334946B, Reactor 2 Hydraulic Proportioning Systems, · PDF fileReactor 2 Hydraulic - Troubleshooting ... Reactor 2 Hydraulic Proportioning Systems, Repair, Parts (English ... 334946,

Troubleshooting

TroubleshootingTroubleshootingTroubleshooting

TroubleshootTroubleshootTroubleshoot ErrorsErrorsErrors

There are three types of errors that can occur. Errorsare indicated on the display as well as by the lighttower (optional).

ErrorErrorError DescriptionDescriptionDescription

AlarmsAlarmsAlarms A parameter critical tothe process has reacheda level requiring thesystem to stop. Thealarm needs to beaddressed immediately.

DeviationsDeviationsDeviations A parameter criticalto the process hasreached a level requiringattention, but notsufficient enough tostop the system at thistime.

AdvisoriesAdvisoriesAdvisories A parameter that isnot immediately criticalto the process. Theadvisory needs attentionto prevent more seriousissues in the future.

See Error Codes, page 17, for causes and solutionsto each error code.

To troubleshoot the error:

1. Press the soft key for help with the active error.

Note

Press or to return to thepreviously displayed screen.

2. The QR code screen will be displayed. Scanthe QR code with your smartphone to be sentdirectly to online troubleshooting for the activeerror code. Otherwise, manually navigate tohttp://help.graco.com and search for the activeerror.

3. If no internet connection is available, seeError Codes, page 17, for causes and solutionsfor each error code.

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Reactor 2 Hydraulic - Troubleshooting - Error Codes

Troubleshooting

ErrorErrorError CodesCodesCodesNote

When an error occurs be sure to determine the code before resetting it. If you forget which error codeoccurred, see the Errors screen to view the last 200 errors, with date, time, and description.

ErrorErrorError LocationLocationLocation TypeTypeType DescriptionDescriptionDescription CauseCauseCause SolutionSolutionSolution

Short circuit inheater wiring.

Check wiring for touchingwires.

A4DA Heater A High Current A

Bad Heater. Confirm resistance ofheater. Heater resistanceshould be 18–21 Ω foreach heater element, 9–12Ω combined for 10 kWsystems, 6-8 Ω for 15 kWsystems, and 4–6 Ω for20 kW systems. If out oftolerance, replace heaterelement.

Short circuit inheater wiring.

Check wiring for touchingwires.

A4DB Heater B High Current B

Bad Heater. Confirm resistance ofheater. Heater resistanceshould be 18–21 Ω foreach heater element, 9–12Ω combined for 10 kWsystems, 6-8 Ω for 15 kWsystems, and 4–6 Ω for20 kW systems. If out oftolerance, replace heaterelement.

Check continuity oftransformer windings.Normal readings are about0.2Ω on both primary andsecondary. If reading is 0Ωreplace transformer.

A4DH Hose High Current Hose Short circuit inhose wiring.

Check for shorts betweenthe primary winding and thesupport frame or enclosure.

A7DA Heater A Unexpected CurrentA

Shorted TCM If error cannot be clearedor regenerates consistently,replace module.

A7DB Heater B Unexpected CurrentB


A7DH Hose Unexpected CurrentHose


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Troubleshooting


Tripped circuitbreaker.

Visually check circuitbreaker for a trippedcondition.

A8DA Heater A No Current A

Loose/brokenconnection.

Check heater wiring forloose wires.



A8DB Heater B No Current B





A8DH Hose No Current Hose



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Troubleshooting


Module does nothave software.

Insert a system token intothe ADM module and cyclethe power. Wait until theupload is complete beforeremoving the token.

Dial set to wrongposition.

Ensure the HCM dial is setto the correct position:

• H-30 = 0

• H-40 = 1

• H-50 = 2

• H-XP2 = 3

• H-XP3 = 4

No 24 VDC supplyto module.

Green light on each moduleshould be lit. If green light isnot lit, check to make sureeach CAN cable connectionis tight. Verify the powersupply is outputting 24VDC. If not, check powersupply wiring. If wiring isokay, replace the powersupply.

CACM HCM HCM Communica-tion Error

Loose or brokenCAN cable.

Check the CAN cablesrunning between GCAmodules and tighten ofneeded. If the problemstill persists move eachcable around the connectorand watch the flashingyellow light on the GCAmodules. If the yellow lightstops flashing, replace theCAN cable.

334946B 19


Troubleshooting


Module does nothave software.

Insert a system token intothe ADM module and cyclethe power. Wait until theupload is complete beforeremoving the token.

No 24 VDC supplyto module.

Green light on each moduleshould be lit. If green light isnot lit, check to make sureeach CAN cable connectionis tight. Verify the powersupply is outputting 24VDC. If not, check powersupply wiring. If wiring isokay, replace the powersupply.

CACT TCM TCM CommunicationError

Loose or brokenCAN cable.

Check the CAN cablesrunning between GCAmodules and tighten ofneeded. If the problemstill persists move eachcable around the connectorand watch the flashingyellow light on the GCAmodules. If the yellow lightstops flashing, replace theCAN cable.

Mix chamber too large forsystem selected. Use mixchamber rated for system.

Ensure the system haschemical and the feedpumps are operatingcorrectly.

No material in pumps.Verify pumps are supplyingchemical. If necessary,replace or refill drums.

DADX HCM Pump Runaway Flow rate is toolarge.

Inlet ball valves are closed.Open ball valves.

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Troubleshooting


EVCH ADM Manual Hose ModeEnabled

Manual hose modehas been enabledin System Setupscreen.

Install a functioning fluidtemperature sensor (FTS)on the hose. Manual hosemode will automatically turnoff.

EAUX ADM USB Busy USB drive hasbeen inserted tothe ADM.

Do not remove USB driveuntil download/upload iscomplete.

EVSX HCM Standby System hasentered standby.

Trigger gun to resumespraying.

Turn off standby in setupscreens.

EVUX ADM USB disabled USBdownload/uploadsare disabled.

Enable USB download/up-loads on the AdvancedSetup screen before insert-ing a USB drive.

H2MA Heater A Low Frequency A Line frequency isbelow 45 Hz

Ensure line frequency ofincoming power is between45 and 65 Hz.

H2MB Heater B Low Frequency B Line frequency isbelow 45 Hz


H2MH Hose Low Frequency Hose Line frequency isbelow 45 Hz


H3MA Heater A High Frequency A Line frequency isabove 65 Hz


H3MB Heater B High Frequency B Line frequency isabove 65 Hz


H3MH Hose High FrequencyHose

Line frequency isabove 65 Hz


334946B 21


Troubleshooting


L1AX ADM Low Chemical LevelA

Low material level. Refill material and updatedrum level on ADMMaintenance screen.

Alarm can be disabled onthe System Setup screen.

L1BX ADM Low Chemical LevelB

Low material level. Refill material and updatedrum level on ADMMaintenance screen.

Alarm can be disabled onthe System Setup screen.

MMUX USB Maintenance Due -USB

USB logs havereached a levelwhere data losswill occur if logs arenot downloaded.

Insert a USB drive into theADM and download all logs.

Pressuredifference betweenA and B materialis greater than thedefined value.

Ensure material flow isequally restricted on bothmaterial lines.

Pressureimbalance isdefined too low.

Ensure that the pressureimbalance value, on theSystem Setup screen, is atan acceptable maximumpressure to preventunnecessary alarms andabort dispenses.

Out of material. Fill tanks with material

Fluid leaking fromheater inlet rupturedisk.

Check if heaterand PRESSURERELIEF/SPRAY valve areplugged. Clear. Replacerupture disk. Do not replacewith a pipe plug.

P0AX HCM Pressure ImbalanceA High

Feed systemdefective.

Check feed pump andhoses for blockage. Checkthat feed pumps havecorrect air pressure.

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Troubleshooting









P0BX HCM Pressure ImbalanceB High



Inlet pressurelower than definedvalue.

Ensure that inlet pressureto the pump is sufficient.

P1FA HCM Low Inlet Pressure A

Value defined toohigh.

Ensure that the lowpressure alarm leveldefined on the SystemSetup screen is acceptable.



P1FB HCM Low Inlet Pressure B





P2FA HCM Low Inlet Pressure A



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Troubleshooting




P2FB HCM Low Inlet Pressure B



Systempressurized beforeallowing heat toreach setpoint.

Pressure in the hose andpumps will increase as thesystem heats up. Turn onheat and allow all zonesto reach the temperaturesetpoint before turning onthe pumps.

Bad pressuretransducer.

Verify the ADM pressurereading and the analoggauges at the manifold.Replace transducer if theydo not match.

P4AX HCM High Pressure A

H-XP2 or H-XP3system configuredas H-30, H-40, orH-50.

Alarm level is lower forH-30, H-40 and H-50 thanfor H-XP2 and H-XP3..Ensure dial on HCM is setto position "3" for H-XP2 or“4” for H-XP3.

Systempressurized beforeallowing heat toreach setpoint.

Pressure in the hose andpumps will increase as thesystem heats up. Turn onheat and allow all zonesto reach the temperaturesetpoint before turning onthe pumps.

Bad pressuretransducer.

Verify the ADM pressurereading and the analogguages at the manifold.

P4BX HCM High Pressure B

H-XP2 or H-XP3system configuredas H-30, H-40, orH-50.

Alarm level is lower forH-30, H-40 and H-50 thanfor H-XP2 and H-XP3..Ensure dial on HCM is setto position "3" for H-XP2 or“4” for H-XP3.

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Troubleshooting


Loose/badconnection.

Check to ensure thepressure transducer isproperly installed andall wires are properlyconnected.

P6AX HCM Pressure SensorError A

Bad sensor. Check if the error followsthe transducer. Disconnecttransducer cables fromthe HCM (connectors 6and 7). Reverse A and Bconnections and check ifthe errors follows. If theerror follows the transducer,replace the pressuretransducer.


Check to ensure thepressure transducer isproperly installed andall wires are properlyconnected.

P6BX HCM Pressure SensorError B

Bad sensor. Check if the error followsthe transducer. Disconnecttransducer cables fromthe HCM (connectors 6and 7). Reverse A and Bconnections and check ifthe errors follows. If theerror follows the transducer,replace the pressuretransducer.

Inlet sensors notinstalled.

If inlet sensors are notinstalled, inlet sensorsshould be disabled on theSystem Setup screen.


Check to ensure inletsensor is properly installedand all wires are properlyconnected.

P6FA HCM Pressure SensorError Inlet A

Bad sensor. Check if the error followsthe inlet sensor. Disconnectinlet sensor cables fromthe HCM (connectors 8and 9). Reverse A and Bconnections and check ifthe errors follows. If theerror follows the sensor,replace the inlet sensor.

334946B 25


Troubleshooting


Inlet sensors notinstalled.

If inlet sensors are notinstalled, inlet sensorsshould be disabled on theSystem Setup screen.


Check to ensure inletsensor is properly installedand all wires are properlyconnected.

P6FB HCM Pressure SensorError Inlet B

Bad sensor. Check if the error followsthe inlet sensor. Disconnectinlet sensor cables fromthe HCM (connectors 8and 9). Reverse A and Bconnections and check ifthe errors follows. If theerror follows the sensor,replace the inlet sensor.








P7AX HCM Pressure ImbalanceA High



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Troubleshooting









P7BX HCM Pressure ImbalanceB High



Flow is too high atcurrent setpoint.

Use a smaller mix chamberthat is rated for the unitin use. If recirculating,decrease flow or decreasetemperature setpoint.

Bad RTD or badRTD placementagainst heater.

Swap A and B heater outputcables and RTD cables andsee if issue follows. If so,replace RTD.

Bad heaterelement.

Confirm resistance ofheater. Heater resistanceshould be 9-12 Ω for 10kW systems and 6-8 Ω for15 kW systems. If out oftolerance, replace heaterelement.

T2DA Heater A Low Temperature A

Loose heaterwires.

Check for loose heaterelement wires.

334946B 27


Troubleshooting






Bad heaterelement.

Confirm resistance ofheater. Heater resistanceshould be 9-12 Ω for 10kW systems and 6-8 Ω for15 kW systems. If out oftolerance, replace heaterelement.

T2DB Heater B Low Temperature B

Loose heaterwires.




T2DH Hose Low TemperatureHose

Cold chemical inunheated portionof system passedhose FTS atstartup.

Recirculate heatedchemical back to drumin cold conditions beforestartup.

Recirculate fluid throughheaters until inlet fluidtemperature is abovedefined error level.

T2FA HCM Low TemperatureInlet A

Inlet fluidtemperature isbelow the definedlevel.

Increase the lowtemperature deviationlevel on the System Setupscreen.

Recirculate fluid throughheaters until inlet fluidtemperature is abovedefined error level.

T2FB HCM Low TemperatureInlet B

Inlet fluidtemperature isbelow the definedlevel.

Increase the lowtemperature deviationlevel on the System Setupscreen.

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Troubleshooting


Hose setpoint higher than Aand B setpoints. Decreasehose setpoint.

T3CH Hose Hose Cutback Hose current hasbeen reducedbecause hosehas been drawingcurrent for anextended period.

Hose FTS is in a colderenvironment than the restof the hose. Expose FTS tothe same environment asthe rest of the hose.

High ambienttemperature.

Ensure ambienttemperature is below120°F(48°C) before usingthe system.

Enclosure fan notoperating.

Ensure fan in electricalenclosure is spinning. If itis not, check fan wiring orreplace fan.

T3CT TCM TCM Cutback

Module fan notoperating.

If a TCM fan error (WMI0)has occurred, fan insidethe module is not workingproperly. Check TCM fanfor debris and clear withforced air if necessary.

334946B 29


Troubleshooting


High ambienttemperature.

Ensure ambienttemperature is below120°F(48°C) before usingthe system.

Enclosure fan notoperating.

Ensure fan in electricalenclosure is spinning. If itis not, check fan wiring orreplace fan.

T4CT TCM High TemperatureTCM

Module fan notoperating.

If a TCM fan error (WMI0)has occurred, fan insidethe module is not workingproperly. Check TCM fanfor debris and clear withforced air if necessary.



T4DA Heater A High Temperature A

Flow too highfor temperaturesetpoint, causingtemperatureovershoots whengun is de-triggered.

Use a smaller mix chamberthat is rated for the unit inuse.



T4DB Heater B High Temperature B

Flow too highfor temperaturesetpoint, causingtemperatureovershoots whengun is de-triggered.

Use a smaller mix chamberthat is rated for the unit inuse.

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Troubleshooting


Hose portionexposed to anexcessive heatsource, like hotsun or coiledhose, can passfluid more than27°F (15°C) overhose temperaturesetting to the FTS.

Shade exposed hose fromhot sun or expose FTS tosame environment whenat rest. Uncoil entire hosebefore heating to avoidself-heating.

Setting the A orB setpoint muchhigher than hosesetpoint can causefluid more than27°F (15°C) overhose temperaturesetting to reach theFTS.

Increase hose setpointso it is closer to A and Bsetpoints.

T4DH Hose High TemperatureHose

Cold ambienttemperature iscausing hose toheat

Cold ambient temperatureis chilling the FTS andcausing hose heat to stayon longer than needed.Insulate the FTS area of thehose so that it heats at thesame rate as the rest of thehose.

Overtemperatureswitch sensed afluid temperatureabove 230°F(110°C).

Heater was delivered toomuch power, causing theovertemperature switch toopen. RTD is not readingproperly. After the heatercools down, replace RTD.Switch closes and the errorcan be cleared when theheater temperature fallsbelow 190°F (87°C).

Disconnectedor looseovertemperatureswitchcable/connection.

If heater is not actuallyover temperature, checkall wiring and connectionsbetween the TCM and theovertemperature switches.

T4EA Heater A High TemperatureSwitch A

Overtemperatureswitch failed in theopen position.

Replace overtemperatureswitch.

334946B 31


Troubleshooting


Overtemperatureswitch sensed afluid temperatureabove 230°F(110°C).

Heater was delivered toomuch power, causing theovertemperature switch toopen. RTD is not readingproperly. After the heatercools down, replace RTD.Switch closes and the errorcan be cleared when theheater temperature fallsbelow 190°F (87°C).

Disconnectedor looseovertemperatureswitchcable/connection.

If heater is not actuallyover temperature, checkall wiring and connectionsbetween the TCM and theovertemperature switches.

T4EB Heater B High TemperatureSwitch B

Overtemperatureswitch failed in theopen position.

Replace overtemperatureswitch.

Disconnected orloose RTD cable orconnection.

Check all wiring andconnection to RTD.

T6DA Heater A Sensor Error A

Bad RTD. Switch the RTD withanother and see if the errormessage follows the RTD.Replace RTD if the errorfollows the RTD.

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Troubleshooting


Disconnected orloose RTD cable orconnection.

Check all wiring andconnection to RTD.

T6DB Heater B Sensor Error B

Bad RTD. Switch the RTD withanother and see if the errormessage follows the RTD.Replace RTD if the errorfollows the RTD.

T6DH Hose Sensor Error Hose Disconnected orshorted RTD cablein hose or bad FTS.

Expose each hose RTDconnection to check andretighten any loose con-nector. Measure hose RTDcable and FTS continuity.See Repair Heated Hose,page 60. Order RTD Testkit 24N365 for measure-ment.

Disconnect hose RTD anduse manual hose mode tofinish job until repair can becompleted.

Shorted RTD cablein hose or FTS.

Expose each hose RTDconnection to check forexposed and shorted RTDwires. Measure hose RTDcable and FTS continuity.See Repair Heated Hose,page 60. Order RTD Testkit 24N365 for measure-ment.

Disconnect hose RTD anduse manual hose mode tofinish job until repair can becompleted.

T6DT TCM Sensor Error TCM

Shorted A or BHeater RTD

If the error still occurs withthe hose FTS unplugged,one of the heater RTDsis bad. Unplug the A orB RTD from the TCM. Ifunplugging an RTD fixesthe T6DT error, replace theRTD.

334946B 33


Troubleshooting




Bad heaterelement.

Confirm resistance ofheater. Heater resistanceshould be 9-12 Ω for 10 kWsystems, 6-8 Ω for 15 kWsystems, 4–6 Ω for 20 kWsystems. If out of tolerance,replace heater element.

Loose heaterwires.


T8DA Heater A No TemperatureRise A

Started sprayingbefore heaterreached operatingtemperature.

Wait until operatingtemperature has beenreached before spraying orrecirculating.



Bad heaterelement.

Confirm resistance ofheater. Heater resistanceshould be 9-12 Ω for 10 kWsystems, 6-8 Ω for 15 kWsystems, 4–6 Ω for 20 kWsystems. If out of tolerance,replace heater element.

Loose heaterwires.


T8DB Heater B No TemperatureRise B



T8DH Hose No TemperatureRise Hose



V1IT TCM Low Voltage CAN Bad 24 VDC powersupply.

Check voltage of powersupply. Voltage shouldbe 23-25 VDC. If out oftolerance, replace powersupply.

34 334946B


Troubleshooting


V2IT TCM Low Voltage CAN Bad 24 VDC powersupply.


Loose connectionor tripped circuitbreaker.

Check wiring for looseconnection or tripped circuitbreaker.

V2MA TCM Low Voltage A

Low incoming linevoltage.

Measure voltage at circuitbreaker and ensure voltageis greater than 195 VAC.



V2MB TCM Low Voltage B





V2MH TCM Low Voltage Hose



V3IT TCM High Voltage CAN Bad 24 VDC powersupply.


V3MA TCM High Voltage A Incoming linevoltage is too high.

Ensure incoming systempower is wired properly.Verify voltage at each circuitbreaker is between 195 and264 VAC.

334946B 35


Troubleshooting


V3MB TCM High Voltage B Incoming linevoltage is too high.


V3MH TCM High Voltage Hose Incoming linevoltage is too high.


V4IT TCM High Voltage CAN Bad 24 VDC powersupply.


V4MA TCM High Voltage A Incoming linevoltage is too high.


V4MB TCM High Voltage B Incoming linevoltage is too high.


V4MH TCM High Voltage Hose Incoming linevoltage is too high.


WMI0 TCM TCM Fan Error Fan inside TCMis not operatingproperly.

Check for debris in the TCMfan and clear with forced airif necessary.

WSUX USB Configuration ErrorUSB

A validconfiguration filecan't be found forthe USB.

Inset a system token intothe ADM and cycle power.Wait until the lights on theUSB port stop flashingbefore removing token.

WXUD ADM USB Download Error Log downloadfailed.

Backup and reformat theUSB drive. Retry download.

WXUU ADM USB Upload Error Custom languagefile failed to upload.

Perform normal USBdownload and use the newdisptext.txt file to upload thecustom language.

36 334946B


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334946B, Reactor 2 Hydraulic Proportioning Systems, · PDF fileReactor 2 Hydraulic - Troubleshooting ... Reactor 2 Hydraulic Proportioning Systems, Repair, Parts (English ... 334946,