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

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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.

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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.

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Reactor Error Code Trouble Shooting Guide
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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

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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.

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Rev 2.6 (02/2014) Page 11
E02: High Current (Return to Table Of Contents)
Note: The display that is showing the E02 error is the zone that is seeing the error.
Causes:
1) Electrical short in the heater module.
oHold down actual temperature key for each zone to view current output when the
heat module is on.
oExchange 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

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current error, the LED on that zone’s module will turn red while the error is
displayed.
2) For Hose zone, electrical short in the hose heat transformer
oCheck continuity of transformer windings, and if shorted to ground.
oPerform the hose heat transformer primary and secondary check. (see hose heat
transformer not functioning section in E03)

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E03: No Zone Current (Return to Table Of Contents)
Note: The display that is showing the E03 error is the zone that is seeing the error.
Causes:
1) Tripped circuit breaker in the electrical cabinet.
oFor HOSE, check 183CB HOSE, and 178 CB HOSE.
oFor “A”, 187CB A.
oFor “B”, 197CB B.
2) Loose or broken connection on that zones output
oVisually inspect and check continuity of wiring harnesses from circuit breaker
module, through 238CR contactor, heater modules, and heater.
oCheck continuity in the hose set < 3 ohms, out and back, with whip hose attached.

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3) Hose heat transformer not functioning.
Set Hose Zone target key below current actual temperature and turn on the Hose
Zone only. (not “A” or “B”)
oPerform transformer secondary check.
Measure 90 – 100 VAC between T1 on183CB-HOSE and T2 on
POD HOSE of Hose Heater Module.
If not present measure transformer primary
oPerform transformer primary check.
Measure line voltage between T2 on 238CR and T2 on 178CB-HOSE.
4) Contactor 238CR failed to close contacts.
oVerify line voltage to A1 & A2 of contactor and that all 3 legs pass the proper
voltage through to heater modules.

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238CR
5) Single phasing in a three phase system
oVerify line voltage between all 3 legs of power. L1 to L2, L2 to L3, and L1 to L3.
Note: If the customers incoming power has a Wild Leg/High Leg it must be
installed on the L3 terminal.

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E04: Fluid Temperature Sensor (FTS), or “A” or “B”
Thermocouple not Connected. (Return to Table Of Contents)
Note: The display that is showing the E04 error is the zone that is seeing the error.
Causes:
1) E04 on the “A” or “B” display = While the unit was powered on, the thermocouple
lost communication with the temperature control module.
Checking the “A” and “B” side thermocouple assemblies.
Check the electrical connections at the temperature control module.
oRemove plug J1/SENSOR B (Green 12-pin terminal block) from the
temperature control module and make sure all pins are securely connected.
Pin 5 Thermocouple A - red wire connected.
Pin 6 Thermocouple A - yellow wire connected.
Pin 8 Thermocouple B - red wire connected.
Pin 9 Thermocouple B - yellow wire connected.
oCheck the “A” & “B” thermocouples by removing the J1/SENSOR B
connector from the temperature control module and check the pins with an
ohmmeter.
“A” thermocouple:
With J1/SENSOR B disconnected measure the resistance across pins 5
& 6. It should measure 4 - 6 Ohms at ambient temperature. If not,
replace the “A” thermocouple.
Measure the resistance between Pin 5 & the thermocouple housing.
And then between Pin 6 & the thermocouple housing. It should be
“OL” open loop, if not replace the “A” thermocouple.
“B” thermocouple:
With J1/SENSOR B disconnected measure the resistance across pins 8
& 9. It should measure 4 - 6 Ohms at ambient temperature. If not,
replace the “B” thermocouple.
Measure the resistance between Pin 8 & the thermocouple housing.
And then between Pin 9 & the thermocouple housing. It should be
“OL open loop, if not replace the “B” thermocouple.

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2) E04 on the hose heat display = While the unit was powered on, the Fluid
Temperature Sensor (FTS) lost communication with the temperature control
module.
Check the electrical connections at the temperature control module.
oLooking at plug J1/ SENSOR B on the temperature control module, check and
see if pins 10, 11 & 12 are connected properly.
Pin 12 = purple
Pin 11 = red
Pin 10 = silver (unshielded bare wires)
Check the purple wire cable connections between all hose lengths with FTS
attached...
oTest with an Ohm meter between pins 10 (Silver unshielded bare wire), 11
Red wire, and 12 (Purple wire) of J1/SENSOR B connector disconnected from
the Temperature Control Module.
Pins 11 to 12 approximately 35 ohms per 50’ (15.2m) of FTS cable,
plus 10 ohms for the FTS.
Pins 10 to 12 “OL” open loop > 100K ohms.
Check the FTS operation by connecting the FTS directly to the Reactor.
oLocate the FTS.
Unplug the FTS electrical connection.
Plug the Reactor end of the connector directly into the FTS electrical
connector to see if temperature data appears.

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Check the FTS with an ohmmeter.
oLocate the FTS.
oWith the main power off, unplug the FTS and measure the pins on the FTS.
Pins 1 to 2 10 Ohms
Pins 1 to 3 = Infinity “OL” Open Loop
Pin 3 to FTS ground screw = 0 ohms
Pin 1 to FTS component “A” (ISO) fitting = Infinity
If the FTS fails any test, replace.
0A (zero amps) on the Hose Zone Display.
oIf the FTS is disconnected or the display shows E04, turn the main disconnect off, then
on to clear the alarm, and default the machine into manual current hose heat mode. 0A
(zero amps) will show in the actual display with the hose zone off.
oWhen in the target mode of the hose heat zone, amperage can be adjusted from 20A to
45A with the up and down arrow keys.
oTo prevent hose overheating, install a thermometer close to the gun end, within the
operators view. Insert thermometer through foam insulation cover of the “A” component
hose so stem is next to the inner tube. Thermometer reading will be approximately 20°F
less than the actual fluid temperature. It the thermometer reading exceeds 160°F (71°C),
reduce the current with the down arrow key.
oThermometer reading should never exceed 160°F (71°C). Never leave the
machine unattended while in a manual current control mode.

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E05: Control Module Over Temperature (Return to Table Of Contents)
Cause:
oThe control module has an on-board temperature sensor. Heat is turned off if the module
temperature exceeds 185°F (85°C) to prevent damage to the circuit board. (See also High
Motor Temp section under E27).
E06: Communication Cable Unplugged (Return to Table Of Contents)
Causes:
1) Communication cable that connects heater control module (Silver) to the heater
modules (Blue) connection is loose or dirty.
Unplug and re-plug cable that connects heater control module (Silver) to the heater
modules (Blue).
2) Communication cable faulty.
Check the cable connections end to end for continuity. If problems persist, replace the
cable. p/n- 247801

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E09: Heater and Display Communication Malfunction
(Return to Table Of Contents)
Cause:
1) Communications between the heater control module and the display is not functioning.
When communication is lost, the display will show E09.
Check all wiring between the display and the heater control module.
oPay close attention to the wire crimping on plug J5/DISPLAY C of temperature
control module.
oSwap J5 of temp control side with J13 on motor control side to see if problem is in
the harness/control or display.
If E09 remains on the same display, replace the Display
If E09 moves to other display then reverse the J13 connections on the display
boards to determine if cable or temperature control module is the cause.