Graco REACTOR E-XP1 User manual

Reactor Error Code Trouble Shooting Guide
Rev 2.6 (02/2014) Page 1

Reactor Error Code Trouble Shooting Guide
Rev 2.6 (02/2014) Page 2
This is not a substitution for the Operations or Repair instruction manual.
Read, understand and follow all instruction manuals and warning labels supplied with all
equipment. Only trained and qualified personnel should perform repairs on the equipment. To
access the latest manuals in your preferred language go to “www.graco.com” and use the
“Search” function.

Reactor Error Code Trouble Shooting Guide
Rev 2.6 (02/2014) Page 3

Reactor Error Code Trouble Shooting Guide
Rev 2.6 (02/2014) Page 4
Table of Contents
HEAT CONTROL ERROR LIST
E01 - High Fluid temperature
E02 - High Current
E03 - No current
E04 - Missing t/c thermocouple
E05 - Power module over temperature
E06 - Control module to power module communications error
E09 - Missing display
E99 - Display communications error
MOTOR CONTROL ERROR LIST - E and H Series
E21 - Transducer A faulty
E22 - Transducer B faulty
E23 - High Pressure
E24 - Pressure imbalance
E25. - High line voltage
E26 - Low line voltage
E27 - High motor temp
E28 - High current, locked rotor
E29. - Brush wear
E30 - Display communications error
E31 - Motor drive fault
E32 -Motor control board over temp
E99 - Display communications error
Recommended Tech Tools

Reactor Error Code Trouble Shooting Guide
Rev 2.6 (02/2014) Page 5
E01: High Fluid temperature (Return to Table Of Contents)
Note: The display that is showing the E01 error is the zone that is seeing the error.
Check to see if you really do have high a temperature, by using an external
temperature-sensing device. If actual fluid temperature is above 190° F (88°C) you will
need to cool the unit down to be able to do any testing. Using your feed pumps to move
cool material into the Reactor will speed cooling time.
Causes:
1) The "A" or "B" Thermocouple (Ref # 310) picked up a high fluid temp of 229°F
(109°C) or greater.
Check connections between the temperature control module and the heater "A" & "B"
Thermocouples. Make sure all of the wires are securely connected into connector
J1/SENSOR B.
Check continuity of the "A" & "B" thermocouples by removing the J1/SENSOR B
connector from the temperature control module socket. On the plug end check the
resistance across pins 5 & 6 = 4 - 6 ohms. Pins 8 & 9 = 4 - 6 ohms. Pins 6 & 9 to
chassis ground as “OL” open loop at ambient temperature.
See figure below

Reactor Error Code Trouble Shooting Guide
Rev 2.6 (02/2014) Page 6
2) One of the over temperature switches (Ref # 308) picked up a high fluid temp
greater than 230° F (110°C). At 190° F (88°C) the contacts close again.
Check continuity of the over temperature switches by removing the J1/SENSOR B
connector from the temperature control module socket. On the plug end check the
resistance across pins 1 & 2 and pins 3 & 4 for continuity, (nearly zero ohms).
See figure above
3) Either the "A" or the "B" Thermocouple has failed, or is not in contact with a
working heater element.
Check and see if the "A" or the "B" Thermocouple is damaged or not making contact
with a working heater element. See section Thermocouple in manual 312066 E-
Series, 312063 H-Series, 313540 H-VR-Series.

Reactor Error Code Trouble Shooting Guide
Rev 2.6 (02/2014) Page 7
Primary Heaters / Heater Elements
6.0 kW – 1500w (30-35 ohms) x 2 each per side = 15–17.5 ohms combined.
10.2 kW – 2550w (18-21 ohms) x 2 each per side = 9-10.5 ohms combined.
8.0 kW – 2000w (23-26 ohms) x 2 each per side = 11.5-13 ohms combined.
7.65 kW – 2550w (18-21 ohms) x 3 each per side = 6-7 ohms combined.

Reactor Error Code Trouble Shooting Guide
Rev 2.6 (02/2014) Page 8

Reactor Error Code Trouble Shooting Guide
Rev 2.6 (02/2014) Page 9
4) Heater modules failed to turn off any heat zone, causing a run-away condition.
Exchange zone module with another one. Turn zone on and check for error. If error
moves to another zone, replace the faulty module. (When there is a high current error, the
LED on that zone’s module will turn red while the error is displayed.
Check and see if the heater module (BLUE) is turning off when the unit hits the set point
temperature.
oFor “A” heater test points T4 on 238CR & T2 on POD A connector.
oFor “B” heater test points T6 on 238CR & T2 on POD B connector.
oFor HOSE test points T1 on 183 CB HOSE & T1 on POD HOSE connector.
oSet the “A”, “B”, and HOSE set point 10°F/C below the actual
temperature, and turn the heat zones on one at a time. The red light on
the display above the zone should be blinking and there should be little
to no voltage on the voltmeter.
Measuring voltage while the red light is blinking would
indicate that the output on the heater module has failed.
Replace the heater module. Note: all 3 modules are the same
and can be swapped for troubleshooting.
5) If fluid is below 190° F (88°C) and you are still getting the high temp error:
Causes:
Faulty connection of either of the "A" & "B" thermocouple to the heater control
module

Reactor Error Code Trouble Shooting Guide
Rev 2.6 (02/2014) Page 10
One of the over temperature switches failed in the “open” position. Open circuit in
the over temperature wiring harness, or switch “B” jumper is loose or open on a
dual zone heater systems.
Make sure connector J1/SENSOR B is firmly plugged into the heater control
module.
Check connections between the temperature control module and the heater over
temperature switches and the "A" & "B" temperature sensor. Make sure all of the
wires are securely connected into connector J1/SENSOR B.
Check continuity of the over temperature switches and the "A" & "B"
Thermocouples by removing the J1/SENSOR B connector from the temperature
control module socket. On the plug end check the resistance across pins 1 & 2 =
nearly Zero ohms, pins 3 & 4 = nearly Zero ohms. Pins 5 & 6 = 4 - 6 ohms. Pins
8 & 9 = 4 - 6 ohms. Pins 6 & 9 to chassis ground as “OL” open loop at ambient
temperature.