Graco Reactor E-10 Operation manual

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2005, Graco Inc. is registered to I.S. EN ISO 9001
311075E
Instructions - Parts List
For spraying or dispensing 1:1 mix ratio materials, including
epoxies, polyurethane foam, and polyurea coatings.
Not for use in explosive atmospheres.
See page 3 for a list of models and maximum working pressures.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
Heated Package,
with Fusion™Gun
Nonheated Package,
with 2K Ultra-Lite™Gun
and Cold Spray
disposable mixer
TI6989b
TI6987b

Related Manuals
2311075E
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Isocyanate Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Foam Self-ignition . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Moisture Sensitivity of Isocyanates . . . . . . . . . . . . 7
Keep Components A and B Separate . . . . . . . . . . 7
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . . 7
Component Identification . . . . . . . . . . . . . . . . . . . . 8
Controls and Indicators . . . . . . . . . . . . . . . . . . . . 10
Motor/Pump Control Function Knob . . . . . . . . . 10
STATUS Indicator . . . . . . . . . . . . . . . . . . . . . . . 10
Motor Power Switch/Circuit Breaker . . . . . . . . . 10
Heater Power Switch/Circuit Breaker . . . . . . . . 11
Heater Temperature Controls . . . . . . . . . . . . . . 11
Fluid Temperature Sensors and Displays . . . . . 11
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Startup of Heated Units . . . . . . . . . . . . . . . . . . . . . 17
Heatup Guidelines . . . . . . . . . . . . . . . . . . . . . . 18
Heat Management Tips . . . . . . . . . . . . . . . . . . . 18
Heating Foam Resins with 245 fa Blowing Agents
19
Spraying/Dispensing . . . . . . . . . . . . . . . . . . . . . . . 20
Pause (Heated Units) . . . . . . . . . . . . . . . . . . . . . . . 21
Refilling Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 22
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . 28
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Before Beginning Repair . . . . . . . . . . . . . . . . . . 31
Removing Supply Tanks . . . . . . . . . . . . . . . . . . 31
Recirc/Spray Valves . . . . . . . . . . . . . . . . . . . . . . 32
Displacement Pump . . . . . . . . . . . . . . . . . . . . . 33
Control Module . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fluid Heaters (if supplied) . . . . . . . . . . . . . . . . . 38
Pressure Transducers . . . . . . . . . . . . . . . . . . . . 38
Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Cycle Counter Switch Replacement . . . . . . . . . 39
Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Suggested Spare Replacement Parts . . . . . . . . . 54
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 58
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 58
Related Manuals
The following manuals are for Reactor E-10 components and accessories. Some are supplied with your package,
depending on its configuration. Part No. 15G777 Compact Disk includes all Reactor E-10 manuals. Manuals are also
available at www.graco.com.
Displacement Pump
Part No. Description
311076 Instruction-Parts Manual (English)
Fluid Heater
Part No. Description
311210 Instruction-Parts Manual (English)
Fusion Air Purge Spray Gun
Part No. Description
309550 Instruction-Parts Manual (English)
Fusion Mechanical Purge Spray Gun
Part No. Description
309856 Instruction-Parts Manual (English)
2K Ultra-Lite Dispense Valve
Part No. Description
309000 Instruction-Parts Manual (English)
311230 2K Ultra-Lite Cold Spray and Joint Fill Kits
(English)

Models
311075E 3
Models
The model no., series letter, and serial no. are located on the back of the Reactor E-10. For faster assistance, please
have that information ready before calling Customer Service.
* See page 13 for detailed electrical requirements.
Package
Part No.,
Series
Bare
Proportioner
Part No.,
Series Volts
* Electrical
Connection
Package
Description Application
Maximum
Working
Pressure,
psi (MPa, bar)
249800,
A
249570, A 120 V 15 A cord
(motor)
15 A cord
(heaters)
Heated Reactor E-10,
insulated 5-hose bun-
dle, Fusion™Air
Purge spray gun
• Polyurethane
Foam
• Hot Polyureas
2000 (14, 140)
249802,
A
249571, A 240 V 10 A cord
(motor)
10 A cord
(heaters)
Heated Reactor E-10,
insulated 5-hose bun-
dle, Fusion™Air
Purge spray gun
• Polyurethane
Foam
• Hot Polyureas
2000 (14, 140)
249804,
A
249572, A 240 V 20 A cord
(motor and
heaters)
Heated Reactor E-10,
insulated 5-hose bun-
dle, Fusion™Air
Purge spray gun
• Polyurethane
Foam
• Hot Polyureas
2000 (14, 140)
249806,
A
249576, A 120 V 15 A cord
(motor only)
Nonheated Reactor
E-10, 3-hose bundle,
2K Ultra-Lite™gun
• Self-leveling
Joint Fillers
• Cold Polyureas
2000 (14, 140)
249808,
A
249577, A 240 V 10 A cord
(motor only)
Nonheated Reactor
E-10, 3-hose bundle,
2K Ultra-Lite™gun
• Self-leveling
Joint Fillers
• Cold Polyureas
2000 (14, 140)

Warnings
4311075E
Warnings
The following general warnings are for the setup, use, grounding, maintenance, and repair of this equipment. Addi-
tional, more specific warnings may be found throughout the body of this manual where applicable. Symbols appear-
ing in the body of the manual refer to these general warnings. When these symbols appear throughout the manual,
refer back to these pages for a description of the specific hazard.
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.
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.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.

Warnings
311075E 5
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 work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a 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 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.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco
replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your Graco 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.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• 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 equipment,
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

Overview
6311075E
Overview
The Reactor E-10 is a portable, electric-powered, 1:1
mix ratio proportioner, for use with a wide variety of
coatings, foams, sealants, and adhesives. Materials
must be self-leveling and pourable, and may be applied
with impingement mix spray guns, disposable mixer
guns, or flush-type mix manifolds.
Reactor E-10 is gravity-fed from 7 gal. (26.5 liter) supply
tanks mounted on the unit. The tanks are translucent to
allow monitoring of fluid level.
Severe duty, positive displacement reciprocating piston
pumps meter fluid flow to the gun for mixing and apply-
ing. When set to recirculation mode, Reactor E-10 will
circulate fluids back to the supply tanks.
Heated models include separate thermostatically con-
trolled heaters for each fluid, and an insulated hose bun-
dle with circulation return hoses. This allows the hoses
and gun to be preheated to the desired temperature
before spraying. Digital displays show the temperatures
of the two fluids.
An electronic processor controls the motor, monitors
fluid pressures, and alerts the operator if errors occur.
See STATUS Indicator, page 10, for further information.
Reactor E-10 has two recirculation speeds, slow and
fast, and an adjustable pressure output.
Slow Recirculation
• Slow circulation results in a higher temperature
transfer in the heater, so hoses and gun heat up
quicker.
• Good for touchup or low flow spraying, up to moder-
ate temperature.
• Not used to circulate full tanks up to temperature.
• Use with 245 fa blowing agent foams, to minimize
heat returned to tank and reduce frothing.
Fast Recirculation
• Use to support higher flow rates or higher tempera-
tures by preheating the tanks.
• Agitates fluid within tanks, to avoid heating only the
fluid at the top of the tank.
• Use for flushing.
Pressure Adjust
Automatically maintains selected pressure output for
dispensing or spraying.

Isocyanate Hazard
311075E 7
Isocyanate Hazard
Foam 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 felt washers in the pump wet-cups satu-
rated with Graco ISO pump oil, Part No. 217374.
The lubricant creates a barrier between the ISO and
the atmosphere.
• Use moisture-proof hoses specifically designed for
ISO, such as those supplied with your system (see
page 49).
• 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
22.
• Always lubricate threaded parts with Part No.
217374 ISO pump oil or grease when reassembling.
Keep Components A and
B Separate
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 23.
• 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.
Read material manufacturer’s warnings and material
MSDS to know the specific hazards of isocyanates.
Use equipment in a well-ventilated area. Wear respi-
rator, gloves, and protective clothing when using iso-
cyanates.
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.
CAUTION
To prevent cross-contamination of the equipment’s
wetted parts, never interchange component A (isocy-
anate) and component B (resin) parts.

Component Identification
8311075E
Component Identification
Key for FIG. 1
A Supply Tank A
B Supply Tank B
C Pump A
D Pump B
EHeaterA
FHeaterB
G Fluid Pressure Gauges
H Recirc/Spray and Overpressure Relief Valves
J Control Panel; see FIG. 3, page 10
K Electric Motor and Drive Housings
L Insulated Hose Bundle (includes circulation return hoses)
M Fusion Air Purge Spray Gun
N Desiccant Dryer (mounts on supply tank A)
P Recirculation Tubes
Q Air Line Inlet (quick-disconnect fitting)
R Outlet Hose Connections
S Return Hose Connections
T Fluid Temperature Sensors
U Hose Rack and Control Shield
V Fluid Inlet Ball Valves (1 on each side)
W Fluid Inlet Strainers (1 on each side)
XPowerCord
Y Lift Ring
Z Air Filter/Moisture Separator
FIG. 1: Component Identification, Heated Packages (Part No. 249804 Shown)
A
N
B
C
D
E
F
G
H
J
K
L
M
TI6987b
P
P
R
ST
T
U
V
W
X
Y
Q
Z

Component Identification
311075E 9
Key for FIG. 2
A Supply Tank A
B Supply Tank B
C Pump A
D Pump B
G Fluid Pressure Gauges
H Recirc/Spray and Overpressure Relief Valves
J Control Panel; see FIG. 3, page 10
K Electric Motor and Drive Housings
L Hose Bundle
M 2K Ultra-Lite Spray Gun, with disposable static mixer
N Desiccant Dryer (mounts on supply tank A)
P Recirculation Tubes
Q Air Line Inlet (quick-disconnect fitting)
R Outlet Hose Connections
U Hose Rack and Control Shield
V Fluid Inlet Ball Valves (1 on each side)
W Fluid Inlet Strainers (1 on each side)
XPowerCord
Y Lift Ring
Z Air Filter/Moisture Separator
FIG. 2: Component Identification, Nonheated Packages (Part No. 249808 Shown)
TI6989b
A
N
B
C
D
G
H
J
K
L
M
P
P
R
U
V
W
X
Y
Q
Z

Controls and Indicators
10 311075E
Controls and Indicators
Motor/Pump Control Function
Knob
Use knob (CF) to select desired function.
STATUS Indicator
• Indicator (ST) steady on: Motor Power switch is
turned on and control board is working.
• Indicator (ST) blinking: If error occurs, STATUS indi-
cator will blink 1 to 7 times to indicate status code,
pause, then repeat. See T
ABLE 1 for a brief descrip-
tion of status codes. For more detailed information
and corrective action, see page 26.
Motor Power Switch/Circuit
Breaker
Switch (MP) turns power on to control board and func-
tion knob. The switch includes a 20 A circuit breaker.
FIG. 3. Controls and Indicators (heated unit shown)
MP
CF
ST
HP
TD TD
TI7016a
Icon Setting Function
Stop/Park Stops motor and automati-
cally parks pumps.
Slow Recirc Slow recirculation speed.
Fast Recirc Fast recirculation speed.
Pressure
Adjust
Adjusts fluid pressure to
gun in spray mode.
Table 1: Status Codes
(see also the label on back of the control enclosure)
Code
No. Code Name
1 Pressure imbalance between A and B sides
2 Unable to maintain pressure setpoint
3 Pressure transducer A failure
4 Pressure transducer B failure
5 Excessive current draw
6 High motor temperature
7 No cycle counter switch input
The default is to shut down if a status code indica-
tion occurs. Codes 1 and 2 may be set to disable
automatic shutdown if desired; see page 26. The
other codes are not settable.

Controls and Indicators
311075E 11
Heater Power Switch/Circuit
Breaker
See FIG. 3. Switch (HP) turns power on to heater ther-
mostats. The switch includes a 20 A circuit breaker.
Present on heated units only.
Heater Temperature Controls
See FIG. 4. Control knobs (HC) set temperature of com-
ponent A and B heaters. Indicator lights (HL) turn on
when thermostats are heating, and off when heater
reaches setpoint. Present on heated units only.
Fluid Temperature Sensors and
Displays
See FIG. 3. Fluid temperature sensors (T) monitor actual
temperature of component A and B fluid going to spray
gun. Temperatures are then displayed (TD). Present on
heated units only.
Unit is shipped set to °F. To change to °C, see page 34.
FIG. 4. Heater Temperature Controls
HC
HC
HL
HL
TI6984a
E
F
T
T

Setup
12 311075E
Setup
Connect Reactor E-10 to the correct power source for
your model. See T
ABLE 2. Models with two power cords
must be connected to two separate, dedicated circuits.
See FIG. 5.
Some models include cord adapters (55, 56) for use out-
side North America. Connect the appropriate adapter to
the unit’s power cord before connecting to your power
source.
The equipment must be grounded. Grounding reduces
the risk of static and electric shock by providing an
escape wire for the electrical current due to static build
up or in the event of a short circuit.
1. Locate Reactor E-10
a. Locate Reactor E-10 on a level surface.
b. Do not expose Reactor E-10 to rain.
2. Electrical requirements
Improper wiring may cause electric shock or other
serious injury if work is not performed properly. Have
a qualified electrician perform any electrical work. Be
sure your installation complies with all National, State
and Local safety and fire codes.
3. Ground system
a. Reactor E-10: grounded through power
cord.
b. Generator (if used): follow your local
code. Start and stop generator with
power cord(s) disconnected.
c. Spray gun: grounded through the sup-
plied fluid hoses, connected to a prop-
erly grounded Reactor E-10. Do not
operate without at least one grounded
fluid hose.
d. Object being sprayed: follow your local
code.
e. Solvent pails used when flushing: follow
your local code. Use only metal pails,
which are conductive, placed on a
grounded surface. Do not place pail on
a nonconductive surface, such as paper,
plastic, 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.

Setup
311075E 13
Table 2: Electrical Requirements
Model Required Power Source Power Cord Connector
120 V, 1 phase, 50/60 Hz, two 15 ft
(4.5 m) power cords, Heated
Two separate, dedicated circuits
rated at minimum of 15 A each
240 V, 1 phase, 50/60 Hz, two 15 ft
(4.5 m) power cords, Heated
Two separate, dedicated circuits
rated at minimum of 10 A each
240 V, 1 phase, 50/60 Hz, one 15 ft
(4.5 m) power cord, Heated
Single dedicated circuit rated at
minimum of 16 A
120 V, 1 phase, 50/60 Hz, one 15 ft
(4.5 m) power cord, Nonheated
Single dedicated circuit rated at
minimum of 15 A
240 V, 1 phase, 50/60 Hz, one 15 ft
(4.5 m) power cord, Nonheated
Single dedicated circuit rated at
minimum of 8 A
Two NEMA 5-15T
Two IEC 320, with two
local adapters:
Euro CEE74 Adapter
Australia/China Adapter
One NEMA 6-20P
One NEMA 5-15T
One NEMA 6-20P
Table 3: Extension Cord Requirements
Model
Required Wire Size
Up to 50 ft (15 m) Up to 100 ft (30 m)
Nonheated and two cord heated models AWG 14 AWG 12
Single cord heated model AWG 12 AWG 10
Cords must be 3-conductor grounded, rated for your environment.
FIG. 5. Use Two Separate Circuits for Two Cord Models
1
Ensure no other high amp loads are connected
while running Reactor E-10.
To verify separate circuits, plug in Reactor E-10
or a worklight and cycle breakers on and off.
1
2
To avoid electric shock, always unplug both cords
before servicing Reactor E-10.
1
Heater Power
Motor Power TI7061a
2

Setup
14 311075E
4. Connect fluid hoses
Connect fluid supply hoses to outlet hose con-
nections (R, FIG. 6). Red hoses for component A
(ISO), blue for component B (RES). Fittings are
sized to prevent connection errors. Connect
other end of hoses to A and B inputs of gun.
Heated units only: connect recirculation hoses
from gun recirculation ports to connections (S).
5. Connect gun air hose
Connect gun air hose to the gun air input and to
the air filter outlet (Z). If you are using more than
one hose bundle, join the air hoses with the nip-
ple (305) provided with the hose bundle.
On heated units with Fusion guns, connect the
supplied ball valve and quick-disconnect coupler
to the gun air hose, then connect the coupler to
the gun air fitting.
6. Connect main air supply
Connect the main air supply to the quick discon-
nect fitting (Q) on the unit. Air supply hose must
be at least 5/16 in. (8 mm) ID up to 50 ft (15 m)
or 3/8 in. (10 mm) ID up to 100 ft (30 m).
Air Filter/Moisture Separator (Z) is equipped with
an automatic moisture drain.
7. Flush before first use
The Reactor E-10 is tested with a plasticizer oil
at the factory. Flush out the oil with a compatible
solvent before spraying. See page 24.
FIG. 6. Hose Connections
TI6988b
TI6990b
Heated Units
Nonheated Units
R
S
R
Q
Z
Z
Q
AIR
AIR
B (RES)
A (ISO)
A (ISO)
B (RES)

Setup
311075E 15
8. Fill wet-cups
Keep the felt washers in the pump wet-cups sat-
urated with Graco ISO pump oil, Part No.
217374. The lubricant creates a barrier between
the ISO and the atmosphere.
9. Fill fluid tanks
CAUTION
To prevent cross-contamination of fluids and equip-
ment parts, never interchange component A (isocy-
anate) and component B (resin) parts or containers.
Have at least two 5 gal. (19 liter) pails to transfer fluid
from drums to supply tanks. Label one pail “A” and the
other “B”, using the red and blue labels provided.
Always doublecheck which material you have before
pouring it in the supply tanks. Pouring is easier if pails
are not filled to the top.
Open only one supply tank at a time, to avoid splash-
ing material from one tank into the other when filling.
Fill wet-cups through slots
in plate, or loosen screws
and swing plate aside.
TI6985a
Pump rod and connecting rod move during opera-
tion. Moving parts can cause serious injury such as
pinching or amputation. Keep hands and fingers
away from wet-cup during operation. Shut off Motor
Power before filling wet-cup.
Using a drill and mixing blade, mix filled or sepa-
rated materials in the pail before adding to the
tanks. Material left in the tanks overnight may need
to be remixed in the tanks.
a. Lift hose rack. Remove tank A cover and
pour ISO into tank A (red side, with des-
iccant filter in cover). Replace cover .
Desiccant filter is blue when fresh, and turns pink
when saturated. Be sure shipping plugs are
removed from openings on desiccant filter.
b. Remove tank B cover and pour resin
into tank B (blue side). Replace cover
.
. Add thin coating of grease lubricant to tank o-ring if lid is difficult
to assemble to tank.
1
TI7017a
1
TI7018a
1

Setup
16 311075E
10. Purge air and flush fluid from
lines
a. Remove both recirculation tubes (P)
from the tanks and secure each one in a
dedicated waste container.
b. Set function knob to Stop/Park .
c. Plug in power cord(s). See TABLE 2,
page 13.
d. Open both pump fluid inlet valves (V,
shown in open position).
e. Turn on Motor Power.
TI7022a
P
V
TI7019a
f. Set Recirc/Spray valves to Recirc.
g. Set function knob to Slow Recirc or
Fast Recirc .
h. When clean fluids exit both recirculation
tubes (P), set function knob to
Stop/Park .
i. Replace recirculation tubes in supply
tanks.
j. On nonheated units, purge the hoses
through the gun without a static mixer
installed.
For heated units, continue with Startup of Heated
Units, page 17.
Nonheated units are ready to spray/dispense. Go to
Spraying/Dispensing, page 20.
OR

Startup of Heated Units
311075E 17
Startup of Heated Units
Some models heat the fluid, which can cause equip-
ment surfaces to become very hot. To avoid severe
burns:
• Do not operate Reactor E-10 without all covers
and shrouds in place.
• Do not touch hot fluid or equipment.
• Allow equipment to cool completely before touch-
ing it.
• Wear gloves if fluid temperature exceeds 110°F
(43°C).
1. Perform Setup, pages 12-16.
2. Set function knob to Slow Recirc or Fast
Recirc . See Heatup Guidelines, page 18,
then continue with steps 3-6.
OR
3. Turn on Heater Power.
4. Temporarily set heater control knobs to maxi-
mum setting.
5. Circulate through heaters until temperature
readouts display desired temperature. See
TABLE 4 below.
6. Adjust heater control knobs as necessary for a
stable spray temperature.
Table 4: Heatup Time Guidelines for starting a cold machine with 5 gal. (19 l) per side (see Notes below)
Fluid Spray Target
Temperature
35 ft (10.7 m) Hose
(1 bundle)
70 ft (21 m) Hose
(2 bundles)
125°F (52°C) 20 minutes 25 minutes
150°F (65°C) 40 minutes 50 minutes
Use fast circulation until temperature is within 20°F
(11°C) of target, then use slow circulation to reach
final temperature.
Different fluids will absorb heat at different rates.
When refilling a warm machine, heatup times will
be less.

Startup of Heated Units
18 311075E
Heatup Guidelines
Slow Recirculation
• Slow Recirc results in a higher temperature transfer
in the heater, so hoses and gun heat up quicker.
• Good for touchup or low flow spraying, up to moder-
ate temperature.
• Not used to circulate full tanks up to temperature.
• Use with 245 fa blowing agent foams, to minimize
heat returned to tank and reduce frothing.
Fast Recirculation
• Fast Recirc keeps heaters on fulltime to bring fluid
tanks up to temperature. The higher your usage
rate, the more heat needed in the tanks before
spraying.
•For normal usage rates: Use Fast Recirc to get
tanks to approximately 50°F (28°C) below
desired spray temperature, then use Slow
Recirc to raise hose and gun to desired temper-
ature.
•For higher flow rates or continuous spraying:
Use Fast Recirc to bring temperature of tanks to
approximately 20°F (11°C) below desired spray
temperature, then use Slow Recirc to raise hose
and gun to desired temperature.
•Volume in tanks: Use only what you need. For
example, 2.5 gal. (10 l) in each tank will heat up
almost twice as fast as 5 gal. (20 l).
• Mixes fluid within tanks, to avoid heating only the
fluid at the top of the tank.
• Use for flushing.
Heat Management Tips
• Heaters perform better with lower flow rates or
smaller mix modules.
• Triggering the gun for short periods helps maintain
efficient heat transfer, keeping material at the
desired temperature. Triggering the gun for a long
period does not allow enough heating time, and cold
material will enter the hose.
• If temperature displays fall below acceptable limits,
set function knob to Slow Recirc and circulate
again to bring temperatures back up.
• Each 35 ft (10.7 m) hose bundle adds about 5 min-
utes to heatup time, with most materials.
Water-based materials take longer to heat up. Maxi-
mum recommended hose length is 105 ft (32 m).
• Use Fast Recirc until tanks are warm to the
touch, then use Slow Recirc until displays read
desired temperature.
• For a quicker start, do initial heatup circulation with
the tanks 1/4 to 1/3 filled, then add more material.
The fluids must be circulated from the pumps
through the heaters, hoses, and back to the tanks
to ensure warm fluids are supplied to the gun.

Startup of Heated Units
311075E 19
Heating 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.
Never fill the 7 gal. (26 l) supply tanks beyond the 5 gal.
(19 l) line on the tanks, to leave room for some frothing.
At High Ambient Temperature (above
75°F/24°C)
• Pour resins slowly to avoid frothing.
• Only use Slow Recirc , to avoid heating and agi-
tating the tank. If temperature doesn’t keep up, set
function knob to Stop/Park , then set to Slow
Recirc again.
• When you stop to refill the tanks, avoid boiling off
fluid in the heaters by following these steps:
a. Shut off Heater Power.
b. Leave hoses under pressure.
c. Fill tanks, page 15.
d. Set Recirc/Spray valves to Recirc.
e. Set function knob to Slow Recirc .
f. Turn on Heater Power.
At Cool Ambient Temperature (below
75°F/24°C)
• Use Fast Recirc to heat tanks to 75-90°F.
(24-32°C), then use Slow Recirc to raise hose
and gun to desired spray temperature.
• If the top of the resin in tank starts frothing, do not
use Fast Recirc any more.

Spraying/Dispensing
20 311075E
Spraying/Dispensing
Air is supplied to spray gun with gun piston safety
lock or trigger safety lock engaged and gun fluid
manifold valves A and B closed (if present).
1. Set function knob to Stop/Park .
2. Set Recirc/Spray valves to Spray.
3. Turn function knob to Pressure Adjust .
Keep turning to the right until fluid pressure
gauges show desired pressure.
TI7069a
Fusion Gun 2K Ultra-Lite Gun
4. Check fluid pressure gauges to ensure proper
pressure balance. If imbalanced, reduce pres-
sure of higher component by slightly turning
Recirc/Spray valve for that component toward
Recirc, until gauges show balanced pressures.
The pressure imbalance alarm (Status Code 1)
is inactive for 10 sec after entering spray pres-
sure mode, to allow time to balance pressures.
Watch gauges for 10 sec to be sure pressure holds
on both sides and pumps are not moving.
5. Open gun fluid manifold valves A and B
(impingement mix guns only).
On impingement guns, never open fluid manifold
valves or trigger gun if pressures are imbalanced.
I
n t
hi
s examp
l
e,
B
s
id
e
pressure is higher, so
use the B side valve to
balance pressures.