Graco Reactor 2 E-30 Use and care manual

Repair-Parts
Reactor 2 E-30 and E-XP2
Proportioning System
333024F
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 locations.
Important Safety Instructions. Read all warnings and instructions in
this manual. Save these instructions.
WLE
PROVEN QUALITY. LEADING TECHNOLOGY.
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Contents
Warnings .............................................................3
Important Isocyanate Information...........................7
Models.................................................................9
Approvals........................................................... 11
Accessories........................................................ 11
Supplied Manuals............................................... 12
Related Manuals ................................................ 12
Trou leshooting.................................................. 13
Trou leshoot Errors ..................................... 13
Pressure Relief Procedure .................................. 43
Shutdown........................................................... 44
Flushing............................................................. 46
Repair................................................................ 47
Before Beginning Repair............................... 47
Flush Inlet Strainer Screen ........................... 47
Change Pump Lu ricant............................... 48
Remove Pump............................................. 49
Install Pump ................................................ 50
Repair Drive Housing ................................... 51
Repair Electric Motor.................................... 54
Repair Circuit Breaker Module ...................... 55
Replace Fluid Inlet Sensor............................ 56
Replace Pressure Transducers..................... 56
Replace Fans .............................................. 57
Repair Primary Heater.................................. 60
Repair Heated Hose..................................... 64
Repair Fluid Temperature Sensor
(FTS)............................................. 66
Replace Power Supply ................................. 69
Replace Surge Protector .............................. 69
Replace Advanced Display Module
(ADM)............................................ 69
Replace Motor Control Module (MCM)........... 70
Software Update Procedure.......................... 70
Replace Temperature Control Module
(TCM)............................................ 70
Parts.................................................................. 71
Electrical Schematics.......................................... 91
Reactor 2 Repair Spare Parts Reference ............. 94
Performance Charts............................................ 95
Technical Specifications...................................... 98
Notes ............................................................. 100
Graco Extended Warranty for Reactor® 2
Components ....................................... 101
2333024F
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Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation point sym ol alerts you to a general warning and the hazard sym ols refer to procedure-specific
risks. When these sym ols appear in the ody of this manual or on warning la els, refer ack to these
Warnings. Product-specific hazard sym ols and warnings not covered in this section may appear throughout
the ody of this manual where applica le.
WARNING
ELECTRIC SHOCK H Z RD
This equipment must e grounded. Improper grounding, setup, or usage of the system can
cause electric shock.
• Turn off and disconnect power at main switch efore disconnecting any ca les and efore
servicing or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must e done y 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 applica le
guidelines.
PERSON L 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;
urns; eye injury and hearing loss. This protective equipment includes ut is not limited to:
• A properly fitting respirator, which may include a supplied-air respirator, chemically
impermea le gloves, protective clothing and foot coverings as recommended y the fluid
manufacturer and local regulatory authority.
• Protective eyewear and hearing protection.
333024F 3
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Warnings
WARNING
SKIN INJECTION H Z RD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may
look like just a cut, ut 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 ody.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, ody, glove, or rag.
• Follow the Pressure Relief Procedure when you stop spraying and efore cleaning, checking,
or servicing equipment.
• Tighten all fluid connections efore operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
FIRE ND EXPLOSION H Z RD
Flamma le fumes, such as solvent and paint fumes, in work area canigniteorexplode.Tohelp
prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, porta le electric lamps, and
plastic drop cloths (potential static arc).
• Keep work area free of de ris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flamma le
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 pro lem.
• Keep a working fire extinguisher in the work area.
THERM L EXP NSION H Z RD
Fluids su jected 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 ased on your operating conditions.
4333024F
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Warnings
WARNING
PRESSURIZED LUMINUM P RTS H Z RD
Use of fluids that are incompati le 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 hydrocar on
solvents or fluids containing such solvents.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material
supplier for compati ility.
PL STIC P RTS CLE NING SOLVENT H Z RD
Many solvents can degrade plastic parts and cause them to fail, which could cause serious
injury or property damage.
• Use only compati le water- ased solvents to clean plastic structural or pressure-containing
parts.
•See Technical Data in this and all other equipment instruction manuals. Read fluid and
solvent manufacturer’s MSDSs and recommendations.
EQUIPMENT MISUSE H Z RD
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 compati le with equipment wetted parts. See Technical Data
in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete
information a out your material, request MSDS from distri utor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all 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.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distri utor for information.
• Route hoses and ca les away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over end hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applica le safety regulations.
MOVING P RTS H Z RD
Moving parts can pinch, cut or amputate fingers and other ody parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing
equipment, follow the Pressure Relief Procedure and disconnect all power sources.
333024F 5
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Warnings
WARNING
BURN H Z RD
Equipment surfaces and fluid that is heated can ecome very hot during operation. To avoid
severe urns:
• Do not touch hot fluid or equipment.
6333024F
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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 e carefully maintained and adjusted
according to instructions in the manual.
• To prevent 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 impermea le
gloves, protective clothing and foot coverings as recommended y 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 efore 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 y 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:
333024F 7
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Important Isocyanate Information
Material Self-Ignition
Some materials may ecome 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
Bwettedparts.
• Never use solvent on one side if it has een
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.
• When changing materials, flush the equipment
multiple times to ensure it is thoroughly clean.
• Always clean the fluid inlet strainers after
flushing.
• Check with your material manufacturer for
chemical compati ility.
• When changing etween epoxies and urethanes
or polyureas, disassem le and clean all fluid
components and change hoses. Epoxies often
have amines on the B (hardener) side. Polyureas
often have amines on the B (resin) side.
Moisture Sensitivity of Isocyanates
Exposure to moisture (such as humidity) will cause
ISO to partially cure, forming small, hard, a rasive
crystals that ecome suspended in the fluid.
Eventually a film will form on the surface and the ISO
will egin 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 lu ricant. The
lu ricant creates a arrier etween the ISO and
the atmosphere.
• Use only moisture-proof hoses compati le with
ISO.
• Never use reclaimed solvents, which may
contain moisture. Always keep solvent
containers closed when not in use.
• Always lu ricate threaded parts with an
appropriate lu ricant when reassem ling.
NOTE: The amount of film formation and rate of
crystallization varies depending on the lend of ISO,
the humidity, and the temperature.
Foam Resins with 45 fa Blowing
Agents
Some foam lowing agents will froth at temperatures
a ove 90°F (33°C) when not under pressure,
especially if agitated. To reduce frothing, minimize
preheating in a circulation system.
8333024F
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Models
Models
Reactor E-30 and E-30 Elite
All elite systems include fluid inlet pressure and temperature sensors, Graco InSite
™
, and Xtreme-Wrap 50 ft
(15 m) head hose. For part num ers, see Accessories, 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)
pproximate Output per
Cycle ( +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

230
1Ø 230 3Ø∆ 400 3ØY 230 1Ø 230 3Ø∆ 400 3ØY 230 1Ø 230 3Ø∆ 400 3ØY 230 1Ø 230 3Ø∆ 400 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)
24K24024K24024K24024K24024Y24024Y24024Y24024Y240 Heated Hose
50 ft (15 m)
24K240 (scuff guard)
24Y240 (Xtreme-Wrap)
Qty 1 Qty 5 Qty 1 Qty 5 Qty 1 Qty 5 Qty 1 Qty 5
Heated Whip Hose
10 ft (3 m)
246050 246050 246050 246050
Graco Insite
™
✓✓
Fluid Inlet Sensors (2)
✓✓
*Full load amps with all devices operating at
maximum capa ilities. Fuse requirements at
various flow rates and mix cham er sizes
may e less.

Total system watts used y system, ased on
maximum heated hose length for each unit.
• E–30andE–XP2series:310ft(94.5m)
maximum heated hose length, including
whip hose.
★See Approvals, page 11.

Packages include gun, heated hose, and
whip hose. Elite packages also include Graco
InSite and fluid inlet sensors.

Low line input voltage will reduce power
availa le and heaters will not perform at full
capacity.
Voltage Configurations Key
ØPhase
∆DELTA
YWYE
333024F 9
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Models
Reactor E-XP and E-XP Elite
All elite systems include fluid inlet pressure and temperature sensors, Graco InSite
™
, and Xtreme-Wrap 50 ft
(15 m) head hose. For part num ers, 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)
pproximate Output per
Cycle ( +B) gal. (liter)
0.0203 (0.0771) 0.0203 (0.0771)
Max Flow Rate gpm/min
(l/min)
2(7.6) 2(7.6)
Total System Load † 
(Watts)
23,000 23,000
Configurable Voltage
Phase

230 1Ø 230 3Ø∆ 400 3ØY 230 1Ø 230 3Ø∆ 400 3ØY
Full Load Peak Current
(amps) *100 62 35 100 62 35
Fusion P Package 
(Gun Part No.)
AP2012
(246100)
AP2112
(246100)
Probler P2 Package 
(Gun Part No.)
P22012
(GCP2R0)
P22112
(GCP2R0)
Heated Hose
50 ft (15 m)
24K241
(scuff guard) 24Y241 (Xtreme-Wrap)
Heated Whip Hose
10 ft (3 m)
246055 246055
Graco InSite
™
✓
Fluid Inlet Sensors (2)
✓
*Full load amps with all devices operating at
maximum capa ilities. Fuse requirements
at various flow rates and mix cham er sizes
may e less.

Total system watts used y system, ased 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.
★See Approvals, page 11.

Packages include gun, heated hose, and
whip hose. Elite packages also include
GracoInSiteandfluidinletsensors.

Low line input voltage will reduce power
availa le and heaters will not perform at full
capacity.
Voltage Configurations Key
ØPhase
∆DELTA
YWYE
10 333024F
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