Spray Foam Proportioner Troubleshooting

Temperature Control Diagnostic Codes

Code #	Code Name	Alarm Zone
01	High fluid temperature	Individual
02	High hose current	Hose only
03	No hose current with hose heater on	Hose only
04	FTS not connected	Individual
05	Board overtemperature	All
30	Momentary loss of communication	A
99	Loss of communication	A

Code #

Code Name

Alarm Zone

High fluid temperature

Individual

High hose current

Hose only

No hose current with hose heater on

Hose only

FTS not connected

Individual

Board overtemperature

All

Momentary loss of communication

Loss of communication

Motor Control Diagnostic Codes

Code #	Code Name	Alarm Zone
21	No transducer (component A)	A
22	No transducer (component B)	A
23	High fluid pressure	A
24	Pressure Imbalance	A/W
27	High motor temperature	A
30	Momentary loss of communication	A
31	Pumpline reversing switch failure/high cycle rate	A
99	Loss of communication	A

Code #

Code Name

Alarm Zone

No transducer (component A)

No transducer (component B)

High fluid pressure

Pressure Imbalance

A/W

High motor temperature

Momentary loss of communication

Pumpline reversing switch failure/high cycle rate

Loss of communication

Temperature Control Diagnostic Codes

Code #	Code Name	Alarm Zone
01	High fluid temperature	Individual
02	High zone current	Hose only
03	No zone current with hose heater on	Hose only
04	FTS not connected	Individual
05	Board overtemperature	All
06	Communication cable unplugged from module	A
99	Loss of communication	A

Code #

Code Name

Alarm Zone

High fluid temperature

Individual

High zone current

Hose only

No zone current with hose heater on

Hose only

FTS not connected

Individual

Board overtemperature

All

Communication cable unplugged from module

Loss of communication

Motor Control Diagnostic Codes

Code #	Code Name	Alarm Zone
21	No transducer (component A)	A
22	No transducer (component B)	A
23	High fluid pressure	A
24	Pressure Imbalance	A/W
25	High line voltage	A
26	Low line voltage	A
27	High motor temperature	A
28	High current	A
29	Brush wear	A
99	Communication Error 2	A

Code #

Code Name

Alarm Zone

No transducer (component A)

No transducer (component B)

High fluid pressure

Pressure Imbalance

A/W

High line voltage

Low line voltage

High motor temperature

High current

Brush wear

Communication Error 2

Manuals

Parts & Repair

Operating Instructions

Electrical Diagrams

Proportioning Pumps

Manuals

Parts & Repair

Operating Instructions

Electrical Diagrams

Troubleshooting Guides

Reactor Electronics

Problem	Cause	Solution
Both sides of display do not illuminate.	No power	Turn disconnect ON
	Low voltage.	Ensure input voltage is within specifications, page 42.
	Loose wire.	Check connections, page 42.
	Display disconnected.	Check cable connections, page 42.
Temperature display does not illuminate.	Display disconnected.	Check cable connections, page 42.
	Display cable damaged or corroded.	Clean connections; replace cable if is damaged.
	Defective circuit board.	Swap display connection to motor control board with connection to heater control board. If temperature display illuminates, heater control board is causing problem. Otherwise, display cable or display is failing.
Pressure display does not illuminate.	Display disconnected.	Check cable connections, page 42.
	Display cable damaged or corroded.	Clean connections; replace cable if is damaged.
	Defective circuit board.	Swap display connection to motor control board with connection to heater control board. If pressure display illuminates, motor control board is causing problem. Otherwise, display cable or display is failing.
Erratic display; display turns on and off.	Low voltage.	Ensure input voltage is within specifications, page 42.
	Poor display connection.	Check cable connections, page 42. Replace damaged cable.
	Display cable damaged or corroded.	Clean connections; replace cable if is damaged.
	Display cable not grounded.	Ground cable, page 42.
	Display extension cable too long.	Must not exceed 100 ft (30.5 m)
Hose display reads OA at startup.	FTS disconnected or not installed.	Verify proper installation of FTS (see Operation manual 312062), or adjust FTS to desired current setting.
Display does not respond properly to button pushes.	Poor display connection.	Check cable connections, page 42. Replace damaged cable.
	Display cable damaged or corroded.	Clean connections; replace cable if is damaged.
	Ribbon cable on display circuit board disconnected or broken.	Connect cable (page 42) or replace.
	Broken display button.	Replace, page 42.
Red stop button does not work.	Broken button (fused contact).	Replace, page 42.
Red stop button does not work.	Loose wire.	Check connections, page 42.
Fan not working.	Blown fuse.	Verify with ohmmeter; replace if necessary (page 42).
Fan not working.	Loose wire.	Check fan wire.
Defective fan.	Replace, page 42.

Primary Heaters

Problem	Cause	Solution
Primary heater(s) does not heat.	Heat turned off.	Press A or B Zone 1 keys.
	Temperature control alarm.	Check temperature display for diagnostic code, page 8.
	Signal failure from thermocouple.	See E04: Fluid Temperature Sensor (FTS) or thermocouple disconnected, page 9.
Control of primary heat is abnormal; high temperature overshoots or E01 error occurs intermittently.	Dirty thermocouple connections.	Examine connection of thermocouples to long green plug on heater control board. Unplug and re-plug thermocouple wires, cleaning off any debris. Unplug and re-plug long green connector.
	Thermocouple not contacting heater element.	Loosen ferrule nut (N), push in thermocouple (310) so tip (T) contacts heater element (307). Holding themocouple tip (T) against heater element, tighten ferrule nut (N) 1/4 turn past tight. See page 38 for illustration.
	Failed heater element.	See Primary Heaters, page 37.
	Signal failure from thermocouple.	See E04: Fluid Temperature Sensor (FTS) or thermocouple disconnected, page 9.
	Thermocouple wired incorrectly.	See E04: Fluid Temperature Sensor (FTS) or thermocouple disconnected, page 9. Power up zones one at a time and verify that temperature for each zone rises.

Hose Heat System

Problem	Cause	Solution
Hose heats but heats slower than usual or it does not reach temperature.	Ambient temperature is too cold.	Use auxiliary hose heat system.
	FTS failed or not installed correctly.	Check FTS, page 9.
Low supply voltage.	Verify line voltage. Low line voltage significantly reduces power available to hose heat system, affecting longer hose lengths.
Hose does not maintain temperature while spraying.	A and B setpoints too low.	Increase A and B setpoints. Hose is designed to maintain temperature, not to increase it.
	Ambient temperature is too cold.	Increase A and B setpoints to increase fluid temperature and keep it steady.
	Flow too high.	Use smaller mix chamber. Decrease pressure.
	Hose was not fully preheated.	Wait for hose to heat to correct temperature before spraying.
	Low supply voltage.	Verify line voltage. Low line voltage significantly reduces power available to hose heat system, affecting longer hose lengths.
Hose temperature exceeds setpoint.	A and/or B heaters are overheating material.	Check primary heaters for either a thermocouple problem or a failed element attached to thermocouple, page 9.
Hose temperature exceeds setpoint.	Faulty thermocouple connections.	Verify that all FTS connections are snug and that pins of connectors are clean. Examine connection of thermocouples to long green plug on heater control board. Unplug and re-plug thermocouple wires, cleaning off any debris. Unplug and re-plug long green connector on heater control board.
Erratic hose temperature.	Faulty thermocouple connections.	Verify that all FTS connections are snug and that pins of connectors are clean. Examine connection of thermocouples to long green plug on heater control board. Unplug and re-plug thermocouple wires, cleaning off any debris. Unplug and re-plug long green connector.
Erratic hose temperature.	FTS not installed correctly.	FTS should be installed close to end of hose in same environment as gun. Verify FTS installation, page 40.
Hose does not heat.	FTS failed or is not contacting correctly.	Check FTS, page 40.
	FTS not installed correctly.	FTS should be installed close to end of hose in same environment as gun. Verify FTS installation, page 40.
	Temperature control alarm.	Check temperature display or diagnostic code, page 40.
Hoses near Reactor are warm, but hoses downstream are cold.	Shorted connection or failed hose heating element.	With hose heat on and temperature setpoint above displayed hose zone temperature, verify voltage between connectors at each section of hose. Voltage should drop incrementally for each section of hose further from Reactor. Use safety precautions when hose heat is turned on.

Hydraulic Drive System

Problem	Cause	Solution
Electric motor will not start or stops during operation.	Loose Connections	Check connections at motor control board
	Circuit breaker tripped	Reset breaker (813); see Circuit Breaker Module, page 30. Check 230 Vac at output of breaker.
	Damaged motor control board	Replace board. See Motor Control Board, page 32.
Hydraulic pump does not develop pressure. Low or zero pressure with screeching noise	Pump is not primed or lost its prime	Check electric motor rotation. Both motor and hydraulic pump must rotate counterclockwise when viewed from shaft end. If rotation is incorrect, reverse leads L1 and L2. See Connect Electrical Cord in Operation manual 312602 Check dipstick to ensure that hydraulic reservoir is properly filled (see Operation manual). Check that inlet fitting is fully tight, to ensure no air is leaking into the pump inlet. To prime pump, run unit at lowest pressure setting and slowly increase pressure. In some cases it may be necessary to remove motor cover and drive belt to allow for manual (counterclockwise) rotation of hydraulic pump. Turn fan pulley by hand. Verify oil flow by removing oil filter to see flow into filter manifold. Reinstall oil filter. Do NOT operate unit without a properly installed oil filter.
	Screeching noise is characteristic of cavitation and is normal at intial startup for a maximum of 30 seconds	If noise continues longer than 30 seconds, press motor ** key to shut off the motor. Check that the inlet fittings are tight and that the pump has not lost its prime
	Hydraulic fluid is too hot	Ensure that the reservoir is properly serviced. Improved ventilation to allow more efficient heat dissipation
	Electric motor operating in wrong direction for 3 Phase system.	Motor must operate counter-clockwise from pully end.
	Drive belt loose or broken.	Check drive belt condition. Replace if broken.

Proportioning System

Problem	Cause	Solution
Proportioning pump not hold pressure when stalled	Pump piston or intake valve leaking	Observe gauges to determine which pump is losing pressure Determine in which direction the pump has stalled by observing which directional valve indicator light is on. See Table 2, page 25 to isolate the problem. Repair the valve; see pump manual 312068.
Material imbalance. See Pressure/ Material Imbalance, page 25.	Restriction at the gun	Clean the gun; see your seperate gun manual
	Inadequate flow from pump; cavitation.	Increase fluid supply to proportioning pump: Use 2:1 supply pump Use minimum 3/4 in. (19 mm) ID supply hose, as short as practical Fluid is too thick. Consult your material supplier for the recommended fluid temperature to maintain a viscosity of 250 to 1500 centipoise. Clean inlet strainer screen, page 44. Worn pump inlet valve ball/seat or gasket. Replace, see pump manual 312068.
	Pressure relief/circulation valve leaking back to supply.	Remove return line and determine if flow is present while in SPRAY mode
Pumps do not reverse direction or pumps do not move.	Bent or loose activator plate, rocker arm, or reversing switch.	See Pumps Do Not Reverse Direction, page 26.
	Loose piston packing bolt	See Pumps Do Not Reverse Direction, page 26.
	Faulty directional valve.	See Pumps Do Not Reverse Direction, page 26.
Erratic pump movement	Pump cavitation.	Feed pump pressure is too low. Adjust pressure to maintain 100 psi (0.7 MPa, 7 bar) minimum. Fluid is too thick. Consult your material supplier for recommended fluid temperature to maintain a viscosity of 250 to 1500 centipoise.
	Loose activator plate, rocker arm, or reversing switch.	See Pumps Do Not Reverse Direction, page 26.
	Faulty directional valve.	Replace directional valve.
Pump output low	Obstructed fluid hose or gun; fluid hose ID too small	Open, clear; use hose with larger ID
	Worn piston valve or intake valve in displacement pump	See pump manual 312068
	Inadequate feed pump pressure	Check feed pump pressure and adjust to 100 psi (0.7 MPa, 7 bar) minimum
Fluid leak at pump rod seal	Worn throat seals	Repalce. See pump manual 312068
No pressure on one side	Fluid leaking from pump outlet rupture disk (216).	Check if heater (2) and PRESSURE RELIEF/SPRAY valve (SA or SB) are plugged. Clear. Replace rupture disk (216) with a new one; do not replace with a pipe plug.
No pressure on one side	Inadequate feed pump pressure	Check feed pump pressure and adjust to 100 psi (0.7 MPa, 7 bar) minimum

Problem

Cause

Solution

Both sides of display do not illuminate.

No power

Turn disconnect ON

Low voltage.

Ensure input voltage is within specifications, page 42.

Loose wire.

Check connections, page 44.

Display disconnected.

Check cable connections, page 44.

Temperature display does not illuminate.

Display disconnected.

Check cable connections, page 44.

Display cable damaged or corroded.

Clean connections; replace cable if is damaged.

Defective circuit board.

Swap display connection to motor control board with connection to heater control board. If temperature display illuminates, heater control board is causing problem. Otherwise, display cable or display is failing.

Pressure display does not illuminate.

Display disconnected.

Check cable connections, page 44.

Display cable damaged or corroded.

Clean connections; replace cable if is damaged.

Defective circuit board.

Swap display connection to motor control board with connection to heater control board. If pressure display illuminates, motor control board is causing problem. Otherwise, display cable or display is failing.

Erratic display; display turns on and off.

Low voltage.

Ensure input voltage is within specifications, page 44.

Poor display connection.

Check cable connections, page 44. Replace damaged cable.

Display cable damaged or corroded.

Clean connections; replace cable if is damaged.

Display cable not grounded.

Ground cable, page 44.

Display extension cable too long.

Must not exceed 100 ft (30.5 m)

Hose display reads OA at startup.

FTS disconnected or not installed.

Verify proper installation of FTS (see Operation manual 312062), or adjust FTS to desired current setting.

Display does not respond properly to button pushes.

Poor display connection.

Check cable connections, page 44. Replace damaged cable.

Display cable damaged or corroded.

Clean connections; replace cable if is damaged.

Ribbon cable on display circuit board disconnected or broken.

Connect cable (page 44) or replace.

Broken display button.

Replace, page 44.

Red stop button does not work.

Broken button (fused contact).

Replace, page 44.

Loose wire.

Check connections, page 44.

Fan not working.

Blown fuse.

Verify with ohmmeter; replace if necessary (page 42).

Loose wire.

Check fan wire.

Defective fan.

Replace, page 44.

Problem

Cause

Solution

Primary heater(s) does not heat.

Heat turned off.

Press A or B Zone 1 keys.

Temperature control alarm.

Check temperature display for diagnostic code, page 7.

Signal failure from thermocouple.

See E04: Fluid Temperature Sensor (FTS) or thermocouple disconnected, page 9.

Control of primary heat is abnormal; high temperature overshoots or E01 error occurs intermittently.

Dirty thermocouple connections.

Examine connection of thermocouples to long green plug on heater control board. Unplug and re-plug thermocouple wires, cleaning off any debris. Unplug and re-plug long green connector.

Thermocouple not contacting heater element.

Loosen ferrule nut (N), push in thermocouple (310) so tip (T) contacts heater element (307). Holding themocouple tip (T) against heater element, tighten ferrule nut (N) 1/4 turn past tight. See page 40 for illustration.

Failed heater element.

See Primary Heaters, page 19.

Signal failure from thermocouple.

See E04: Fluid Temperature Sensor (FTS) or thermocouple disconnected, page 9.

Thermocouple wired incorrectly.

See E04: Fluid Temperature Sensor (FTS) or thermocouple disconnected, page 9. Power up zones one at a time and verify that temperature for each zone rises.

Problem

Cause

Solution

Hose heats but heats slower than usual or it does not reach temperature.

Ambient temperature is too cold.

Use auxiliary hose heat system.

FTS failed or not installed correctly.

Check FTS, page 9.

Low supply voltage.

Verify line voltage. Low line voltage significantly reduces power available to hose heat system, affecting longer hose lengths.

Hose does not maintain temperature while spraying.

A and B setpoints too low.

Increase A and B setpoints. Hose is designed to maintain temperature, not to increase it.

Ambient temperature is too cold.

Increase A and B setpoints to increase fluid temperature and keep it steady.

Flow too high.

Use smaller mix chamber. Decrease pressure.

Hose was not fully preheated.

Wait for hose to heat to correct temperature before spraying.

Low supply voltage.

Verify line voltage. Low line voltage significantly reduces power available to hose heat system, affecting longer hose lengths.

Hose temperature exceeds setpoint.

A and/or B heaters are overheating material.

Check primary heaters for either a thermocouple problem or a failed element attached to thermocouple, page 9.

Faulty thermocouple connections.

Verify that all FTS connections are snug and that pins of connectors are clean. Examine connection of thermocouples to long green plug on heater control board. Unplug and re-plug thermocouple wires, cleaning off any debris. Unplug and re-plug long green connector on heater control board.

Erratic hose temperature.

Faulty thermocouple connections.

FTS not installed correctly.

FTS should be installed close to end of hose in same environment as gun. Verify FTS installation, page 42.

Hose does not heat.

FTS failed or is not contacting correctly.

Check FTS, page 42.

FTS not installed correctly.

FTS should be installed close to end of hose in same environment as gun. Verify FTS installation, page 42.

Temperature control alarm.

Check temperature display or diagnostic code, page 40.

Hoses near Reactor are warm, but hoses downstream are cold.

Shorted connection or failed hose heating element.

With hose heat on and temperature setpoint above displayed hose zone temperature, verify voltage between connectors at each section of hose.

Voltage should drop incrementally for each section of hose further from Reactor. Use safety precautions when hose heat is turned on.

Troubleshooting Proportioners

Spray Foam Equipment

Troubleshooting Guide:

Select your foam machine:

Temperature Control Diagnostic Codes

Code #

Code Name

Alarm Zone

Motor Control Diagnostic Codes

Code #

Code Name

Alarm Zone

Temperature Control Diagnostic Codes

Code #

Code Name

Alarm Zone

Motor Control Diagnostic Codes

Code #

Code Name

Alarm Zone

Manuals

Manuals

Troubleshooting Guides

Reactor Electronics

Primary Heaters

Hose Heat System

Hydraulic Drive System

Proportioning System

Troubleshooting Guides

Reactor Electronics

Primary Heaters

Hose Heat System

Graco DVD

Proud Distrubutors of: