Graco Reactor E-10 Operation manual

313221A
Instructions - Parts List
For spraying or dispensing 4:1 mix ratio materials, including
epoxies, polyurethane foam, and polyurea coatings.
Not for use in explosive atmospheres.
See page 4 for a list of models and maximum working pressures.
Important Safety Instructions
Read all warnings and instructions in this manual. Save these instructions.

2313221A
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . 3
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Keep Components A and B Separate . . . 8
Component Identification . . . . . . . . . . . . . 9
Controls and Indicators . . . . . . . . . . . . . 10
Motor/Pump Control Function Knob . . . 10
STATUS Indicator . . . . . . . . . . . . . . . . . 10
Motor Power Switch/Circuit Breaker . . . 11
Heater Power Switch/Circuit Breaker . . 11
Heater Temperature Controls . . . . . . . . 11
Fluid Temperature Sensors and Displays .
11
Air Compressor Power Switch/Circuit
Breaker . . . . . . . . . . . . . . . . . . . . . . 12
Air Compressor Controls . . . . . . . . . . . 12
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Startup of Heated Units . . . . . . . . . . . . . . 19
Spraying/Dispensing . . . . . . . . . . . . . . . . 20
Pause (Heated Units) . . . . . . . . . . . . . . . . 21
Pressure Relief Procedure . . . . . . . . . . . 22
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 22
Maintenance . . . . . . . . . . . . . . . . . . . . . . . 23
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . .24
Troubleshooting . . . . . . . . . . . . . . . . . . . .26
Status Codes . . . . . . . . . . . . . . . . . . . .26
Troubleshooting Chart . . . . . . . . . . . . .29
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Before Beginning Repair . . . . . . . . . . . .35
Recirc/Spray Valves . . . . . . . . . . . . . . .36
Displacement Pump . . . . . . . . . . . . . . .37
Control Module . . . . . . . . . . . . . . . . . . .39
Fluid Heaters . . . . . . . . . . . . . . . . . . . .44
Pressure Transducers . . . . . . . . . . . . . .44
Drive Housing . . . . . . . . . . . . . . . . . . . .45
Cycle Counter Switch Replacement . . .46
Electric Motor . . . . . . . . . . . . . . . . . . . .47
Compressor . . . . . . . . . . . . . . . . . . . . .48
Motor Brushes . . . . . . . . . . . . . . . . . . .49
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Suggested Spare Replacement Parts . .56
Accessories . . . . . . . . . . . . . . . . . . . . . . .56
Dimensions . . . . . . . . . . . . . . . . . . . . . . . .58
Technical Data . . . . . . . . . . . . . . . . . . . . .59
Graco Standard Warranty . . . . . . . . . . . .60
Graco Information . . . . . . . . . . . . . . . . . .60

Related Manuals
313221A 3
Related Manuals
The following manuals are for Reactor E-10 - 4:1components and accessories. Some are sup-
plied with your package, depending on its configuration. Manuals are available at
www.graco.com.
Fluid Heater
Part
No. Description
311210 Instruction-Parts Manual (English)
Fusion Air Purge Plural Component Gun
Part
No. Description
309550 Instruction-Parts Manual (English)
Displacement Pump - White Material
Part
No. Description
311076 Instruction-Parts Manual (English)
Static Mixer Kit
Part
No. Description
313122 Instruction-Parts Manual (English)

Models
4313221A
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 14 for detailed electrical requirements.
Reactor E10
4:1 Volts * Electrical Connection
Maximum
Working
Pressure,
psi
(MPa, bar)
256765 120
V
15 A cord
(motor)
15 A cord
(heaters)
15 A cord
(compressor)
2000
(14, 140)

Warnings
313221A 5
Warnings
The following general warnings are for the setup, use, grounding, maintenance, and repair of this
equipment. Additional, more specific warnings may be found throughout the body of this manual
where applicable. Symbols appearing 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, includ-
ing 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
6313221A
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 hydrocar-
bon 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.
• This equipment is for professional use only.
• Do not leave the work area while equipment is energized or under pressure. Turn
off all equipment and follow the Pressure Relief Procedure in this manual when
equipment is not in use.
• Do not exceed the maximum working pressure or temperature rating of the low-
est 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 dis-
tributor 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 infor-
mation.
• 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.
WARNING

Warnings
313221A 7
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. Dis-
connect 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 equip-
ment/fluid has cooled completely.
WARNING

Overview
8313221A
Overview
The Reactor E-10 is a portable, electric-pow-
ered, 4:1 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 impinge-
ment mix spray guns, disposable mixer guns,
or flush-type mix manifolds.
Reactor E-10 is siphon-fed from 5 gallon pails
that can be mounted on the unit.
Severe duty, positive displacement reciprocat-
ing piston pumps meter fluid flow to the gun for
mixing and applying. When set to recirculation
mode, Reactor E-10 will circulate fluids back to
the 5 gallon pails.
The Reactor E-10 includes separate thermo-
statically controlled heaters for each fluid. Digi-
tal displays show the temperatures of the two
fluids.
An electronic processor controls the motor,
monitors fluid pressures, and alerts the opera-
tor if errors occur. See STATUS Indicator,
page 10, for further information.
An air compressor provides and regulates air
pressure for the spray gun.
Reactor E-10 has two recirculation speeds,
slow and fast, and an adjustable pressure out-
put.
Slow Recirculation
• Slow circulation results in a higher temper-
ature transfer in the heater, so hoses and
gun heat up quicker.
• Good for touchup or low flow spraying, up
to moderate temperature.
• Not used to circulate full tanks up to tem-
perature.
Fast Recirculation
• Use to support higher flow rates or higher
temperatures 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 out-
put for dispensing or spraying.
Keep Components A
and B Separate
CAUTION
To prevent cross-contamination of the equip-
ment’s wetted parts, never interchange com-
ponent A (white fluid) and component B (red
fluid) parts.

Component Identification
313221A 9
Component Identification
Key for FIG. 1
A Pump A
B Pump B
C Heater A
D Heater B
E Compressor
F Crossbar
G Pail Mounting Bracket
H Fluid Pressure Gauges
J Recirc/Spray and Overpressure Relief Valves
K Control Panel; see FIG. 2, page 10
L Electric Motor and Drive Housings
M Suction Tubes
N Recirculation Tubes
P Air Line outlet
R Outlet Hose Connections
S Recirculation Tube Connections
T Fluid Temperature Sensors
U Air Filter/Moisture Separator
FIG. 1: Component Identification
C
N
D
K
L
E
T
F
M
N
M
U
P
A
B
G
J
H
H
S
S
R

Controls and Indicators
10 313221A
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, STA-
TUS indicator will blink 1 to 7 times to indi-
cate status code, pause, then repeat. See
TABLE 1 for a brief description of status
codes. For more detailed information and
corrective action, see page 26.
FIG. 2. Controls and Indicators (heated unit shown)
MP
CF
ST
HP
TD TD
TI7016a
Icon Setting Function
Stop/Park Stops motor and auto-
matically 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 indication occurs. Codes 1 and 2
may be set to disable automatic shut-
down if desired; see page 27. The other
codes are not settable.

Controls and Indicators
313221A 11
Motor Power Switch/Circuit
Breaker
Switch (MP) turns power on to control board
and function knob. The switch includes a 20 A
circuit breaker.
Heater Power Switch/Circuit
Breaker
See FIG. 2. Switch (HP) turns power on to
heater thermostats. The switch includes a 20 A
circuit breaker.
Heater Temperature Controls
See FIG. 3. Control knobs (HC) set tempera-
ture of component A and B heaters. Indicator
lights (HL) turn on when thermostats are heat-
ing, and off when heater reaches setpoint.
Fluid Temperature Sensors
and Displays
See FIG. 2. Fluid temperature sensors (T)
monitor actual temperature of component A
and B fluid going to spray gun. Temperatures
are then displayed (TD).
Unit is shipped set to °F. To change to °C, see
page 39.
FIG. 3. Heater Temperature Controls
HC
HC
HL
HL
C
D
T
T

Controls and Indicators
12 313221A
Air Compressor Power
Switch/Circuit Breaker
Switch (CP) turns power on to compressor and
regulator. The switch includes a 20 A circuit
breaker.
Air Compressor Controls
Pressure Gauge (PG) indicates set air pres-
sure by regulator.
Regulator (AR) sets desired air pressure.
FIG. 4
AR PG CP

Setup
313221A 13
Setup
Connect Reactor E-10 to the correct power
source for your model. See TABLE 2. Models
with two power cords must be connected to
two separate, dedicated circuits. See FIG. 5.
The equipment must be grounded. Grounding
reduces the risk of static and electric shock by
providing an escape wire for the electrical cur-
rent 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 gener-
ator with power cord(s) discon-
nected.
c. Spray gun: grounded through the
supplied fluid hoses, connected
to a properly 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 conduc-
tive, placed on a grounded sur-
face. Do not place pail on a
nonconductive surface, such as
paper, plastic, or cardboard,
which interrupts grounding conti-
nuity.
f. To maintain grounding continuity
when flushing or relieving pres-
sure, hold a metal part of spray
gun firmly to the side of a
grounded metal pail, then trigger
gun.

Setup
14 313221A
Table 2: Electrical Requirements
Model Required Power Source Power Cord Connector
120 V, 1 phase, 50/60 Hz,
three 15 ft (4.5 m) power cords,
Heated
Three separate, dedicated
circuits rated at minimum of
15 A each
Three NEMA 5-15
T
Table 3: Extension Cord Requirements
Model
Required Wire Size
Up to 50 ft (15
m) Up to 100 ft (30 m)
Two cord heated models AWG 14 AWG 12
Cords must be 3-conductor grounded, rated for your
environment.
FIG. 5. Use Three Separate Circuits
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 all cords
before servicing Reactor E-10.
Heater Power
Motor Power TI12383a
2
Compressor Power

Setup
313221A 15
4. Connect fluid hoses
Connect fluid supply hoses to outlet
hose connections (R, FIG. 6). Fittings
are sized to prevent connection errors.
Connect other end of hoses to A and B
inputs of gun.
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 nipple (305)
provided with the hose bundle.
On heated units with Fusion guns, con-
nect the supplied ball valve and
quick-disconnect coupler to the gun air
hose, then connect the coupler to the
gun air fitting.
6. Turn on air compressor
Turn on air compressor power. Set regu-
lator to desired output pressure as indi-
cated on the gauge.
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 plasti-
cizer oil at the factory. Flush out the oil
with a compatible solvent before spray-
ing. See page 24.
FIG. 6. Hose Connections
R
Z

Setup
16 313221A
8. Fill wet-cups
Keep the felt washers in the pump
wet-cups saturated with Owens Corning
plasticizer; see Owens Corning Distribu-
tor. The lubricant creates a barrier
between the red fluid and the atmo-
sphere.
9. Install suction tube
CAUTION
To prevent cross-contamination of fluids and
equipment parts, never interchange compo-
nent A and component B parts or containers.
Label one pail “A” and the other “B”, using
the labels provided. Always doublecheck
which material you have before placing suc-
tion tubes in pails.
Fill wet-cups through slots
in plate, or loosen screws
and swing plate aside.
TI6985a
Pump rod and connecting rod move during
operation. Moving parts can cause serious
injury such as pinching or amputation. Keep
hands and fingers away from wet-cup dur-
ing operation. Shut off Motor Power
before filling wet-cup.
Using a drill and mixing blade, mix filled or
separated materials in the pail. Material
left in the tanks overnight may need to be
remixed.
a. Open red and white fluid pails
and position in front of suction
tubes.
b. Stand behind unit and hold cross-
bar. Lean unit backwards until the
suction tubes are above the sup-
ply pails.
c. Place suction tubes in pails.
A
B
A
B

Setup
313221A 17
10. Mount pails
a. Insert pail handles on mounting
bracket (G).
b. Install one end of strap (SR)
through eye bolt (EB) on A side of
unit. Use second strap for B side.
c. Latch straps (SR) together in
front of pails.
P
A
B
G
EB
SR
SR
SR
AB
11. Purge air and flush fluid from
lines
a. Remove both recirculation tubes
(N) from the pails and secure
each one in a dedicated waste
container (W).
b. Set function knob to Stop/Park
.
c. Plug in power cord(s). See TABLE
2, page 14.
d. Turn on Motor Power.
N
A
B
W

Setup
18 313221A
e. Set Recirc/Spray valves to
Recirc.
f. Set function knob to Slow Recirc
or Fast Recirc .
g. When clean fluids exit both recir-
culation tubes (P), set function
knob to Stop/Park .
h. Replace recirculation tubes in
pails.
i. On nonheated units, purge the
hoses through the gun without a
static mixer installed.
For heated units, continue with Startup of
Heated Units, page 19.
Nonheated units are ready to spray/dis-
pense. Go to Spraying/Dispensing, page
20.
O

Startup of Heated Units
313221A 19
Startup of Heated Units
Equipment surfaces can 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 touching it.
• Wear gloves if fluid temperature exceeds
110°F (43°C).
1. Perform Setup, pages 13-18.
2. Set function knob to Slow Recirc or
Fast Recirc .
3. Turn on Heater Power.
4. Temporarily set heater control knobs to
maximum setting.
OR
5. Circulate through heaters until tempera-
ture readouts display desired tempera-
ture.
6. Adjust heater control knobs as neces-
sary for a stable spray temperature.

Spraying/Dispensing
20 313221A
Spraying/Dispensing
Air is supplied to spray gun with gun piston
safety lock 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 pres-
sure.
Fusion
4. Check fluid pressure gauges to ensure
proper pressure balance. If imbalanced,
reduce pressure 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 pressure mode, to allow time to
balance pressures.
Watch gauges for 10 sec to be sure pres-
sure 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.