332575AEN

Instructions-Parts

Booster Heater Upgrade Kit

To install a booster heater on Reactor E-30i Proportioners. For professional use only.

Part No. 24T552Important Safety InstructionsRead all warnings and instructions in this manual and in the Reactor E-30i and E-XP2i Operation manual. Save all instructions.

ti21875a

Installation

2 332575A

Installation

1. Flush system. See proportioner operation manual for complete instructions.

2. Shutdown system. See proportioner operation man-ual for complete instructions.

Remove Components1. Remove the screws (S) and motor shield (M). Set

aside and do not discard.

2. Remove two screws (S) and front plate (F). Set aside and do not discard.

3. Remove three screws (S) from back plate. Rest fan assembly on frame.

4. Remove the electrical enclosure back panel (P). Set aside and do not discard.

5. Remove four plugs from system frame. Use a screwdriver to remove the top plug first and then press the larger plug out of the frame.

Repairing this equipment requires access to parts that may cause electric shock or other serious injury if work is not performed properly. Be sure to shut off all power to equipment before repairing.

FIG. 1

M

S

S

F

ti21876a

S

SF

B

P

ti21877a

ti21878a

Installation

332575A 3

Rotate Displacement Pumps1. Remove fluids lines between the pump fluid outlets

and fluid manifold inlets.

2. Remove fittings from pump fluid outlets.

3. Cut the iso lubrication tubing (T) at the end of the fit-tings (F). Cut remaining tubing from barbed fittings.

4. Use a 7/16 wrench to remove the two barbed fittings (F) and 1/2 in. wrench to remove elbow fittings (F). Do not discard.

5. Loosen bottom swivel (S).

6. Loosen locknut (G) by hitting firmly with a non-sparking hammer.

7. Grab cylinder with hands and rotate the pump until the outlet port is facing outward.

NOTE: Remove plugs from exposed iso lube ports if necessary.

8. To have more access during the heater installation, remove the fuel tank. See proportioner repair man-ual for complete instructions.

Install Heater and Tubing1. Apply thread sealant on elbow (44) threads and

tighten in fluid outlet until the outlet faces downward.

2. Install two grommets (40) in frame ports. See FIG. 2, page 4.

3. Install screws (41) in the inner mounting ports on the heater (3).

4. Route heater (3) behind the B side of the motor, with the RTDs facing upward and fluid fittings facing backward. Rotate heater and position on frame so that screws (41) drop in key holes.

NOTE: Pull the motor fan assembly out of the way dur-ing heater installation.

5. Remove plugs from fluid tubes (34, 43).

ti21880a

ti21881a

G

T

F

S

ti21883a

44

43 34

Installation

4 332575A

6. Install tubes (31, 32) between heater outlets (3) and fluid manifold. Torque to 43 ft-lbs (4.8 N•m).

7. Install u-shaped tubes (34, 43) between the heater (3) and pump. Torque to 43 ft-lbs (4.8 N•m).

NOTE: If longer tubes do not align with manifold, loosen four mounting screws under the manifold. If the tubes do not align with the heater outlet, rotate the elbow (44).

8. Tighten swivel at pump inlet.

9. Tighten locknut (G) by hitting firmly with a non-sparking hammer.

10. Install barbed fittings in the ISO pump. Apply thin film of TSL to barbed fittings. Using two hands, sup-port tubes (T) while pushing straight onto barbed fit-tings. Do not let tubes kink or buckle. Secure each tube with a wire tie between two barbs.

11. Reinstall motor fan and motor shield.

12. Use a 3/8 wrench to tighten heater screws (41).

FIG. 2: Heater Installation

4140

34

40

32, 43

41ti21884a

31

3

44

Installation

332575A 5

Install Low Power Temperature Control Modules (LPTCM)1. Use a hammer to remove knockouts from electrical

enclosure.

2. Install gaskets (21) on inside of enclosure.

3. Install LPTCM bases (15) with eight screws (41).

4. Tighten modules (14) to bases (15).

FIG. 3

21

41

ti21887a15

Installation

6 332575A

Connect Cables

Apply Labels

1. Apply heater and module labels from label on all supplied cables and system parts.

NOTE: Some identification labels will need to be applied to cables already installed on the system.

2. Apply red and blue TCM labels on inside and out-side of enclosure.

Cable Ref. Cable and Label Identification Qty.

11 2

16 1

20 1

36 1

38 2

42 1

TCM-A-5 PWR

TCM-B-5 PWR

TCM-A-CAN TCM-H TCM-H-6 TCM-A

TCM-B-CAN TCM-A TCM-A-CAN TCM-B

J23 TCM-A/BTCM-A-1 J23

TCM-B-1 J23

TCM-B-3 HTR-B

TCM-A-3 HTR-A

TCM-A-2 J24 J24 TCM-A

Installation

332575A 7

Connect Module Wires

See Booster Heater Wiring Diagram, page 9.

1. Open electrical enclosure door.

1. Disconnect 12 black power supply cable from large HPTCM. Remove TCM - H6PSU label.

2. Apply TCMB-CAN PSU label on black power supply cable and connect to LPTCM B base CAN fitting.

3. Connect cables (21, 26, and 30) to modules inside electrical enclosure.

4. Connect power supply cable (21) to circuit breaker.

5. Remove tall wire track cover and press LPTCM cables in track. Bundle cables with zip tie (45) and reinstall wire track cover.

Connect Heater Wires

See Outside Electrical Enclosure with Optional Heater Wiring Diagram, page 10.

1. Insert black wire leads through side grommets (40) on frame cabinet.

2. Remove red plugs from splice kit connectors (39). Connect power splice kits (39) to black heater rod wires. Feed black cables out side grommet (40).

3. Pull B side RTD and overtemp switch cable towards the A side RTD and zip tie above the B side RTD.

4. Connect double splitter (36) to the heater overtem-perature switch cable (J23 OVERTEMP-SW).

5. Connect cable (TCMA-2 HTRDA) to the A side RTD and cable (TCMB-2 HTRTDB) to the B side RTD.

6. Connect connectors (J23TCMA, J23 TCMB) to split-ter (36).

7. Feed heater signal cables behind fluid inlet tube and zip tie them to frame.

8. Cover heater signal cables with split loom (35).

9. Zip tie split loom with fir tree cable tie (33) in frame.

10. Secure splice kit connector cables to inside of cabi-net with zip ties (45).

11. Connect over temp switch cables to LPTCMA and LPTCMB.

12. Use zip ties (45) to bundle cables exposed from back end of split loom. Zip tie split loom (35) against other split looms secured to the bottom of the frame.

FIG. 4: Heater Wire Routing

ti21888a

40

39

B Side- RTD

A Side- RTDOvertemp Switch

4545

33

35

45

LPTCMA

LPTCMB

Installation

8 332575A

13. Install the electrical enclosure back panel (P).

14. Install heater shroud (4) and screws (41) on heater.

Test1. Set rotary dials for LPTCMA and LPTCMB. See

Booster Heater Wiring Diagram, page 9.

2. Power on system. Load software with token (37) in all GCA modules.

3. Check connections for leaks.

P

ti21877a

ti21877a

4

41

41

Electrical Schematics

332575A 9

Electrical Schematics

Booster Heater Wiring Diagram

CIRCUIT BREAKER24J728

ENCLOSURE BOUNDARY

BULKHEAD, 121612

CA

N, 1

2159

7

CA

N,

125

789

POWERSUPPLY, 123374

CAN, 125789

WHT

WHTBLK

16K799BLK

GRN

16K799

HPTCM, 24L950

LPTCM, 24L951

LPTCM, 24L951

CAN, 123652‘CAN-1 TCM-H’

‘TCM-H-6 CAN-1’

‘TCM-H-6 TCM-A’

‘TCM-B-CAN PSU’

‘TCM-B-CAN TCM-A’

‘TCM-A-CAN TCM-B’

‘TCM-A-CAN TCM-H’

‘TCM-A-5 PWR’

‘TCM-B-5 PWR’

‘CAN-1 MCM’

BLK

GRN

To MCM

1

2

4

4

5

3

CT02

CB

01

CB

02

CB

03

CB

04

CB

05

CB

06

CB

07

CB

08

TB

12

TB

11

TB18TB17TB16TB15TB14TB13

{{{

GND

L2

L1

WHTGRN

Rotary switch set to “0”.

Rotary switch set to “A”.

Rotary switch set to “B”.

Torque terminal blocks to 5-7 in.-lbs (0.5-0.8 N•m).

Torque circuit breaker connections to 23-25 in.-lbs (2.5-2.8 N•m).

1

2

3

4

5

Electrical Schematics

10 332575A

Outside Electrical Enclosure with Optional Heater Wiring Diagram

16A111

BOOSTER HEATER, 24L936

BLACK

BLACK

ElectricalEnclosure

BLACK

BLACK

BLAC K

WHITE

124262

124262

125760 123408J23 OVERTEMP-SWJ23 TCM-A/B

TCM-B-1 J23

TCM-A-1 J23

TCM-A-3 HTR-A

TCM-B-3 HTR-B

TCM-A-2 J24

TCM-B-2 HT-RTD-B

TCM-A24L951

TCM-B24L951

J24 TCM-A J24 HT-RTD-A

125762

125762

255716

2x 255716

255716

16A111

HEATER A

HEATER B

RTD ‘A’

RTD ‘B’

OT SWITCH

BLAC K

WHITE

125358

1

1

Heater viewed from the back of the proportioner.

Torque power wire connections to 55-62 in.-lbs (6.2-7 N•m).1

Parts

332575A 11

Parts

24T552, Boost Heater Upgrade Kit

Replacement Danger and Warning labels, tags, and cards are available at no cost.

* See cable identification table, page 6.

--- Not available for purchase.

Not shown.

1

Torque to 43 ft-lbs (4.8 N•m).1 4

3

41

44

44

34

43

31

3241

21

18

15

14

17

40

40

3933

1

1

1

Ref. Part Description Qty.1 ENCLOSURE, upgrade;

includes items 11-211

2 PROPORTIONER, upgrade;includes 31-45

1

3 24L936 HEATER, assy, 4.0 kW; 2 zone;see Reactor manual

1

4 16K361 COVER, heater 111* 16K799 CABLE, volex, femail, 16 AWG 212 --- LABEL, cable 113 --- LABEL, cable 114 256270 MODULE, LPTCM 215 289697 MODULE, cube, base 216* 125789 CABLE, CAN, female x female

0.5m1

17 --- SCREW, machine, #8x1.375 218 114417 SCREW, self tap, pan hd 819 277674 ENCLOSURE, cube door 220* 121597 CABLE, CAN, 90 f x 90 f 121 15V933 GASKET, LPHM 231 16K227 TUBE, A-side, outlet 132 16K229 TUBE, B-side outlet 1

33 125625 TIE, cable, fir tree 234 16K228 TUBE, B-side, inlet 135 --- CONDUIT, flexible, non-metallic 436* 125760 HARNESS, splitter, parallel, M8-3 137 --- TOKEN 138* 125762 CABLE, volex, 16 AWG, male, 76

in.2

39 --- KIT, heater wire connector 140 114269 GROMMET, rubber 241 113769 SCREW, flanged, hex hd 442* 125358 CABLE, M8, 4 pin, mxf 143 16K226 TUBE, A-side, inlet 144 125643 FITTING, elbow 3/8 NPT x #8 JIC 245 125871 TIE, cable, 7.5 in. 10

Ref. Part Description Qty.

All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice.

For patent information, see www.graco.com/patents.

Original instructions. This manual contains English. MM 332575

Graco Headquarters: MinneapolisInternational Offices: Belgium, China, Japan, Korea

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This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

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