Graco Reactor 2 E-XP2 Instruction Manual

Operation
Reactor 2 E-30 and E-XP2
Proportioning Systems 333023D
EN
Electric, Heated, Plural Component Proportioner for spraying polyurethane foam and polyurea coatings.
Not for outdoor use. 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.
PROVEN QUALITY. LEADING TECHNOLOGY.

Contents
Warnings ........................................................... 3
Important Isocyanate Information......................... 7
Models............................................................... 9
Approvals........................................................... 11
Accessories........................................................ 11
Supplied Manuals ............................................... 12
Related Manuals ................................................ 12
Typical Installation, without circulation.................. 13
Typical Installation, with system fluid manifold
to drum circulation................................. 14
Typical Installation, with gun fluid manifold to
drum circulation..................................... 15
Component Identification..................................... 16
Advanced Display Module (ADM).................. 18
Electrical Enclosure...................................... 23
Motor Control Module (MCM)........................ 24
Temperature Control Module (TCM) Cable
Connections................................... 25
Installation.......................................................... 26
Setup................................................................. 27
Grounding ................................................... 27
Close gun fluid manifold valves A and
B ................................................... 27
General Equipment Guidelines ..................... 27
Connect Power ............................................ 28
Supply Wet Cups With Throat Seal Liquid
(TSL) ............................................. 29
Install Fluid Temperature Sensor .................. 29
Register and Activate the Graco InSite........... 29
Advanced Display Module (ADM)
Operation.............................................. 30
Advanced Setup Screens ............................. 33
System 1 ..................................................... 34
System 2 ..................................................... 34
Recipes....................................................... 34
Run Mode ................................................... 35
Startup............................................................... 41
Fluid Circulation.................................................. 44
Circulation Through Reactor ......................... 44
Circulation Through Gun Manifold ................. 45
Jog Mode........................................................... 45
Spraying ............................................................ 46
Spray Adjustments....................................... 47
Manual Hose Heat Mode .............................. 48
Shutdown........................................................... 50
Pressure Relief Procedure .................................. 52
Flushing............................................................. 53
Maintenance ...................................................... 54
Preventative Maintenance Schedule ............. 54
Proportioner Maintenance ............................ 54
Flush Inlet Strainer Screen ........................... 55
Pump Lubrication System............................. 56
Errors ................................................................ 57
View Errors.................................................. 57
Troubleshoot Errors ..................................... 57
Troubleshooting.................................................. 58
Error Codes and Troubleshooting.................. 58
USB Data........................................................... 59
Download Procedure.................................... 59
USB Logs.................................................... 59
System Configuration Settings ...................... 60
Custom Language File ................................. 61
Upload Procedure........................................ 61
Performance Charts............................................ 62
Technical Specifications...................................... 65
Graco Extended Warranty for Reactor® 2
Components ......................................... 67
2333023D

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 back to these
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 eyesoronskin,
inhaled, or swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable
guidelines.
• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning
equipment.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury,
including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective
equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent
manufacturer.
333023D 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:
• Use equipment 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.
• Do not 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.
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.
4333023D

Warnings
WARNING
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.
• Many other 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.
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.
• 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 youareusingit.
• 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.
• Pressurized equipment can start without warning. Before checking, moving, or servicing
equipment, follow the Pressure Relief Procedure and disconnect all power sources.
333023D 5

Warnings
WARNING
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid
severe burns:
• Do not touch hot fluid or equipment.
6333023D

Important Isocyanate Information
Important Isocyanate Information
Isocyanates (ISO) are catalysts used in two component materials.
Isocyanate Conditions
Spraying or dispensing materials containing
isocyanates creates potentially harmful mists,
vapors, and atomized particulates.
Read material manufacturer’s warnings and
material MSDS to know specific hazards and
precautions related to isocyanates.
Prevent inhalation of isocyanate mists, vapors,
and atomized particulates by providing sufficient
ventilation in the work area. If sufficient ventilation
is not available, a supplied-air respirator is required
for everyone in the work area.
To prevent contact with isocyanates, appropriate
personal protective equipment, including
chemically impermeable gloves, boots, aprons,
and goggles, is also required for everyone in the
work area.
Material Self-Ignition
Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings
and material MSDS.
Keep Components A and B Separate
Cross-contamination can result in cured
material in fluid lines which could cause serious
injury or damage 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.
Moisture Sensitivity of Isocyanates
Exposure to moisture (such as humidity) will cause
ISO to partially cure; forming small, hard, abrasive
crystals, which 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.
333023D 7

Important Isocyanate Information
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.
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 compatibility.
• When 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
often have amines on the B (resin) side.
8333023D

Models
Models
Reactor 2 E-30 and E-30 Elite
All elite systems include fluid inlet sensors, Graco InSite™, and Xtreme-Wrap 50 ft (15 m) heated hose. For
part numbers, see Accessories, page 11
Base Model Elite Model
Model E-30, 10 kW E-30, 15 kW Elite, 10 kW Elite, 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
230
1Ø
230
3Ø∆
380
3ØY
230
1Ø
230
3Ø∆
380
3ØY
230
1Ø
230
3Ø∆
380
3ØY
230
1Ø
230
3Ø∆
380
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)
AP2011
(246102)
AP2110
(246102)
AP2111
(246102)
Fusion CS Package 
(Gun Part No.)
CS2010
(CS02RD)
CS2011
(CS02RD)
CS2110
(CS02RD)
CS2111
(CS02RD)
Probler P2 Package 
(Gun Part No.)
P22010
(GCP2R2)
P22011
(GCP2R2)
P22110
(GCP2R2)
P22111
(GCP2R2)
Heated Hose
50 ft (15 m)
24K240 (scuff
guard)
24K240 (scuff
guard)
24Y240 (Xtreme-
Wrap)
24Y240 (Xtreme-
Wrap)
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 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.
★See Approvals, page 11.
Packages include gun, heated hose, and
whip hose. Elite packages also include
Graco InSite and fluid inlet sensors.
333023D 9

Models
Reactor 2 E-XP2 and E-XP2 Elite
All elite systems include fluid inlet sensors, Graco InSite™, and Xtreme-Wrap 50 ft (15 m) heated hose. For
part numbers, see Accessories, page 11
Base Model Elite Model
Model
E–XP2, 15 kW E–XP2, 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
240 1Ø 240 3Ø 380 3Ø 240 1Ø 240 3Ø 380 3Ø
Full Load Peak Current
(amps)
100 62 35 100 62 35
Fusion AP Package 
(Gun Part No.)
AP2012
(246101)
AP2112
(246101)
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)
246050 246050
Graco Insite™✓
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.
★See Approvals, page 11.
Packages include gun, heated hose, and
whip hose. Elite packages also include
Graco InSite and fluid inlet sensors.
10 333023D

Approvals
Approvals
Intertek approvals apply to proportioners without
hoses.
Proportioner Approvals:
9902471
Conforms to ANSI/UL Std. 499
Certified to CAN/CSA Std. C22.2 No. 88
Note
Heated hoses provided with a system or sold
individually are not approved by Intertek.
Accessories
Kit Number Description
24U315 Air Manifold Kit (4 outlets)
24U314 Wheel and Handle Kit
24T280 GracoInSiteKit
16X521 GracoInSiteExtensioncable24.6ft
(7.5 m)
24N449 50 ft (15 m) CAN cable (for remote
display module)
24K207 Fluid Temperature Sensor (FTS)
with RTD
24U174 Remote Display Module Kit
15V551 ADM Protective Covers (10 pack)
15M483 Remote Display Module Protective
Covers (10 pack)
24M174 Drum Level Sticks
121006 150 ft (45 m) CAN cable (for remote
display module)
24N365 RTD Test Cables (to aide resistance
measurements)
333023D 11

Supplied Manuals
Supplied Manuals
The following manuals are shipped with the Reactor
2. Refer to these manuals for detailed equipment
information.
Manuals are also available at www.graco.com.
Manual Description
333023 Reactor 2 E-30 and E-XP2
Operation
333091 Reactor 2 E-30 and E-XP2 Startup
Quick Guide
333092 Reactor 2 E-30 and E-XP2
Shutdown Quick Guide
Related Manuals
The following manuals are for accessories used with
the Reactor.
Component Manuals in English:
Manuals are available at www.graco.com.
System Manuals
333024 Reactor 2 E-30 and E-XP2,
Repair-Parts
Displacement Pump Manual
309577 Electric Reactor Displacement Pump,
Repair-Parts
Feed System Manuals
309572 Heated Hose, Instructions-Parts
309852 Circulation and Return Tube Kit,
Instructions-Parts
309815 Feed Pump Kits, Instructions-Parts
309827 Feed Pump Air Supply Kit,
Instructions-Parts
Spray Gun Manuals
309550 Fusion ™ AP Gun
312666 Fusion ™ CS Gun
313213 Probler®P2 Gun
Accessory Manuals
3A1905 Feed Pump Shutdown Kit,
Instructions-Parts
3A1906 Light Tower Kit, Instructions-Parts
3A1907 Remote Display Module Kit,
Instructions-Parts
332735 Air Manifold Kit, Instructions-Parts
332736 Handle and Wheel Kit,
Instructions-Parts
333276 Graco InSite ™ Kit, Instructions-Parts
12 333023D

Typical Installation, without circulation
Typical Installation, without circulation
B
G
K
M
J
G
H
K
L
J
D
S
C*
P
E
A
F
N
N
(RES)
(ISO)
Figure 1
* Shown exposed for clarity. Wrap with tape during operation.
A Reactor Proportioner
BHeatedHose
C Fluid Temperature Sensor (FTS)
D HeatedWhipHose
EFusion Spray Gun
FGun Air Supply Hose
G Feed Pump Air Supply Lines
HAgitator Air Supply Line
JFluid Supply Lines
K Feed Pumps
L Agitator
MDesiccantDryer
N Bleed Lines
PGun Fluid Manifold (part of gun)
S Remote Display Module Kit (optional)
333023D 13

Typical Installation, with system fluid manifold to drum circulation
Typical Installation, with system fluid manifold to drum
circulation
(RES)
M
K
M
R
J
G
HK
L
B
J
D
S
C*
P
E
F
R
A
(ISO)
G
Figure 2
* Shown exposed for clarity. Wrap with tape during operation.
A Reactor Proportioner
BHeatedHose
C Fluid Temperature Sensor (FTS)
D Heated Whip Hose
EFusion Spray Gun
FGun Air Supply Hose
G Feed Pump Air Supply Lines
HAgitator Air Supply Line
JFluid Supply Lines
K Feed Pumps
L Agitator
M Desiccant Dryer
PGun Fluid Manifold (part of gun)
R Recirculation Lines
S Remote Display Module (optional)
14 333023D

Typical Installation, with gun fluidmanifoldtodrumcirculation
Typical Installation, with gun fluid manifold to drum
circulation
Figure 3
* Shown exposed for clarity. Wrap with tape during operation.
A Reactor Proportioner
BHeatedHose
C Fluid Temperature Sensor (FTS)
CK Circulation Block (accessory)
D HeatedWhipHose
FGun Air Supply Hose
G Feed Pump Air Supply Lines
HAgitator Air Supply Line
JFluid Supply Lines
K Feed Pumps
L Agitator
MDesiccantDryer
PGun Fluid Manifold (part of gun)
R Recirculation Lines
S Remote Display Module (optional)
333023D 15

Component Identification
Component Identification
Figure 4
16 333023D

Component Identification
Key
BA ISO Side Pressure Relief Outlet
BB RES Side Pressure Relief Outlet
CD Advanced Display Module (ADM)
DG Drive Gear Housing
EC Electrical Cord Strain Relief
EM Electric Motor
FA ISO Side Fluid Manifold Inlet
FB RES Side Fluid Manifold Inlet
FH Fluid Heaters (behind shroud)
FM Reactor Fluid Manifold
FV Fluid Inlet Valve(RESsideshown)
GA ISO Side Pressure Gauge
GB RES Side Pressure Gauge
HA ISO Side Hose Connection
HB RES Side Hose Connection
HC Heated Hose Electrical Connectors
MP Main PowerSwitch
PA ISO Side Pump
PB RES Side Pump
RR Graco InSite Cellular Module (Elite models
only)
RS Red Stop Button
SA ISO Side PRESSURE RELIEF/SPRAY
Valve
SB RES Side PRESSURE RELIEF/SPRAY
Valve
TA ISO Side Pressure Transducer (behind
gauge GA)
TB RES Side Pressure Transducer (behind
gauge GB)
XA Fluid Inlet Sensor (ISO side, Elite models
only)
XB Fluid Inlet Sensor (RES side, Elite models
only)
333023D 17

Component Identification
Advanced Display Module (ADM)
The ADM display shows graphical and text
information related to setup and spray operations.
NOTICE
To prevent damage to the softkey buttons, do not
press buttons with sharp objects such as pens,
plastic cards, or fingernails.
Figure 5 Front View
18 333023D

Component Identification
Table 1 : ADM Keys and Indicators
Key Function
Startup/Shutdown
Key and Indicator
Press to startup or shutdown the system.
Stop
Press to stop all proportioner processes. This Is not a safety or emergency stop.
Soft Keys
Press to select the specific screen or operation shown on the display directly next to
each key.
Navigation Keys
•
Left/Right Arrows: Usetomovefromscreentoscreen.
•
Up/Down Arrows: Usetomoveamongfieldsonascreen,itemsonadropdown
menu, or multiple screens within a function.
Numeric Keypad Use to input values.
Cancel
Usetocanceladataentryfield.
Setup
Press to enter or exit Setup mode.
Enter
Press to choose a field to update, to make a selection, to save a selection or value, to
enter a screen, or to acknowledge an event.
333023D 19

Component Identification
Figure 6 Back View
CJ Flat Panel Mount (VESA 100)
CK Model and Serial Number
CL USB Port and Status LEDs
CM CAN Cable Connection
CN Module Status LEDs
CP Accessory Cable Connection
CR Token Access Cover
CS Battery Access Cover
Table 2 ADM LED Status Descriptions
LED Conditions Description
Green Solid Run Mode, System On
Green Flashing Setup Mode, System On
Yellow Solid Run Mode, System Off
System Status
Yellow Flashing Setup Mode, System Off
Green Flashing Data recording in progress
Yellow Solid Downloading information to USB
USB Status (CL)
Green and Yellow Flashing ADM is busy, USB cannot transfer
information when in this mode
Green Solid Power applied to module
Yellow Solid Active Communication
Red Steady Flashing Software upload from token in
progress
ADM Status (CN)
Red Random Flashing or Solid Module error exists
20 333023D