object s such as pens, plastic car ds, or fingernails . For more infor mation abou t the engin e control m odule, see Append ix A: Engine C ontrol Mo dule, page 93 . Figure 1 1 Engine Control Modul e Icon Descri pt[...]

Component Ident i fi cation Load Center F3 Radiator Fan Fuse F4 Load Center Power Fuse K1 Fuel Relay K2 Starter Relay K3 Glow Plug Relay K4 Radiator Fan Relay MV Manual Valve Swit ch LED Related Component Color ON-State Description D1 Fuel Shutoff Solenoid (FS) Green Fuel shutof f solenoi d on the engine is open. D2 Starter (ST) Red Starter is cra[...]

Component Ident i fi cation Temperature C ontrol Modules Located inside t he Electrical Enclosure (DB). High Power Temperature Co ntrol Modu le (HPTCM) Cable Con nections 3 1 2 Figure 12 5 7 6 8 4 Figu re 13 1N o t u sed 2 Fluid Temperatu re Sensor (FTS) Connection 3 Out put Power Connecti on 4 Con tactor Contr ol Connection 5 Inp ut Power Connect[...]

Component Ident i fi cation Adjust Rotary Switch The rotary swi tch setting i ndicates which zone t he temperature con trol module wil l control in the system. The HPTCM uses an 8-posit ion rotary swi tch. The LPTCM uses a 16-position r otary switch. Set the rotar y switch (S) to the specific selection according to the settin gs listed in the fol[...]

Component Ident i fi cation Circuit Break ers CB01 CB02 CB03 CB04 CB05 CB06 CB07 CB08 CT01 Circuit B reakers Inside Ele ctrical Enclosure (DB ) Figure 1 8 Note Not all wires are shown. Ref. Size Component CB01 30 A High Power Tem perature Control Modu le (HPTCM) CB02 20 A Mot or Control Modul e (MCM) CB03 5A Two Motor Fans, Cabinet Fan, Power Sup [...]

Component Ident i fi cation CB10 Circuit Breakers Ins ide Alternator A ssembly Figure 20 Ref. Size Component CB10 90 A 120/240V Alte rnator Circuit Breaker Configuration Options Improper configurat ion can result in electric sho ck. All changes from the recomme nded circuit brea ker configuration must mee t all Nationa l, State, and Loca l safe[...]

Overview Overview The system use s two coolant loops to use h eat released from the engine to heat the A and B component mat erial to the target temperatures defined on the ADM (PD). The engine cool ant loop (gra y) circulat es heated coolant from t he engine (EE), th rough the heat exchanger (H E ), radiator (ER), and back to the engine. C oola n[...]

Overview The proporti oner coolan t loop circu lates cool ant through seco ndary heat exch angers (HE) locat ed on the back of the proportion er to heat t he A and B component material before the mat erial i s pressurized in the propo rtioner pumps (PA, PB). Aft er the A and B mate rial has be en heated i n the heat exchangers, the materi al enters[...]

Overview Coolant only flows t hrough the se condary heat exchangers when the heat exchange r control valves (VA, VB) ar e open and the A an d B component temperat ures are below the targe t temperatur es set on the ADM. S ee Fig. 24 . When the c ontr ol valves (VA, VB) close, the A and B materia l has reached target temperature. Coolant flows thr[...]

Setup Setup NOTICE Proper syste m setup, st artup, and shutdown procedures are criti cal to electri cal equipment reliability. The f ollowing procedu res ensure steady voltage. Failure to follow these proced ures will cause voltage fluctu ations that can damage electrical equipment and v oid the warran ty. NOTICE Do not remo ve or separate the pro[...]

Setup A5 A1 A2 AS AN A3 AT A3 A4 A2 A6 A4 34 3A1705J[...]

Setup Trailer Setup Guidelines Route exhaust system a w ay from combustible materials t o prevent mater ials from ig niting or gas recircul ation int o a wall, ceili ng, or a concealed space. Provide exhaust system guards to prevent burns. NOTICE Provide recommended siz e louvers. Failure to do so can damage the engi ne and voi d the engine warrant[...]

Setup Install Wall ( optional) Install a wal l between the proporti oner and generat or to: • Temperatu re conditi on the trailer spa ce where chemical is stor ed. Check with chemical manufactur er for chemical st orage temperat ures. • Reduce noise fo r the operator wh ile the Reactor is running. The supplied f uel lines and b attery cable m a[...]

Setup Top View Wi th Wa ll Figure 2 7 Side View With Wall Figure 28 3A1705J 37[...]

Setup Connect Batte ry Improper batte ry instal lation or mai ntenance may result in electr ic shock, chemical burns, or explosion. Battery maintenance must only be performed or supervised by personnel knowledgeable of b atteries and t he required precautions. Keep unauthori zed personnel a way from batteri es. See Technical Specificat ions, page [...]

Setup Electrical Co nnections Connect air compres sor, breathing air, an d auxiliary power electri cal connectio ns to the specified circu it breakers. See Circuit B reakers, page 2 8 . 1. Remove one or more knock-outs on si de of electrical enclosure, as required, an d route wires thr ough for air comp ressor, breathing air, and au xiliary equipm[...]

Setup Connect Press ure Relief Lines Do not operate Reacto r without al l covers and shrouds in place. 1. Recommended: Connect high pressur e hose (R) to relief fittings (BA, BB) of both PRESSURE RELIEF/SPRAY valves. Route hose back to c omponent A an d B drums. See Typical Instal lation, wit h circulatio n, page 13 . 2. Alternately: Secure suppli[...]

Setup Close gun fluid manifold valves A and B Connect Whip Hose to Gun Or Gun Fluid Manifold See hose manual for pr oper connecti ons. Pressure Check Hose See hose manual. Pressure check for le aks. If no leaks, wrap hose and electrica l connection s to protect from damag e. Connect Remote Display Module See Remote Display Module kit manu al for i[...]

Setup Supply Wet Cup s With Throat Seal Liquid (TSL) Pump rod and connectin g rod move during operation. Moving parts can cause serious inju ry such as pinching or amputation. Keep hands and fingers away from wet-cup duri ng operation. To prevent the p ump from moving , turn the main power switch OFF. • Component A (ISO) Pump: Keep reservoi r (R[...]

Advanced Displa yM o d u l e( A D M )O p e r a t i o n Advanced Disp lay Module (ADM) Operation When main powe r is turned on by turni ng the main power switch ( MP) to the ON position, the splash screen will b e displayed unti l communica tion and initializat ion is complete. Then the power key icon screen wil l display unt il the ADM power on/o f[...]

Advanced Displa yM o d u l e( A D M )O p e r a t i o n Setup Mode The ADM will start in the Run screen s at the Home screen . From the Run scr eens ,p r e s s to access the Setup screens. The system defaults wit h no password, entered as 0000. Enter the current passw ord then press .P r e s s to navigate through the Setup Mode screens. See Setup Sc[...]

Advanced Displa yM o d u l e( A D M )O p e r a t i o n Setup Screens Navi gation Di agram Figure 36 3A1705J 45[...]

Advanced Displa yM o d u l e( A D M )O p e r a t i o n Advanced Setu p Screens Advanced setup screens ena ble users to set units, adjust values, set for ma ts, and view softwa re informatio n for each compone nt. Press to scroll thr ough the Advanced setup screens, Once in the desi red Advanced setup s creen, press to access the fields and make ch[...]

Advanced Displa yM o d u l e( A D M )O p e r a t i o n System Use this screen t o set the activatio n pressure for the Pressure Imbalance Alar m and Advisory, enable or disable diagno stic scr eens, enable d rum alarms, set the maximum drum volume, e nable drum alarms, and set lo w material a larm leve l. Recipes Use this screen to add recipes, vie[...]

Advanced Displa yM o d u l e( A D M )O p e r a t i o n Run Mode The ADM will start in t he Run screens at the “Home” screen. Press to navigat e through the Ru n Mode screens. See Ru n Screens Navigation Dia gram, page 44 . From the Run screens, press to access the Setup screens. 48 3A1705J[...]

Advanced Displa yM o d u l e( A D M )O p e r a t i o n Run Screens Navigati on Diagram Figure 37 3A1705J 49[...]

Advanced Displa yM o d u l e( A D M )O p e r a t i o n Home — System Off This is the home scree n when the syst em is off. This screen displays act ual temperatur es, actual pressures at the flui d manifold, jo g speed, coolant temperature , and number of cycles. Home — System Active When the system is a ctive, th e home screen di splays actua[...]

Advanced Displa yM o d u l e( A D M )O p e r a t i o n Maintenance Use this screen to vie w daily and lifetime cy cles or gallons th at have been pumped and gal lons or lit ers remaining i n the drums. The lifetime v alu e is the numbe r of pump cycle s or gallons sinc e t he first time the ADM was turned on. The daily value a utomatically re sets[...]

Advanced Displa yM o d u l e( A D M )O p e r a t i o n Diagnostic Use this screen to view info rmation for all system components. The follo wing information is d isplayed: Temperature • Hx A Chem: Heat Exchange r A Chemical • Hx B Chem: Heat Exchange r B Chemical • Hose Chemical • Booster A Chemical • Booster B Chemical • Booster A PCB [...]

Advanced Displa yM o d u l e( A D M )O p e r a t i o n Troubleshooting This screen disp lays the last ten e rrors that occurred on the s ystem. Use the up and down arrows to sel ect an errors and press to view troublesh ooting in formatio n for the select ed error . Press to acce ss troubleshootin g screen for an error code th at is not li sted on [...]

Advanced Displa yM o d u l e( A D M )O p e r a t i o n System Events Use the table bel ow to find a descri ption for al l system events. All events ar e logged in t he USB log files. Event Code Descript ion EA C X Recipe Select ed EA DA Heat On A EA DB Heat On B EA DH Heat On Hose EA P X Pump On EA RX Jog On EA UX USB Drive Inserted EB 0 X ADM Re[...]

Startup Startup To prevent seriou s injury, only oper ate Reactor with all c overs and shrouds i n place. NOTICE Proper syste m setup, st artup, and shutdown procedures are criti cal to electri cal equipment reliability. The f ollowing procedu res ensure steady voltage. Failure to follow these proced ures will cause voltage fluctu ations that can [...]

Startup 8. Check coolant color. Use a flashlight to inspect the color of t h e coolant through sig ht glass (SG). Th e mesh filter should be visible inside t he sight glass and t he coolant should be green. If there are a lot o f air b ubbles, then the cool ant level may be low. If the c oolant is a milky color, th en that indicat es A o rBm a t [...]

Startup f. Open fluid inlet valv es (FV). Check for lea ks. Do not mix component s A and B during startup. Always pro vide two grounde d waste contai ners to keep component A and component B fluids separate . g. Hold gun fluid manifold over two gro unded waste containers. Open fluid valves A and B until clea n, air-free fluid co mes from valve[...]

Temporary Manua l Hose Tempe rature Control Temporary Manual Hose Temperature Co ntrol If T6DH error c ode appears fr om a break in the hose RTD cable or FTS sen sor, follow the st eps for temporary manua l hose temperat ure control. Repair or replace the hose RTD cable or FTS as soon as job is finished. 1. Connect the spare RTD (15V837), shipped [...]

Fluid Circulati on Fluid Circula tion Circulation T hrough Reactor NOTICE Do not circul ate flu id contain ing a blo wing agent without c ons ulting with your mat erial suppl ier regarding fl ui d temperature l imits. To circulate thr ough gun manifol d and preheat h ose, see Circulation Thr ough Gun Manifold , page 60 . 1. Follow Sta rtup, page [...]

Jog Mode Circulation T hrough Gun Manifold NOTICE Do not circula te fluid containi ng a blowin g agent without cons ult ing with your mat erial supp lier regarding flu id te mperature limit s. Circulating fluid throug h the gun manif old allo ws rapid prehe at ing of the hose. 1. Install gun flu id manifol d (P) on accessory circulation kit (CK[...]

Spraying Spraying The Fusion AP gun is shown. 1. Engage gun pist on safety l ock. 2. Close gun flu id inlet valves A and B. 3. Attach gun flui d manifold. Connect gun air lin e. Open air line v alve. 4. Adjust the gun air regulator on the pr oportioner control pane l to desired gun air pressure. Do not exceed 130 psi (0.2 MPa , 2 bar). 5. Set PRE[...]

Spraying 12. Open gun fluid inlet valves A and B. Note On impingement guns, never open fluid manifold va lves or trigger gun if pressures are imbalanced. 13. Disengage gun piston safety lo ck. 14. Tes t spr ay onto ca rdboard. A djust pressure and tempera ture to get des ired results . 15. Equipment is ready to spr ay. Spray Adjustm ents Flow rat[...]

Shutdown Shutdown NOTICE Proper system setup, startup , and shut down procedures ar e crit ical to electri cal equipment reliability . The following procedur es ensure steady voltage. Fa i lure to follow these procedure s will cause volta g e fluctuations that can dama ge electrical e qui pment and voi d the warranty. 1. Press to stop the pu mps. [...]

Pressure Relief Procedure Pressure Relief Procedure This equipme nt st ays pressurized until pressure is manually r elieved. To help prevent serious injury from p ressurized fluid, such as skin injection, splashing flu id and moving parts, follow the Pressure Rel ief Procedure whe n you stop spray ing and before c l eaning, checking, or servicing[...]

Flushing Flushing To prevent fire and explosion, flush equ ipment only in a well-vent ilated area. Do not spray flammable fluids. Do not turn on heaters while flushing w ith flamma ble solvents. • Flush out old fluid with new fluid, or flush out old fluid with a compatibl e solvent before intr oducing new fluid. • Use the lowest poss[...]

Maint enan ce Maintenance Prior to perfo rming any maint enance procedures, follow Pressu re Relie f Procedur e, page 64 . Preventative Maintenance Schedule The operati ng cond itions of yo ur particul ar system determine h ow often maintenance is r equired. Establish a preventive mainten ance schedule by recording w hen and what kin d of maintena [...]

Maintenance Engine Maintenance The engine ins tructi ons that accompany yo ur unit detail sp eci fic procedures f or maintenance of the engine. Fo llowing the engine manufacturer ’s recommenda ti ons will extend eng ine work life. Daily • Cooling System Cool ant Level — Check • Engine Air Cleaner Service Ind icator — Insp ect • Engine [...]

Maint enan ce Pump Lubricat ion System Check the conditio n of the ISO pump lubricant da ily. Change the lubri cant if it becomes a gel, its co lor darkens, or it becomes diluted wit h isocyanate. Gel formatio n is due to mois ture absorpti on by the pump lubrica nt . The interv al betwee n changes depends on th e envir onment in which t he equipme[...]

Maintenance Drain Coolant To avoid burns, do not perf orm maintenance on the coolant system unti l the coolant syst em has reached ambient temperat ure. Drain coola nt from the en gine and prop ortioner coolant loops once a year or if the cool ant lines need to be disconnected, i n order to inst all a wall bet ween the generator an d proportio ner.[...]

Maint enan ce 6. To drain engin e coolant loop: a. Remove t he eng ine coolant l oop (RC) ca p. b. Remov e engine guards as shown. Let the guards rest on t h ee n g i n et oa c c e s s t h ed r a i n valve. Engine Coolant Loop Drain V alve Figure 43 c. Place a waste contai ner under the drai n valve. Open the drai n valve and drain coolant. d. To r[...]

Maintenance 3. Replace cap. Tigh ten past the “safety” l atch positi on. 4. Press start bu tton twice on the engine control modul e. 5. Turn main pow er switch on. 6. Inspect coolant flow in sight glass (SG) fo r bubbles and t o verify that t he coolant is flowing. 7. Inspect coolant loops f or leaking fittin gs or valves. 8. The coolant has[...]

Maint enan ce Refill Engine C oolant Loop Refill the engin e coolant loo p when the coolant is below the cold le vel line at ambient te mperatur e. To avoid burns, do not perf orm maintenance on the coolant system until t he coolant system has reached ambient t emperature. Only use coolant sol utions that are c ompatible wi th the system. See Coo[...]

Errors Errors View Errors When an error occurs the error in formatio n screen displ ays the active error code and descripti on . T o diagnose t he active erro r, se e Troublesho ot Errors, page 73 . The error code, alar m bell, and active erro rs will scroll in the status ba r. For a list of the ten m ost recent errors see Troublesho oting, page 74[...]

Troubleshootin g Troubleshooting See Errors, page 73 for informat ion about error s that can occur on the system. See Troubleshoot ing, page 53 for the ten most recent errors that have occurred on the system. See Troubleshoot Er rors, page 73 to diagnose e rrors on the ADM that have occurre d on the system. See Error Code s and Troubleshooti ng for[...]

Troubleshootin g Error Code Error Location Type Nam e Cause Solution Wiring probl em. Check wiring b etween HPTCM and cont actor. Look for short ed wire between HPTCM and contactor te rminals A1 and A2. A4CH Hose ALARM High Relay Current Hose Shorted con tactor. Measure resi stance between A1 a nd A2 terminals. The resis tance should be ab out 289?[...]

Troubleshootin g Error Code Error Location Type Name Cause Solution Short circuit of motor wiring. Check wiring t ot h em o t o r to ensure no b a re wires are touching a nd tha t no wires are s h orted to ground. Motor will no t rotate. Replace motor. See system repair manu al. A4NM MCM ALARM High Motor Current Chemical pump is stuck Repair or rep[...]

Troubleshootin g Error Code Error Location Type Nam e Cause Solution Module does not have software or dial is set to wrong position. Insert a system token into the missing G CA module and cycle the power. Wait until the red light on th e module stops flashing before removing the token. V erify the dial on the module is in the correct position: 0 f[...]

Troubleshootin g Error Code Error Location Type Name Cause Solution Mix chamber to o l arge for system select ed. Use mix chamber rated for system. Ensure the sy stem has chemical a nd the feed pumps are ope rating correctly. No material in pumps. Verify pump sa r e supplying c hemical. If necessary, replace or refill drums. DADX MCM ALARM Pump Ru[...]

Troubleshootin g Error Code Error Location Type Nam e Cause Solution MBN0 MCM ADVI- SORY Motor Brush Wear Brushes have w orn down and need replacing. Replace Brush es. See system repair ma nual. MMUX USB ADVI- SORY USB Log Full USB logs have reached a level were d ata loss will occur if logs are not download ed. Use a USB driv ea n d download all l[...]

Troubleshootin g Error Code Error Position Type Nam e Cause Sol ution Pressure diff erence between A and B mater ial is greater tha nt h e defined value. Ensure the mat erial flow is equally rest r i c t e do nb o t h materia l line s. Pressure imb alance is defined too l o w. Ensure that t h e pressure imbalance va lue, on the System Setup scre[...]

Troubleshootin g Error Code Error Position Type Name Cause Solut ion Recirculating materi al to heat with drum feed pumps only. Recirculate mat erial using Jog mode fo r heat exchanger heatin g. Coolant circ ul ation pump not working. Check for 240 VAC on pump. If ther ei st h ec o r r e c t voltage, rep lace circulation pump. S ee sys tem repair m[...]

Troubleshootin g Error Code Error Position Type Nam e Cause Sol ution Flow is too high a t current setpoint. Use a smaller mix chamber that is rated for the uni t in use. T2DA T2DB Boost A Boost B ALARM Low Chemical Temperature Bad heater(s ) Confirm resis ta nce of heater is 23–26.5 oh ms. Rep lace if OL/open loop . T2DH Hose ALARM Low Chemical[...]

Troubleshootin g Error Code Error Position Type Name Cause Solut ion Cooling fan no t oper ating. If fan is n ot wo rking check wiring betwee nC B 0 3a n d fan. If wiring is good, replace fan. T4CA T4CB T4CH Boost A Boost B Hose ALARM (T4CA or T4CB) LPTCM Over Temperature (T4CH) HPTCM Over Temperatur e Overheated module. Turn controller off. Wait a[...]

Troubleshootin g Error Code Error Position Type Nam e Cause Sol ution Hose portion exposed to an excessive heat source, like hot sun or coiled hose, can pas s fluid more than 27°F (15°C) ove r temperatur e s e t t i n gt ot h eF T S . Shade ex posed hose from hot sun or expo se FTS to same environm ent when at rest. Uncoi l entire hose before he[...]

Troubleshootin g Error Code Error Position Type Name Cause Solut ion T6AE Heat Exchanger A Broken or loos e RTD cable or connection . Check all wiri ng and connection to RTD. T6BE Heat Exchanger B T6DA Boost A T6DB Boost B T6DE Engine Heat Exchanger ALARM RTD Fault Bad RTD. Switch the RT D with another and see if th e error message follows the R TD[...]

Troubleshootin g Error Code Error Position Type Nam e Cause Sol ution Low chemical supply temperature. Recirculate heated chemical back to drum in cold conditions before spraying. Chemical below 32°F(0°C) a t startup. System stored below 20°F(-7°C) causing slow control valve operatio n. Ensure ambient temperature is above 20°F(-7°C). Plugged [...]

Troubleshootin g Error Code Error Position Type Name Cause Solut ion Bad heater rod (boost). Measure resistance, 23 – 2 6 Ω, of heater rod, repla ce if reading ope n. Low chemical supply temperature . Recirculate heated chemi cal back to drum in cold conditions before spraying chemical be low 32°F(0 °C) at startu p. Use Jog Mode for heat excha[...]

Troubleshootin g Error Code Error Position Type Nam e Cause Sol ution Bad Connectio n bet ween MCM (Port 2) an dl o a d center board. Check connect ion and cables. WMCE MCM ALARM Load Center Fa ult Bad load cent er. Re place load cen ter. See System Repair manual. WSCX ADM ADVISORY Invalid CAN Configuration Duplicate nod e on CAN network. Verify L[...]

USB Data USB Data USB Logs Note T h eA D M c a nr e a d / w r i t e t oF A T( F i l e Allocation Table ) storage devices. NTFS, used by 32 GB or greater storage device s, is not supported. During operati on, the ADM stores system and performan ce related i nformati on to memor y in the form of log fi les. The ADM main tains four lo g files: • E[...]

USB Data Daily Log The daily log file name is 3–DAIL Y.CSV and is stored in the DATAxxxx folder. The daily log m aintains a record of the total cycle and volum e spr ayed on any day that the system is powered up. T he vo lume units will be the same units that were use d in the Job Log. The following da ta is stored in this file: • Date that m[...]

USB Data Download Procedure Note System configuratio n setting files and custom language file s can be modified if t he files are in the UPLOAD folder of the U SB flash drive. See System Configuration S ettings File, Custom Languag e File, and Upload Procedure sections. Note If needed, s et the number of days to download on the Advanced Setu[...]

USB Data Create Custom Language Strin gs The custom language file is a tab-deli mited text file that cont ains two column s. The first col umn consists of a list of strings in the lang uage selected a t the time of download . The seco nd column can be us ed to enter the cust om language str ings. If a custom language was pre viously insta lled, [...]

Appendix A: Engi ne Contro l Module Appendix A: En gine Control Module Run Screens There are seve n run screens on t he engine con trol modul e: • Line-to-n e utral volt age • Line-to-l i ne voltage • Frequency •E n g i n e S p e ed • Engine lif etime counter •B a t t e r y v o ltage Press to scroll thro ugh the run scr eens. Pre ss to [...]

Appendix A: Engi ne Control Module Mode Icons An icon is di splayed in t he mode icon a rea of the dis play to i ndicate wh at mod e the unit i s current ly in. Icon Descrip tion Details Stopped Engin e is at re st and the unit is i n stop mode. Auto Engine is at r est and the unit is in auto mode. Manual Engine is at rest a nd the unit is in man u[...]

Appendix A: Engi ne Contro l Module Alarms There are two types of ala rms that can occur on the s ystem. Alarms are indica t e db ya ni c o nt h eR u na n d Information screens. Warning When present on system, a warning alar m will not stop the generat or. Icon Description Details Battery Hig h Voltage The DC Supply has ri sen above the high vol ts[...]

Dimen sions Dimensions Top View Figure 45 Side View Figure 46 96 3A1705J[...]

Dimensions Top View: System with Compre ssor and Hose Rack Accessori es Figure 47 Front View Figure 48 Side View: System with Compressor and Hose Rack Accessori es Figure 49 3A1705J 97[...]

Dimen sions Pallet Mounting Dimensi ons Figure 50 98 3A1705J[...]

Performa nce Cha rts Performance Charts Use these charts t o help ident ify the pro portione r that wil l work most ef fic iently with eac h mix chamber. Flow rates are based on a material viscosity of 60 cps. Proportioners For Foam AR6060 (03) AR7070 (04) AR5252 (02) AR4242 (01) 2000 (138) 1 500 (103) 1 000 (69) 500 (34) 05 (2.3) 15 (6.8) 20 (9.1[...]

Performance Cha rts Table 2 Fusion Air Purge, Flat Patt ern 3500 (241, 24.1) 3000 (207, 20.7) 2500 (174, 17.4) 2000 (138, 13.8) 1 500 (103, 10.3) 1 000 (69, 6.9) 500 (35, 3.5) AF2020 (FTXX24 TIP) E-XP2i 0 0.5 (1 .9) 1.5 (5.7) 1.0 (3.8) 2.0 (7.6) AF2929 (FTXX38 TIP) AF4242 (FTXX38 TIP) AF5252 (FTXX48 TIP) PRESSURE psi (bar) FLOW gal./m in (kg/min) T[...]

Performa nce Cha rts Table 4 Fusion Mechanical Purge, Flat Pattern 3500 (241, 24.1) 3000 (207, 20.7) 2500 (174, 17.4) 2000 (138, 13.8) 1 500 (103, 10.3) 1 000 (69, 6.9) 500 (35, 3.5) E-XP2i 0 0.4 (1 .5) 0.6 (2.3) 0.8 (3.0) 0.2 (0.7) 1.4 (5.3) 1.2 (4.5) 1.6 (6.0) 1.8 (6.8) 1 (3.8) 2.0 (7.6) XF1313 (FTM424) MF1818 (FTM424) XF1818 (FTM424) XF2323 (FTM[...]

Technical Speci fi cations Technical Spe cifications E-30i Models U.S. Metric Maximum Flui d Working Pr essure Pressure 2000 psi 14 MPa, 140 bar Maximum Flu id Temper ature E-30i 140°F 60°C E-30i with booster heater 180°F 82°C Maximum O utput Output 30 lb/min 13.5 kg/min Maximum Heated Hose Length Length 310 ft 94 m Output per Cycle A and B 0[...]

Technical Speci fi cations Recommended Air Compressors Champion® BR- 5, Base Mount Specifications 5 HP, 240 V, 1 Phase, 60 Hz, 21 cfm Belt guard aftercool er Required F eatures Pilot valve unlo ader Quincy QP–5–5B, Base M ount Specifications 5 HP, 240 V, 1 Phase, 60 Hz, 17.2 cfm Belt guard aftercool er Required F eatures Pilot valve unlo ad[...]

Technical Speci fi cations E-XP2i Models U.S. Metric Maximum Flui d Working Pr essure Pressure 3500 psi 24.1 MPa, 241 bar Maximum Flui d Temperature E-XP2i 180°F 82°C Maximum Output Output 2 gpm 7.6 lpm Maximum Heated Hose Length Length 310 ft 94 m Output per Cycle A and B 0.0203 g al. 0.077 1 l iter Operating Ambien t Temperature Range Temper a[...]

Technical Speci fi cations Recommended Air Compressors Champion® BR- 5, Base Mount Specifications 5 HP, 240 V, 1 Phase, 60 Hz, 21 cfm Belt guard aftercool er Required F eatures Pilot valve unlo ader Quincy QP–5–5B, Base M ount Specifications 5 HP, 240 V, 1 Phase, 60 Hz, 17.2 cfm Belt guard aftercool er Required F eatures Pilot valve unlo ad[...]

Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufac tured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by G raco, Graco will, for a perio[...]