Graco Reactor H-40 Elite Instruction Manual

312062E rev.k
Operation
Hydraulic, Heated, Plural Component Proportioner
For spraying polyurethane foam and polyurea coatings.
Not for use in explosive atmospheres.
U.S. Patent Pending
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.
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Model H-40 Shown
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2
Contents
Models ............................3
Supplied Manuals ...................5
Related Manuals ....................6
Warnings ..........................7
Isocyanate Hazard ..................10
Material Self-ignition ................10
Moisture Sensitivity of Isocyanates ....10
Keep Components A and B Separate . . 11
Foam Resins with
245 fa Blowing Agents ............11
Changing Materials .................11
Typical Installation, with circulation . . . 12
Typical Installation, without circulation 13
Component Identification ............14
Temperature Controls and Indicators . . 16
Main Power Switch ................16
Red Stop Button ..................16
Actual Temperature Key/LED ........16
Target Temperature Key/LED .......17
Temperature Scale Keys/LEDs ......17
Heater Zone On/Off Keys/LEDs ......17
Temperature Arrow Keys ...........17
Temperature Displays .............17
Circuit Breakers ..................18
Motor Controls and Indicators ........19
Motor ON/OFF Key/LED ...........19
PARK Key/LED ..................19
PSI/BAR Keys/LEDs ..............19
Pressure Key/LED ................19
Cycle Count Key/LED ..............20
Hydraulic Pressure Control Knob .....20
Motor Control Arrow Keys ..........20
Spray Adjustments .................20
Setup .............................21
Startup ...........................27
Spraying ..........................31
Standby ...........................33
Shutdown .........................34
Pressure Relief Procedure ...........35
Fluid Circulation ....................36
Circulation Through Reactor .........36
Circulation Through Gun Manifold ....37
Diagnostic Codes ...................38
Temperature Control Diagnostic Codes 38
Motor Control Diagnostic Codes ......39
Maintenance .......................40
Fluid Inlet Strainer Screen ..........41
Pump Lubrication System ...........42
Flushing ..........................43
Dimensions ........................44
Technical Data .....................45
Performance Charts .................46
Graco Standard Warranty ............48
Graco Information ..................48

Models
3
Models
H-25 SERIES
H-40 SERIES
H-50 SERIES
Part, Series
Full Load
Peak Amps*
Per Phase
Voltage
(phase)
System
Watts†
Primary
Heater
Watts
Max Flow
Rate◆
lb/min
(kg/min)
Approximate
Output per
Cycle (A+B)
gal. (liter)
Hydraulic
Pressure
Ratio
Maximum Fluid
Working
Pressure
psi (MPa, bar)
255400, E 69 230V (1) 15,960 8,000 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138)
255401, E 46 230V (3) 15,960 8,000 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138)
255402, E 35 400V (3) 15,960 8,000 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138)
255406, E 100 230V (1) 23,260 15,300 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138)
255407, E 59 230V (3) 23,260 15,300 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138)
255408, E 35 400V (3) 23,260 15,300 22 (10) 0.063 (0.24) 1.91:1 2000 (13.8, 138)
Part, Series
Full Load
Peak Amps*
Per Phase
Voltage
(phase)
System
Watts†
Primary
Heater
Watts
Max Flow
Rate◆
lb/min
(kg/min)
Approximate
Output per
Cycle (A+B)
gal. (liter)
Hydraulic
Pressure
Ratio
Maximum Fluid
Working
Pressure
psi (MPa, bar)
★253400, E 100 230V (1) 23,100 12,000 45 (20) 0.063 (0.24) 1.91:1 2000 (13.8, 138)
253401, E 71 230V (3) 26,600 15,300 45 (20) 0.063 (0.24) 1.91:1 2000 (13.8, 138)
253402, E 41 400V (3) 26,600 15,300 45 (20) 0.063 (0.24) 1.91:1 2000 (13.8, 138)
253407, E 95 230V (3) 31,700 20,400 45 (20) 0.063 (0.24) 1.91:1 2000 (13.8, 138)
253408, E 52 400V (3) 31,700 20,400 45 (20) 0.063 (0.24) 1.91:1 2000 (13.8, 138)
Part, Series
Full Load
Peak Amps*
Per Phase
Voltage
(phase)
System
Watts†
Primary
Heater
Watts
Max Flow
Rate◆
lb/min
(kg/min)
Approximate
Output per
Cycle (A+B)
gal. (liter)
Hydraulic
Pressure
Ratio
Maximum Fluid
Working
Pressure
psi (MPa, bar)
★253725, E 100 230V (1) 23,100 12,000 52 (24) 0.073 (0.28) 1.64:1 1700 (11.7, 117)
253726, E 71 230V (3) 26,600 15,300 52 (24) 0.073 (0.28) 1.64:1 2000 (13.8, 138)
253727, E 41 400V (3) 26,600 15,300 52 (24) 0.073 (0.28) 1.64:1 2000 (13.8, 138)
256505, E 95 230V (3) 31,700 20,400 52 (24) 0.073 (0.28) 1.64:1 2000 (13.8, 138)
256506, E 52 400V (3) 31,700 20,400 52 (24) 0.073 (0.28) 1.64:1 2000 (13.8, 138)

Models
4
H-XP2 SERIES
H-XP3 SERIES
* Full load amps with all devices operating at maximum capabilities. Fuse requirements at vari-
ous flow rates and mix chamber sizes may be less.
†Total system watts, based on maximum hose length for each unit:
• Parts 255400 through 255408, 310 ft (94.6 m) maximum heated hose length, including whip
hose.
• Parts 253400 through 253408, 253725 through 253727, 256505, and 256506, 410 ft (125 m)
maximum heated hose length, including whip hose.
◆Maximum flow rate given for 60 Hz operation. For 50 Hz operation, maximum flow rate is 5/6 of
60 Hz maximum flow.
★CE approval does not apply.
Part, Series
Full Load
Peak Amps*
Per Phase
Voltage
(phase)
System
Watts†
Primary
Heater
Watts
Max Flow
Rate◆
gpm (lpm)
Approximate
Output per
Cycle (A+B)
gal. (liter)
Hydraulic
Pressure
Ratio
Maximum Fluid
Working
Pressure
psi (MPa, bar)
255403, E 100 230V (1) 23,260 15,300 1.5 (5.7) 0.042 (0.16) 2.79:1 3500 (24.1, 241)
255404, E 59 230V (3) 23,260 15,300 1.5 (5.7) 0.042 (0.16) 2.79:1 3500 (24.1, 241)
255405, E 35 400V (3) 23,260 15,300 1.5 (5.7) 0.042 (0.16) 2.79:1 3500 (24.1, 241)
Part, Series
Full Load
Peak Amps*
Per Phase
Voltage
(phase)
System
Watts†
Primary
Heater
Watts
Max Flow
Rate◆
gpm (lpm)
Approximate
Output per
Cycle (A+B)
gal. (liter)
Hydraulic
Pressure
Ratio
Maximum Fluid
Working
Pressure
psi (MPa, bar)
★253403, E 100 230V (1) 23,100 12,000 2.8 (10.6) 0.042 (0.16) 2.79:1 3500 (24.1, 241)
253404, E 95 230V (3) 31,700 20,400 2.8 (10.6) 0.042 (0.16) 2.79:1 3500 (24.1, 241)
253405, E 52 400V (3) 31,700 20,400 2.8 (10.6) 0.042 (0.16) 2.79:1 3500 (24.1, 241)

Supplied Manuals
5
Supplied Manuals
The following manuals are shipped with the
Reactor™Proportioner. Refer to these manu-
als for detailed equipment information.
Order Part 15M334 for a compact disk of
Reactor manuals translated in several lan-
guages.
Manuals are also available at www.graco.com.
Translations
The Reactor Operation manual is available in
the following languages. See the following
chart for specific languages and corresponding
part numbers.
Reactor Hydraulic Proportioner
Part Description
312063 Reactor Hydraulic Proportioner,
Repair-Parts Manual (English)
Reactor Electrical Diagrams
Part Description
312064 Reactor Hydraulic Proportioner,
Electrical Diagrams (English)
Proportioning Pump
Part Description
312068 Proportioning Pump Repair-Parts
Manual (English)
Part Language
312062 English
312419 Chinese
312420 Dutch
312421 French
312422 German
312423 Italian
312424 Japanese
312425 Korean
312426 Russian
312427 Spanish

Related Manuals
6
Related Manuals
The following manuals are for accessories
used with the Reactor™.
Order Part 15M334 for a compact disk of
Reactor manuals translated in several lan-
guages.
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)
Circulation Kit
Part Description
309818 Instruction-Parts Manual
(English)
Circulation Valve Kit
Part Description
312070 Instruction-Parts Manual
(English)
Data Reporting Kit
Part Description
309867 Instruction-Parts Manual
(English)
Rupture Disk Assembly Kit
Part Description
309969 Instruction-Parts Manual
(English)
Proportioning Pump Repair Kits
Part Description
312071 Seal Kits Instruction-Parts
Manual (English)

Warnings
7
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equip-
ment. The exclamation 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
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 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.
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.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before
cleaning, checking, or servicing equipment.

Warnings
8
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 sol-
vents 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.
WARNING

Warnings
9
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• This equipment is for professional use only.
• Do not leave the work are while the equipment is energized or under pressure. Turn off all
equipment and follow the Pressure Relief Procedure in this manual when the equipment
is not in use.
• 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 com-
plete information about your material, request MSDS forms from distributor or retailer.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genu-
ine manufacturer’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 sur-
faces.
• 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
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 com-
pletely.
WARNING

Isocyanate Hazard
10
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 perfor-
mance and the life of all wetted parts.
To prevent exposing ISO to moisture:
• Always use a sealed container with a desic-
cant dryer in the vent, or a nitrogen atmo-
sphere. Never store ISO in an open
container.
• Keep the ISO lube pump reservoir filled
with Graco Throat Seal Liquid (TSL), Part
206995. 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.
• Never use reclaimed solvents, which may
contain moisture. Always keep solvent con-
tainers closed when not in use.
• Never use solvent on one side if it has been
contaminated from the other side.
• Always park pumps when you shutdown,
see page 34.
• Always lubricate threaded parts with Part
217374 ISO pump oil or grease when reas-
sembling.
Spraying 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 provid-
ing sufficient ventilation in the work area. If
sufficient ventilation is not available, a sup-
plied-air respirator is required for everyone in
the work area.
To prevent contact with isocyanates, appro-
priate personal protective equipment, includ-
ing 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 manufac-
turer’s warnings and material MSDS.
The amount of film formation and rate of
crystallization varies depending on the
blend of ISO, the humidity, and the tem-
perature.