Graco Reactor A-XP Series Instruction Manual

Operation
Air Powered, Heated, Plural Component Proportioner
For spraying polyurethane foam and polyurea coatings.
Not for use in explosive atmospheres.
See page 3 for model information, including maximum
working pressure and approvals.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
TI11252a
Model 259060 Shown
312407C
ENG
Russian Patent No. 2359181
Taiwan Patent No. 1 303996
Australian Patent No. 2003291660
Other patents pending.

2312407C
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Supplied Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Isocyanate Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . . . 7
Moisture Sensitivity of Isocyanates . . . . . . . . . . . . 7
Keep Components A and B Separate . . . . . . . . . . 8
Foam Resins with 245 fa Blowing Agents . . . . . . . 8
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . . 8
Typical Installation, with circulation . . . . . . . . . . . 9
Typical Installation, without circulation . . . . . . . 10
Component Identification . . . . . . . . . . . . . . . . . . . 11
Controls and Indicators . . . . . . . . . . . . . . . . . . . . 12
Main Power Switch . . . . . . . . . . . . . . . . . . . . . . 12
Red Stop Button . . . . . . . . . . . . . . . . . . . . . . . . 12
Actual Temperature Key/LED . . . . . . . . . . . . . . 12
Target Temperature Key/LED . . . . . . . . . . . . . . 12
Temperature Scale Keys/LEDs . . . . . . . . . . . . . 12
Heater Zone On/Off Keys/LEDs . . . . . . . . . . . . 13
Temperature Arrow Keys . . . . . . . . . . . . . . . . . . 13
Temperature Displays . . . . . . . . . . . . . . . . . . . . 13
Cycle Counter . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . 13
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 26
Fluid Circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Circulation Through Reactor . . . . . . . . . . . . . . . 27
Circulation Through Gun Manifold . . . . . . . . . . . 28
Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Temperature Control Diagnostic Codes . . . . . . . 29
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Feed Pump Kits . . . . . . . . . . . . . . . . . . . . . . . . . 32
246483 Air Supply Kit . . . . . . . . . . . . . . . . . . . . 32
246978 Circulation Kit . . . . . . . . . . . . . . . . . . . . 32
246477 Return Tube Kit . . . . . . . . . . . . . . . . . . . 32
Heated Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Heated Whip Hoses . . . . . . . . . . . . . . . . . . . . . . 32
Fusion Spray Gun . . . . . . . . . . . . . . . . . . . . . . . 32
246086 Data Reporting Kit . . . . . . . . . . . . . . . . 32
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 36
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 36

Models
312407C 3
Models
Air Powered Reactors
A-XP Series
Heat Packages (do not include proportioner)
HT Series
All A-XP2 models are CE compliant.
Part, Series Model
Voltage
(phase)
Full
Load
Peak
Amps
System
Watts
Heater
Watts
(no
hose)
Pressure
Ratio
Flow
gpm
(lpm) at
78 cpm
Output
per Cycle
(A+B)
gal. (liter)
Maximum Fluid
Working
Pressure
psi (MPa, bar)
259060, A A-XP2 230V (1) 62 14,540 10,200 25:1 1.5 (5.7) 0.0193
(0.73)
3000 (20.7, 207)
259061, A A-XP2 230V (3) 40 14,540 10,200 25:1 1.5 (5.7) 0.0193
(0.73)
3000 (20.7, 207)
259062, A A-XP2 400V (3) 22 14,540 10,200 25:1 1.5 (5.7) 0.0193
(0.73)
3000 (20.7, 207)
Part, Series Model
Voltage
(phase)
Full
Load
Peak
Amps
System
Watts
Heater
Watts
(no hose)
Maximum Fluid
Working Pressures
psi (MPa, bar)
259070, C HT-6.0 230V (1) 44 10,340 6,000 3500 (24.1, 241)
259071, C HT-6.0 230V (3) 27 10,340 6,000 3500 (24.1, 241)
259072, C HT-6.0 400V (3) 18 10,340 6,000 3500 (24.1, 241)
259073, C HT-10.2 230V (1) 62 14,540 10,200 3500 (24.1, 241)
259074, C HT-10.2 230V (3) 40 14,540 10,200 3500 (24.1, 241)
259075, C HT-10.2 400V (3) 22 14,540 10,200 3500 (24.1, 241)
259076, C HT-15.3 230V (1) 84 19,640 15,300 3500 (24.1, 241)
259077, C HT-15.3 230V (3) 57 19,640 15,300 3500 (24.1, 241)
259078, C HT-15.3 400V (3) 33 19,640 15,300 3500 (24.1, 241)

Supplied Manuals
4312407C
Supplied Manuals
The following manuals are shipped with the Reactor™
Proportioner. Refer to these manuals for detailed equip-
ment information.
Order Part 15M334 for a compact disk of Reactor manu-
als translated in several languages
Manuals are also available at www.graco.com.
Related Manuals
The following manuals are for accessories used with the
Reactor™.
Order Part 15M334 for a compact disk of Reactor manu-
als translated in several languages. Order Part 15B381
for a compact disk of Fusion manuals translated in sev-
eral languages.
Reactor Air Powered Proportioner
Part Description
312408 Reactor Air Powered Proportioner,
Repair-Parts Manual (English)
Reactor Electrical Diagrams
Part Description
312409 Reactor Air Powered Proportioner,
Electrical Diagrams (English)
Proportioning Pump
Part Description
308224 President®Pump (A-XP2),
Repair-Parts Manual (English)
Motor
Part Description
306982 President®Air Motor (A-XP2),
Repair-Parts Manual (English)
Displacement Pump
Part Description
307430 Displacement Pumps (A-XP2),
Repair-Parts Manual (English)
Air Regulators
Part Description
308168 Instruction-Parts Manual (English)
Feed Pump Kits
Part Description
309815 Instruction-Parts Manual (English)
Air Supply Kit
Part Description
309827 Instruction-Parts Manual (English) for
Feed Pump Air Supply Kit
Circulation and Return Tube Kits
Part Description
309852 Instruction-Parts Manual (English)
Heated Hose
Part Description
309572 Instruction-Parts Manual (English)
Fusion Air Purge Spray Gun
Part Description
309550 Instruction-Parts Manual (English)
Fusion Mechanical Purge Spray Gun
Part Description
309856 Instruction-Parts Manual (English)
Circulation Kit
Part Description
309818 Instruction-Parts Manual (English)
Data Reporting Kit
Part Description
309814 Instruction-Parts Manual (English)

Warnings
312407C 5
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where
applicable.
WARNING
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power cord before servicing equipment.
• Use only grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on sprayer and extension cords.
• Do not expose to rain. Store indoors.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDS’s 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 impervious gloves when spraying or cleaning equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
• Hearing protection
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 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.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
•FollowPressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.

Warnings
6312407C
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 and clean 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 lights on or off when flammable fumes are present.
• Ground equipment, personnel, object being sprayed, and conductive objects in work area. See
Grounding instructions.
• Use only Graco grounded hoses.
• Check gun resistance daily.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Do not flush with gun electrostatics on. Do not turn on electrostatics until all solvent is removed from
system.
• Keep a working fire extinguisher in the work area.
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids
containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical
reaction and equipment rupture, and result in death, serious injury, and property damage.
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 forms from distributor or retailer.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-
facturer’s replacement parts only.
• Do not alter or modify equipment.
• 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 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 equip-
ment, follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.
WARNING

Isocyanate Hazard
312407C 7
Isocyanate Hazard
Material Self-ignition
Moisture Sensitivity of
Isocyanates
Isocyanates (ISO) are catalysts used in two component
foam and polyurea coatings. ISO will react with moisture
(such as humidity) to form 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. If used, this partially cured ISO
will reduce performance and the life of all wetted parts.
To prevent exposing ISO to moisture:
• 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 lube pump reservoir filled with Graco
Throat Seal Liquid (TSL), Part 206995. The lubri-
cant creates a barrier between the ISO and the
atmosphere.
• Use moisture-proof hoses specifically designed for
ISO, such as those supplied with your system.
• Never use reclaimed solvents, which may contain
moisture. Always keep solvent containers closed
when not in use.
• Never use solvent on one side if it has been contam-
inated from the other side.
• Always park pumps when you shutdown, see page
25.
• Always lubricate threaded parts with Part 217374
ISO pump oil or grease when reassembling.
Spraying materials containing isocyanates creates
potentially harmful mists, vapors, and atomized partic-
ulates.
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 ventila-
tion in work area. If sufficient ventilation is not avail-
able, a supplied-air respirator is required for everyone
in the work area.
To prevent contact with isocyanates, appropriate per-
sonal protective equipment, including chemically
impermeable gloves, boots, aprons, and goggles, is
also required for everyone in the work area.
Some materials may become self-igniting if applied
too thickly. Read material manufacturer’s warnings
and material MSDS.
The amount of film formation and rate of crystalli-
zation varies depending on the blend of ISO, the
humidity, and the temperature.

Keep Components A and B Separate
8312407C
Keep Components A and
B Separate
Foam Resins with 245 fa
Blowing Agents
New 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
• When changing materials, flush the equipment mul-
tiple times to ensure it is thoroughly clean.
• Always clean the fluid inlet strainers after flushing,
see page 31.
• Check with your material manufacturer for chemical
compatibility.
• Most materials use ISO on the A side, but some use
ISO on the B side.
• Epoxies often have amines on the B (hardener)
side. Polyureas often have amines on the B (resin)
side.
CAUTION
To prevent cross-contamination of the equipment’s
wetted parts, never interchange component A (isocy-
anate) and component B (resin) parts.

Typical Installation, with circulation
312407C 9
Typical Installation, with circulation
Key for FIG. 1
A Air Powered Reactor
B Heated Hose (see page 32)
C Fluid Temperature Sensor (FTS)
D Heated Whip Hose (see page 32)
E Fusion Spray Gun (see page 32)
F Gun Air Supply Hose
G Feed Pump Air Supply Lines
(part of Air Supply Kit, page 32)
J Fluid Supply Lines
K Feed Pumps (see page 32)
LAgitator
M Desiccant Dryer (part of Return Tube Kit, page 32)
P Gun Fluid Manifold (part of Fusion gun)
Q Air Quick-Disconnect (part of Circulation Kit, page 32)
R Air Purge Lines (part of Circulation Kit, page 32)
S Air Line Shutoff Valve
U Proportioner Air Supply Line
W Air Filter/Separator
AR Air Regulator (part of Reactor, page 11)
BV Bleed-Type Master Air Valve (part of Reactor, page 11)
FIG. 1: Typical Installation, with circulation (259060)
A
B
C*
DE
F
K
L
M
G
J
K
TI3675b
R
P
W
R
* Shown exposed for clarity. Wrap with tape during operation.
J
G
G
J
AR
BV
S
M
G
Q
Q
U

Typical Installation, without circulation
10 312407C
Typical Installation, without circulation
Key for FIG. 2
A Reactor Proportioner
B Heated Hose (see page 32)
C Fluid Temperature Sensor (FTS)
D Heated Whip Hose (see page 32)
E Fusion Spray Gun (see page 32)
F Gun Air Supply Hose
G Feed Pump Air Supply Lines
(part of Air Supply Kit, page 32)
H Waste Containers
J Fluid Supply Lines
K Feed Pumps (see page 32)
LAgitator
M Desiccant Dryer (part of Return Tube Kit, page 32)
N Bleed Lines
P Gun Fluid Manifold (part of Fusion gun)
Q Air Quick-Disconnect (part of Circulation Kit, page 32)
W Air Filter/Separator
FIG. 2: Typical Installation, without circulation (259060)
A
B
C*
D
E
F
G
H
J
K
L
M
G
J
K
TI11253a
N
P
* Shown exposed for clarity. Wrap with tape during operation.
H
W
Q
G

Component Identification
312407C 11
Component Identification
Key for FIG. 3
AR Air Regulator
BA Component A Pressure Relief Outlet
BB Component B Pressure Relief Outlet
BV Bleed-Type Master Air Valve
CC Cycle Counter
EC Electrical Cord Strain Relief
FA Component A Fluid Manifold Inlet (behind manifold block)
FB Component B Fluid Manifold Inlet
FH Fluid Heaters (behind shroud)
FM Reactor Fluid Manifold
GA Component A Pressure Gauge
GB Component B Pressure Gauge
HA Component A Hose Connection
HB Component B Hose Connection
HC Heated Hose Electrical Connector
MP Main Power Switch
PA Component A Pump
PB Component B Pump
PM Pump Motor
RS Red Heat Stop Button
SA Component A PRESSURE RELIEF/SPRAY Valve
SB Component B PRESSURE RELIEF/SPRAY Valve
SC Fluid Temperature Sensor Cable
TC Temperature Control Display
UA Component A Fluid Inlet Strainer
UB Component B Fluid Inlet Strainer
VA Component A Fluid Inlet Valve
VB Component B Fluid Inlet Valve
FIG. 3: Component Identification
EC
MP
TI2500a-1
Detail of Main Power Switch
(right side of unit)
TI11252a
TC
PM
PA
FM
VB PB
FH
CC
RS
SC
HC
VA
AR
UA
UB
BV
Detail of Reactor Fluid Manifold
TI3592a
GA
GB
SB
FB
BB
HB
HA
BA
FA
SA

Controls and Indicators
12 312407C
Controls and Indicators
Main Power Switch
Located on right side of unit, page 11. Turns Reactor
power ON and OFF . Does not turn
heater zones or pumps on.
Red Stop Button
Located between temperature control panel and motor
control panel, page 11. Press to shut off motor
and heater zones only. Use main power switch to shut
off all power to unit.
Actual Temperature Key/LED
Press to display actual temperature.
Press and hold to display electrical current.
CAUTION
To prevent damage to the softkey buttons, do
not press the buttons with sharp objects
such as pens, plastic cards, or fingernails.
FIG. 4. Temperature Controls and Indicators
°F
°C
A
B
1234567
Zone A
Arrow Keys
Zone B
Arrow Keys
Hose Zone
Arrow Keys
Temperature
Scale Keys
Heater A
On/Off Key
Heater Power Indicators
Target Temperature Key
Actual
Temperature
Key
Heater Displays
Hose Heater
On/Off Key
Heater B
On/Off Key
Cycle Counter Reset Button

Controls and Indicators
312407C 13
Target Temperature Key/LED
Press to display target temperature.
Press and hold to display heater control circuit
board temperature.
Temperature Scale Keys/LEDs
Press or to change temperature scale.
Heater Zone On/Off Keys/LEDs
Press to turn heater zones on and off. Also clears
heater zone diagnostic codes, see page 29.
Temperature Arrow Keys
Press , then press or to adjust tem-
perature settings in 1 degree increments.
Temperature Displays
Show actual temperature or target temperature of
heater zones, depending on selected mode. Defaults to
actual at startup. Range is 32-190°F (0-88°C) for A and
B, 32-180°F (0-82°C) for hose.
Cycle Counter
Displays cycle count.
Circuit Breakers
Located inside Reactor cabinet.
* Depending on model.
LEDs flash when heater zones are on. The duration
of each flash shows the extent that the heater is
turned on.
To clear counter, press reset button.
°F°C
Ref. Size Component
CB1 50 A Hose/Transformer Secondary
CB2 40 A Transformer Primary
CB3 25 or 40 A* Heater A
CB4 25 or 40 A* Heater B
CB5 20 A Motor/Pumps
ti9884a
CB3 CB4 CB5
CB1
CB2
For wiring and cabling, see repair manual 312408.

Setup
14 312407C
Setup
1. Locate Reactor
a. Locate Reactor on a level surface. See Dimen-
sions, page 33, for clearance and mounting
hole dimensions.
b. Do not expose Reactor to rain.
c. To mount on a truck bed or trailer, bolt feet
directly to truck or trailer bed. See page 33.
2. General Equipment Guidelines
• Determine the correct size generator. Using the cor-
rect size generator and proper air compressor will
enable the proportioner to run at a nearly constant
RPM. Failure to do so will cause voltage fluctuations
that can damage electrical equipment. Ensure the
generator matches the voltage and phase of the
proportioner.
Use the following procedure to determine the cor-
rect size generator.
a. List system components that use peak load
requirements in watts.
b. Add the wattage required by the system compo-
nents.
c. Perform the following equation:
Total watts x 1.25 = kVA (kilovolt-amperes)
d. Select a generator size that is equal to or
greater than the determined kVA.
• Use proportioner power cords that meet or exceed
the requirements listed in Table 2. Failure to do so
will cause voltage fluctuations that can damage
electrical equipment.
• Use an air compressor with constant speed head
unloading devices. Direct online air compressors
that start and stop during a job will cause voltage
fluctuations that can damage electrical equipment.
• Maintain and inspect the generator, air compressor,
and other equipment per the manufacturer recom-
mendations to avoid an unexpected shutdown.
Unexpected equipment shutdown will cause voltage
fluctuations that can damage electrical equipment.
• Use a wall power supply with enough current to
meet system requirements. Failure to do so will
cause voltage fluctuations that can damage electri-
cal equipment.
CAUTION
Proper system setup, startup, and shutdown proce-
dures are critical to electrical equipment reliability.
The following procedures ensure steady voltage. Fail-
ure to follow these procedures will cause voltage fluc-
tuations that can damage electrical equipment and
void the warranty.
FIG. 5
TI11252a

Setup
312407C 15
3. Electrical requirements
See TABLE 1.
* 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 for all units, using 310 ft (94.6 m)
hose.
4. Connect electrical cord
Table 2: Power Cord Requirements
a. 230V, 1 phase: Connect power leads to L1 and
L2. Connect green to ground (GND).
b. 230V, 3 phase: Connect power leads to L1, L2,
and L3. Connect green to ground (GND).
Installing this equipment requires access to parts
which may cause electric shock or other serious injury
if work is not performed properly. Have a qualified
electrician connect power and ground to main power
switch terminals, see page 15. Be sure your installa-
tion complies with all National, State and Local safety
and fire codes.
Table 1: Electrical Requirements
(kW/Full Load Amps)
Part Model
Voltage
(phase)
Full
Load
Peak
Amps*
System
Watts**
A-XP SERIES
259060 A-XP2 230V (1) 62 14,540
259061 A-XP2 230V (3) 40 14,540
259062 A-XP2 400V (3) 22 14,540
HT SERIES (Heat Package Only)
259070 HT-6.0 230V (1) 44 10,340
259071 HT-6.0 230V (3) 27 10,340
259072 HT-6.0 400V (3) 18 10,340
259073 HT-10.2 230V (1) 62 14,540
259074 HT-10.2 230V (3) 40 14,540
259075 HT-10.2 400V (3) 22 14,540
259076 HT-15.3 230V (1) 84 19,640
259077 HT-15.3 230V (3) 57 19,640
259078 HT-15.3 400V (3) 33 19,640
Power cord is not supplied. See Table 2. Use 5/32
or 4 mm hex allen wrench to make connections.
Part Model
Cord Specification
AWG (mm2)
259060 A-XP2 6 (13.3), 2 wire + ground
259061 A-XP2 8 (8.4), 3 wire + ground
259062 A-XP2 10 (5.3), 4 wire + ground
259070 HT-6.0 8 (8.4), 2 wire + ground
259071 HT-6.0 10 (5.3), 3 wire + ground
259072 HT-6.0 12 (3.3), 4 wire + ground
259073 HT-10.2 6 (13.3), 2 wire + ground
259074 HT-10.2 8 (8.4), 3 wire + ground
259075 HT-10.2 10 (5.3), 4 wire + ground
259076 HT-15.3 4 (21.2), 2 wire + ground
259077 HT-15.3 6 (13.3), 3 wire + ground
259078 HT-15.3 8 (8.4), 4 wire + ground
L1
L2
GND
ti2515b
L1
L2
GND
ti3248b
L3

Setup
16 312407C
c. 400V, 3 phase: Connect power leads to L1, L2,
and L3. Connect neutral to N. Connect green to
ground (GND).
5. Connect power source to motor
See FIG. 1. Connect air supply line (U) to air
regulator kit inlet. See Technical Data on page
34 for inlet sizes, recommended hose sizes, and
air consumption requirements.
6. Connect feed pumps
a. Install feed pumps (K) in component A and B
supply drums. See FIG. 1 and FIG. 2, pages 9
and 10.
b. Seal component A drum and use desiccant
dryer (M) in vent.
c. Install agitator (L) in component B drum, if nec-
essary.
d. Ensure A and B inlet valves (FV) are closed.
Some 3-phase models utilize a 3-phase motor. The
motor must rotate counterclockwise when viewed
from shaft end. To reverse rotation, disconnect
power and reverse power leads L1 and L2.
L1
L2
GND
ti2725a
L3
N
Supply hoses from feed pumps should be 3/4 in.
(19 mm) ID.
Model HT heat packages only: connect propor-
tioner hoses to npt(f) connections on heater inlet
blocks.
FV
ti3590a

Setup
312407C 17
7. Connect pressure relief lines
a. Recommended: Connect high pressure hose
(R) to relief fittings (BA, BB) of both PRES-
SURE RELIEF/SPRAY valves, Route hose back
to component A and B drums. See FIG. 1, page
9.
b. Alternately: Secure supplied bleed tubes (N) in
grounded, sealed waste containers (H). See
FIG. 2, page 10.
8. Install Fluid Temperature Sensor (FTS)
The Fluid Temperature Sensor (FTS) is supplied. Install
FTS between main hose and whip hose. See Heated
Hose manual 309572 for instructions.
Do not install shutoffs downstream of the PRESSURE
RELIEF/SPRAY valve outlets (BA, BB). The valves
function as overpressure relief valves when set to
SPRAY . Lines must be open so valves can
automatically relieve pressure when machine is oper-
ating.
If circulating fluid back to the supply drums, use high
pressure hose rated to withstand the maximum work-
ing pressure of this equipment.
ti9880a
BA
BB
R
R
SB
SA

Setup
18 312407C
9. Connect heated hose
a. Turn main power OFF .
b. Assemble heated hose sections, FTS, and whip
hose.
c. Connect A and B hoses to A and B outlets on
Reactor fluid manifold (FM). Hoses are color
coded: red for component A (ISO), blue for com-
ponent B (RES). Fittings are sized to prevent
connection errors.
d. Connect cables (Y). Connect electrical connec-
tors (V). Be sure cables have slack when hose
bends. Wrap cable and electrical connections
with electrical tape.
10.Close gun fluid manifold valves A and B
11.Connect whip hose to gun fluid mani-
fold
12.Pressure check hose
See hose manual. Pressure check for leaks. If no leaks,
wrap hose and electrical connections to protect from
damage.
See Heated Hose manual 309572 for detailed
instructions on connecting heated hoses.
CAUTION
The fluid temperature sensor (C) and whip hose (D)
must be used with heated hose, see page 17. Hose
length, including whip hose, must be 60 ft (18.3 m)
minimum.
Manifold hose adapters (N, P) allow use of 1/4 in.
and 3/8 in. ID fluid hoses. To use 1/2 in. (13 mm) ID
fluid hoses, remove adapters from fluid manifold
and install as needed to connect whip hose.
FM
A
B
ti9878a
N
P
Do not connect manifold to gun.
ti9881a
V
Y
ti2411a
ti2417a

Setup
312407C 19
13.Ground system
a. Reactor: is grounded through power cord. See
page 15.
b. Spray gun: connect whip hose ground wire to
FTS, page 17. Do not disconnect wire or spray
without whip hose.
c. Fluid supply containers: follow your local code.
d. Object being sprayed: follow your local code.
e. Solvent pails used when flushing: follow your
local code. Use only metal pails, which are con-
ductive, placed on a grounded surface. Do not
place pail on a nonconductive surface, such as
paper or cardboard, which interrupts grounding
continuity
f. To maintain grounding continuity when flushing
or relieving pressure, hold a metal part of spray
gun firmly to the side of a grounded metal pail,
then trigger gun.
14.Fill wet-cups
Check pump wet-cups daily. Keep filled with Graco
ISO pump oil (217374) to keep air or moisture from
reacting with fluids.
Pump rod and connecting rod move during operation.
Moving parts can cause serious injury such as pinch-
ing or amputation. Keep hands and fingers away from
wet-cups during operation. Shut off pumps before fill-
ing wet-cups.
TI11254a
Wet-Cups

Startup
20 312407C
Startup
1. Check Generator fuel level.
Running out of fuel will cause voltage fluctuations
that can damage electrical equipment.
2. Ensure the main breaker on the genera-
tor is in the off position.
3. Start the generator. Allow it to reach full
operating temperature.
4. Close the bleed valve on the air com-
pressor.
5. Switch on the air compressor starter
and air dryer, if included.
6. Turn on power to the Reactor.
7. Load fluid with feed pumps
a. Check that all Setup steps are complete.
b. Check that inlet screens are clean before daily
startup.
c. Check level and condition of ISO lube daily.
d. Turn on component B agitator, if used.
e. Turn both PRESSURE RELIEF/SPRAY valves
(SA, SB) to SPRAY .
f. Start feed pumps.
g. Open fluid inlet valves (FV). Check for leaks.
h. Use feed pumps to load system. Hold gun fluid
manifold over two grounded waste containers.
Open fluid valves A and B until clean, air-free
fluid comes from valves. Close valves.
CAUTION
Proper system setup, startup, and shutdown proce-
dures are critical to electrical equipment reliability.
The following procedures ensure steady voltage. Fail-
ure to follow these procedures will cause voltage
flucuations that can damage electrical equipment and
void the warranty.
Do not operate Reactor without all covers and
shrouds in place.
The Reactor is tested with oil at the factory. Flush
out the oil with a compatible solvent before spray-
ing. See page 31.
Do not mix components A and B during startup.
Always provide two grounded waste containers to
keep component A and component B fluids separate.
TI10963a
SA
SB
FV
TI10972a
ti2484a