Graco Reactor 2 E-30 Use and care manual

Repair, Parts
Reactor 2 E-30 and E-XP2
Proportioning System 333024N
EN
Electric, heated, plural component proportioning system. For spraying polyurethane foam and polyurea
coatings. For professional use only. Not approved for use in explosive atmospheres or hazardous
(classified) locations.
Important Safety Instructions. Read all warnings and instructions in
this manual before using the equipment. Save these instrustions.
WLD
PROVEN QUALITY. LEADING TECHNOLOGY.

Contents
Warnings ............................................................. 3
Important Isocyanate Information........................... 7
Models................................................................. 9
Approvals........................................................... 11
Accessories........................................................ 11
Supplied Manuals ............................................... 12
Related Manuals ................................................ 12
Troubleshooting.................................................. 13
Troubleshoot Errors ..................................... 13
Pressure Relief Procedure .................................. 49
Shutdown........................................................... 50
Flushing............................................................. 52
Repair................................................................ 53
Before Beginning Repair............................... 53
Flush Inlet Strainer Screen ........................... 53
Change Pump Lubricant............................... 54
Clean Flow Meter......................................... 55
Clean E-XP2 Flow Meter .............................. 56
Remove Pump............................................. 57
Install Pump ................................................ 59
Repair Drive Housing ................................... 59
Repair Electric Motor.................................... 62
Repair Circuit Breaker Module ...................... 63
Replace Fluid Inlet Sensor............................ 64
Replace Flow Meter ..................................... 64
Replace Pressure Transducers..................... 64
Replace Fans .............................................. 65
Repair Primary Heater.................................. 67
Repair Heated Hose..................................... 71
Repair Fluid Temperature Sensor
(FTS) ............................................. 74
Calibration Procedure................................... 75
Transformer Primary Check .......................... 76
Transformer Secondary Check ..................... 77
Replace Transformer.................................... 77
Replace Power Supply ................................. 78
Replace Surge Protector .............................. 78
Replace Motor Control Module (MCM)........... 79
Replace Temperature Control Module
(TCM) ............................................ 79
Replace Advanced Display Module
(ADM)............................................ 80
Software Update Procedure.......................... 80
Update ADM Software.................................. 81
Parts.................................................................. 82
Electrical Schematics........................................ 106
Reactor 2 Repair Spare Parts Reference ........... 109
Performance Charts.......................................... 110
Technical Specifications.................................... 113
Graco Extended Warranty for Reactor® 2
Components ....................................... 115
2333024N

Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific
risks. When these symbols appear in the body of this manual or on warning labels, refer backtothese
Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout
the body of this manual where applicable.
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can
cause electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before
servicing or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes
and regulations.
• Do not expose to rain. Store indoors.
TOXIC FLUID OR FUMES
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin,
inhaled or swallowed.
• Read Safety Data Sheet (SDS) for handling instructions and to know the specific hazards of
the fluids you are using, including the effects of long-term exposure.
• When spraying, servicing equipment, or when in the work area, always keep work area
well ventilated and always wear appropriate personal protective equipment. See Personal
Protective Equipment warnings in this manual.
• Store hazardous fluid in approved containers, and dispose of it according to applicable
guidelines.
PERSONAL PROTECTIVE EQUIPMENT
Always wear appropriate personal protective equipment and cover all skin when spraying,
servicing equipment, or when in the work area. Protective equipment helps prevent serious
injury, including long-term exposure; inhalation of toxic fumes, mists or vapors; allergic reaction;
burns; eye injury and hearing loss. This protective equipment includes but is not limited to:
•Apr
operly fitting respirator, which may include a supplied-air respirator, chemically
impermeable gloves, protective clothing and foot coverings as recommended bythefluid
manufacturer and local regulatory authority.
• Protective eyewear and hearing protection.
333024N 3

Warnings
WARNING
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may
look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking,
or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help
prevent fire and explosion:
•Useequ
ipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and
plastic drop cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
•Donot
plug or unplug power cords, or turn power or light switches on or off when flammable
fumes are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
•Hold
gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless
they are antistatic or conductive.
•Stop operation immediately if static sparking occurs or you feel a shock.Do not use
equipment until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
4333024N

Warnings
WARNING
THERMAL EXPANSION HAZARD
Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure
due to the thermal expansion. Over-pressurization can result in equipment rupture and serious
injury.
• Open a valve to relieve the fluid expansion during heating.
• Replace hoses proactively at regular intervals based on your operating conditions.
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious
chemical reaction and equipment rupture. Failure to follow this warning can result in death,
serious injury, or property damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon
solvents or fluids containing such solvents.
•Manyot
her fluids may contain chemicals that can react with aluminum. Contact your material
supplier for compatibility.
PLASTIC PARTS CLEANING SOLVENT HAZARD
Many solvents can degrade plastic parts and cause them to fail, which could cause serious
injury or property damage.
• Use only compatible water-based solvents to clean plastic structural or pressure-containing
parts.
•SeeTechnical Data in this and all other equipment instruction manuals. Read fluid and
solvent manufacturer’s MSDSs and recommendations.
333024N 5

Warnings
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated
system component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data
in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete
information about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
•Turnoffal
l equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals
and create safety hazards.
•Makesure
all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
•Press
urized equipment can start without warning. Before checking, moving, or servicing
equipment, follow the Pressure Relief Procedure and disconnect all power sources.
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid
severe burns:
•Dono
t touch hot fluid or equipment.
6333024N

Important Isocyanate Information
Important Isocyanate Information
Isocyanates (ISO) are catalysts used in two component materials.
Isocyanate Conditions
Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and
atomized particulates.
• Read and understand the fluid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific
hazards and precautions related to isocyanates.
• Use of isocyanates involves potentially hazardous procedures. Do not spray with this equipment unless
you are trained, qualified, and have read and understood the information in this manual and in the fluid
manufacturer’s application instructions and SDS.
• Use of incorrectly maintained or mis-adjusted equipment may result in improperly cured material, which
could cause off gassing and offensive odors. Equipment must be carefully maintained and adjusted
according to instructions in the manual.
•Toprev
ent inhalation of isocyanate mists, vapors and atomized particulates, everyone in the work
area must wear appropriate respiratory protection. Always wear a properly fitting respirator, which
may include a supplied-air respirator. Ventilate the work area according to instructions in the fluid
manufacturer’s SDS.
• Avoid all skin contact with isocyanates. Everyone in the work area must wear chemically impermeable
gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local
regulatory authority. Follow all fluid manufacturer recommendations, including those regarding handling
of contaminated clothing. After spraying, wash hands and face before eating or drinking.
• Hazard from exposure to isocyanates continues after spraying. Anyone without appropriate personal
protective equipment must stay out of the work area during application and after application for the time
period specified by the fluid manufacturer. Generally this time period is at least 24 hours.
• Warn others who may enter work area of hazard from exposure to isocyanates. Follow the
recommendations of the fluid manufacturer and local regulatory authority. Posting a placard such as the
following outside the work area is recommended:
333024N 7

Important Isocyanate Information
Material Self-Ignition
Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings
and SDS.
Keep Components A and B Separate
Cross-contamination can result in cured
material in fluid lines which could cause serious
injury or damage to equipment. To prevent
cross-contamination:
•Never interchange component A and component
B wetted parts.
• Never use solvent on one side if it has been
contaminated from the other side.
Changing Materials
NOTICE
Changing the material types used in your
equipment requires special attention to avoid
equipment damage and downtime.
•Whenc
hanging materials, flush the equipment
multiple times to ensure it is thoroughly clean.
•Alwa
ys clean the fluid inlet strainers after
flushing.
•Chec
k with your material manufacturer for
chemical compatibility.
•Whe
n changing between epoxies and urethanes
or polyureas, disassemble and clean all fluid
components and change hoses. Epoxies often
have amines on the B (hardener) side. Polyureas
oftenhaveaminesontheB(resin)side.
Moisture Sensitivity of Isocyanates
Exposure to moisture (such as humidity) will cause
ISO to partially cure, forming small, hard, abrasive
crystals that become suspended in the fluid.
Eventually a film will form on the surface and the ISO
will begin to gel, increasing in viscosity.
NOTICE
Partially cured ISO will reduce performance and
the life of all wetted parts.
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere.
Never store ISO in an open container.
• Keep the ISO pump wet cup or reservoir (if
installed) filled with appropriate lubricant. The
lubricant creates a barrier between the ISO and
the atmosphere.
• Use only moisture-proof hoses compatible with
ISO.
• Never use reclaimed solvents, which may
contain moisture. Always keep solvent
containers closed when not in use.
• Always lubricate threaded parts with an
appropriate lubricant when reassembling.
NOTE: The amount of film formation and rate of
crystallization varies depending on the blend of ISO,
the humidity, and the temperature.
Foam Resins with 245 fa Blowing
Agents
Some foam blowing agents will froth at temperatures
above 90°F (33°C) when not under pressure,
especially if agitated. To reduce frothing, minimize
preheating in a circulation system.
8333024N

Models
Models
Reactor 2 E-30 and E-30 Elite
All elite systems include fluid inlet sensors, ratio monitoring, and Xtreme-Wrap 50 ft (15 m) heated hose. For
part numbers,seeAccessories, page 11
E-30 Model E-30 Elite Model
Model 10 kW 15 kW 10 kW 15kW
Proportioner ★ 272010 272011 272110 272111
Maximum Fluid Working
Pressure psi (MPa, bar)
2000 (14, 140) 2000 (14, 140) 2000 (14, 140) 2000 (14, 140)
Approximate Output per
Cycle (A+B) gal. (liter)
0.0272 (0.1034) 0.0272 (0.1034) 0.0272 (0.1034) 0.0272 (0.1034)
Max Flow Rate lb/min
(kg/min)
30 (13.5) 30 (13.5) 30 (13.5) 30 (13.5)
Total System Load † ◊
(Watts)
17,900 23,000 17,900 23,000
Configurable Voltage
Phase ◊
200
–240
VAC
1Ø
200
–240
VAC
3Ø∆
350
–415
VAC
3ØY
200
–240
VAC
1Ø
200
–240
VAC
3Ø∆
350
–415
VAC
3ØY
200
–240
VAC
1Ø
200
–240
VAC
3Ø∆
350
–415
VAC
3ØY
200
–240
VAC
1Ø
200
–240
VAC
3Ø∆
350
–415
VAC
3ØY
Full Load Peak Current* 78 50 34 100 62 35 78 50 34 100 62 35
Fusion AP Package ‡
(Gun Part No.)
AP2010
(246102)
AH2010
(246102)
AP2011
(246102)
AH2011
(246102)
AP2110
(246102)
AH2110
(246102)
AP2111
(246102)
AH2111
(246102)
Fusion CS Package ‡
(Gun Part No.)
CS2010
(CS02RD)
CH2010
(CS02RD)
CS2011
(CS02RD)
CH2011
(CS02RD)
CS2110
(CS02RD)
CH2110
(CS02RD)
CS2111
(CS02RD)
CH2111
(CS02RD)
Probler P2 Package ‡
(Gun Part No.)
P22010
(GCP2R2)
PH2010
(GCP2R2)
P22011
(GCP2R2)
PH2011
(GCP2R2)
P22110
(GCP2R2)
PH2110
(GCP2R2)
P22111
(GCP2R2)
PH2111
(GCP2R2)
24K240 24K240 24K240 24K240 24Y240 24Y240 24Y240 24Y240Heated Hose
50 ft (15 m)
24K240 (scuff guard)
24Y240 (Xtreme-Wrap)
Qty: 1Qty: 5Qty: 1Qty: 5Qty: 1Qty: 5Qty: 1Qty: 5
Heated Whip Hose
10 ft (3 m)
246050 246050 246050 246050
Ratio Monitoring ✓✓
Fluid Inlet Sensors (2) ✓✓
*Full load amps with all devices operating at
maximum capabilities. Fuse requirements at
various flow rates and mix chamber sizes may be
less.
†Total system watts used by system, based on
maximum heated hose length for each unit.
• E–30 and E–XP2 series: 310 ft (94.5 m)
maximum heated hose length, including whip
hose.
★SeeApprovals, page 11.
‡Packages include gun, heated hose, and whip
hose. Elite packages also include ratio monitoring
and fluid inlet sensors.
◊Low line input voltage will reduce power available
and heaters will not perform at full capacity.
Voltage Configurations Key
ØPhase
∆DELTA
YWYE
333024N 9

Models
Reactor 2 E-XP2 and E-XP2 Elite
All elite systems include fluid inlet sensors and Xtreme-Wrap 50 ft (15 m) heated hose. For part numbers, see
Accessories, page 11
E–XP2 Model E–XP2 Elite Model
Model
15 kW 15 kW
Proportioner★272012 272112
Maximum Fluid Working
Pressure psi (MPa, bar)
3500 (24.1, 241) 3500 (24.1, 241)
Approximate Output per
Cycle (A+B) gal. (liter)
0.0203 (0.0771) 0.0203 (0.0771)
Max Flow Rategpm/min
(l/min)
2 (7.6) 2 (7.6)
Total System Load † ◊
(Watts)
23,000 23,000
Configurable Voltage
Phase ◊
200–240
VAC 1Ø
200–240
VAC 3Ø∆
350–415
VAC 3ØY
200–240
VAC 1Ø
200–240
VAC 3Ø∆
350–415
VAC 3ØY
Full Load Peak Current
(amps)
100 62 35 100 62 35
Fusion AP Package ‡
(Gun Part No.)
AP2012
(246100)
AP2112
(246100)
Probler P2 Package ‡
(Gun Part No.)
P22012
(GCP2R1)
P22112
(GCP2R1)
Heated Hose
50 ft (15 m)
24K241
(scuff guard)
24Y241
(Xtreme-Wrap)
Heated Whip Hose
10 ft (3 m)
246055 246055
Fluid Inlet Sensors (2) ✓
Ratio Monitor ✓
*Full load amps with all devices operating at
maximum capabilities. Fuse requirements
at various flow rates and mix chamber sizes
may be less.
†Total system watts used by system, based on
maximum heated hose length for each unit.
• E–30 and E–XP2 series: 310 ft (94.5 m)
maximum heated hose length, including
whip hose.
★SeeApprovals, page 11.
‡Packages include gun, heated hose, and
whip hose. Elite packages also include fluid
inlet sensors.
◊Low line input voltage will reduce power
available and heaters will not perform at full
capacity.
Voltage Configurations Key
ØPhase
∆DELTA
YWYE
10 333024N