Graco Reactor 2 E-XP2 Operation
  1. Manuals
  2. Brands
  3. Graco Manuals
  4. Paint Sprayer
  5. Reactor 2 E-XP2
  6. Operation
Graco Reactor 2 E-XP2 Operation

Graco Reactor 2 E-XP2 Operation

Proportioning systems
Hide thumbs Also See for Reactor 2 E-XP2:
Table of Contents

Advertisement

Quick Links

Operation
Reactor 2 E-30 and E-XP2
Proportioning Systems
Electric, Heated, Plural Component Proportioner for spraying polyurethane foam and polyurea coatings.
Not for outdoor use. For professional use only. Not approved for use in explosive atmospheres or
hazardous locations.
Important Safety Instructions
Read all warnings and instructions in this manual. Save these
instructions.
PROVEN QUALITY. LEADING TECHNOLOGY.
333023D
EN

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Reactor 2 E-XP2 and is the answer not in the manual?

Questions and answers

Related Manuals for Graco Reactor 2 E-XP2

Summary of Contents for Graco Reactor 2 E-XP2

  • Page 1 Operation Reactor 2 E-30 and E-XP2 Proportioning Systems 333023D Electric, Heated, Plural Component Proportioner for spraying polyurethane foam and polyurea coatings. Not for outdoor use. For professional use only. Not approved for use in explosive atmospheres or hazardous locations. Important Safety Instructions Read all warnings and instructions in this manual.

  • Page 2: Table Of Contents

    (TSL) ..........29 System Configuration Settings ...... 60 Install Fluid Temperature Sensor ....29 Custom Language File ......... 61 Register and Activate the Graco InSite ... 29 Upload Procedure ........61 Advanced Display Module (ADM) Performance Charts..........62 Operation..........30 Technical Specifications........

  • Page 3: Warnings

    Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings.
  • Page 4 Warnings WARNING SKIN INJECTION HAZARD High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment. • Do not spray without tip guard and trigger guard installed. •...
  • Page 5 Warnings WARNING PRESSURIZED ALUMINUM PARTS HAZARD Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage. • Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents.
  • Page 6 Warnings WARNING BURN HAZARD Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe burns: • Do not touch hot fluid or equipment. 333023D...

  • Page 7: Important Isocyanate Information

    Important Isocyanate Information Important Isocyanate Information Isocyanates (ISO) are catalysts used in two component materials. Isocyanate Conditions Keep Components A and B Separate Spraying or dispensing materials containing Cross-contamination can result in cured isocyanates creates potentially harmful mists, material in fluid lines which could cause serious vapors, and atomized particulates.

  • Page 8: Changing Materials

    Important Isocyanate Information Foam Resins with 245 fa Blowing Changing Materials Agents NOTICE Some foam blowing agents will froth at temperatures Changing the material types used in your above 90°F (33°C) when not under pressure, equipment requires special attention to avoid especially if agitated.

  • Page 9: Models

    Models Models Reactor 2 E-30 and E-30 Elite All elite systems include fluid inlet sensors, Graco InSite , and Xtreme-Wrap 50 ft (15 m) heated hose. For ™ part numbers, see Accessories, page 11 Base Model Elite Model Model E-30, 10 kW...
  • Page 10 Models Reactor 2 E-XP2 and E-XP2 Elite All elite systems include fluid inlet sensors, Graco InSite , and Xtreme-Wrap 50 ft (15 m) heated hose. For ™ part numbers, see Accessories, page 11 Model Base Model Elite Model E–XP2, 15 kW E–XP2, 15 kW...

  • Page 11: Approvals

    Air Manifold Kit (4 outlets) Proportioner Approvals: 24U314 Wheel and Handle Kit 24T280 Graco InSite Kit 16X521 Graco InSite Extension cable 24.6 ft (7.5 m) 24N449 50 ft (15 m) CAN cable (for remote display module) 24K207 Fluid Temperature Sensor (FTS)

  • Page 12: Supplied Manuals

    The following manuals are shipped with the Reactor The following manuals are for accessories used with 2. Refer to these manuals for detailed equipment the Reactor. information. Manuals are also available at www.graco.com. Component Manuals in English: Manual Description 333023 Reactor 2 E-30 and E-XP2 Manuals are available at www.graco.com.

  • Page 13: Typical Installation, Without Circulation

    Typical Installation, without circulation Typical Installation, without circulation (RES) (ISO) Figure 1 * Shown exposed for clarity. Wrap with tape during operation. Reactor Proportioner Fluid Supply Lines Heated Hose Feed Pumps Agitator Fluid Temperature Sensor (FTS) Heated Whip Hose Desiccant Dryer Fusion Spray Gun Bleed Lines Gun Air Supply Hose...

  • Page 14: Typical Installation, With System Fluid Manifold

    Typical Installation, with system fluid manifold to drum circulation Typical Installation, with system fluid manifold to drum circulation (RES) (ISO) Figure 2 * Shown exposed for clarity. Wrap with tape during operation. Reactor Proportioner Fluid Supply Lines Heated Hose Feed Pumps Fluid Temperature Sensor (FTS) Agitator Heated Whip Hose...

  • Page 15: Typical Installation, With Gun Fluid Manifold To

    Typical Installation, with gun fluid manifold to drum circulation Typical Installation, with gun fluid manifold to drum circulation Figure 3 * Shown exposed for clarity. Wrap with tape during operation. Reactor Proportioner Fluid Supply Lines Heated Hose Feed Pumps Fluid Temperature Sensor (FTS) Agitator Circulation Block (accessory) Desiccant Dryer...

  • Page 16: Component Identification

    Component Identification Component Identification 333023D Figure 4...
  • Page 17 Component Identification ISO Side Pressure Relief Outlet Graco InSite Cellular Module (Elite models only) RES Side Pressure Relief Outlet Red Stop Button Advanced Display Module (ADM) ISO Side PRESSURE RELIEF/SPRAY Drive Gear Housing Valve RES Side PRESSURE RELIEF/SPRAY Electrical Cord Strain Relief...

  • Page 18: Advanced Display Module (Adm)

    Component Identification Advanced Display Module (ADM) NOTICE The ADM display shows graphical and text information related to setup and spray operations. To prevent damage to the softkey buttons, do not press buttons with sharp objects such as pens, plastic cards, or fingernails. Figure 5 Front View 333023D...
  • Page 19 Component Identification Table 1 : ADM Keys and Indicators Function Press to startup or shutdown the system. Startup/Shutdown Key and Indicator Press to stop all proportioner processes. This Is not a safety or emergency stop. Stop Press to select the specific screen or operation shown on the display directly next to each key.
  • Page 20 Component Identification Module Status LEDs Figure 6 Back View Accessory Cable Connection Flat Panel Mount (VESA 100) Token Access Cover Model and Serial Number Battery Access Cover USB Port and Status LEDs CAN Cable Connection Table 2 ADM LED Status Descriptions Conditions Description System Status...
  • Page 21 Component Identification ADM Display Details Alarm/Deviation The current system error is displayed in the middle of Power Up Screen the menu bar. There are four possibilities: The following screen appears when the ADM is Icon Function powered up. It remains on while the ADM runs through No Icon No information or no error has occurred initialization and establishes communication with other...
  • Page 22 Component Identification Icons Icons Softkeys Icon Function Icon Function Component A Start Proportioner Start and Stop Proportioner in Jog Mode Component B Stop Proportioner Estimated Supply Material Turn on or off the specified heat zone. Hose Temperature Park pump Jog Mode Speed Enter Jog Mode.

  • Page 23: Electrical Enclosure

    Component Identification Electrical Enclosure AAA Temperature Control Module (TCM) AAB Motor Control Module (MCM) AAC Enclosure Fan AAD Wiring Terminal Blocks AAE Power Supply AAF Surge Protector AAG Hose Breaker AAH Motor Breaker AAJ A Side Heat Breaker AAK B Side Heat Breaker AAL Transformer Breaker MP Main Power Switch 333023D...

  • Page 24: Motor Control Module (Mcm)

    Base Model Elite Model Accessory output Figure 7 Not used Description Pump Cycle Counter Module Status LEDs see LED Status Table Graco Insite ™ CAN Communication Connections Motor Power Output Motor Temperature Main Power Input Not used Rotary Switch Not used...

  • Page 25: Temperature Control Module (Tcm) Cable

    Component Identification Temperature Control Module (TCM) Cable Connections Figure 8 Power Input Heater Overtemperature CAN Communications Connections Power Out (ISO) Power Out (Res) Power Out (Hose) Module Status LEDs Heater A Temperature (ISO) Heater B Temperature (RES) Hose Temperature 333023D...

  • Page 26: Installation

    Installation Installation Setup From Shipping Configuration 1. Use the supplied bolts to install the supplied L-brackets onto the system frame in the top-most 1. Remove bolts (A) and nuts. square holes. Install brackets on both the left and right side of system frame. 2.

  • Page 27: Setup

    Setup Setup General Equipment Guidelines • Determine the correct size generator. Using the Grounding correct 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. Use the following procedure to determine the correct size generator.

  • Page 28: Connect Power

    Setup Connect Power NOTE: Terminal jumpers are located inside the electrical enclosure door. 3. Install supplied terminal jumpers in the positions shown in image for the power source used. 4. Route power cable through strain relief (EC) in electrical enclosure. All electrical wiring must be done by a qualified electrician and comply with all local codes and 5.

  • Page 29: Supply Wet Cups With Throat Seal Liquid

    • Component B (Resin) Pump: Check felt washers Liquid (TSL) in packing nut/wet-cup (S) daily. Keep saturated with Graco Throat Seal Liquid (TSL), Part No. 206995, to prevent material from hardening on displacement rod. Replace felt washers when worn or contaminated with hardened material.

  • Page 30: Advanced Display Module (Adm)

    Advanced Display Module (ADM) Operation Advanced Display Module (ADM) Operation When main power is turned on by turning the main power switch (MP) to the ON position, the power up screen will be displayed until communication and initialization is complete. Perform the following tasks to fully setup your system.

  • Page 31: Setup Mode

    Advanced Display Module (ADM) Operation Setup Mode The ADM will start in the Run screens at the Home screen. From the Run screens, press access the Setup screens. The system defaults with no password, entered as 0000. Enter the current password then press .
  • Page 32 Advanced Display Module (ADM) Operation Setup Screens Navigation Diagram Figure 11 333023D...

  • Page 33: Advanced Setup Screens

    Advanced Display Module (ADM) Operation Advanced Setup Screens Advanced setup screens enable users to set units, adjust values, set formats, and view software information for each component. Press to scroll through the Advanced setup screens, Once in the desired Advanced setup screen, press to access the fields and make changes.

  • Page 34: System 1

    Advanced Display Module (ADM) Operation System 1 Recipes Use this screen to add recipes, view saved recipes, Use this screen to set the activation pressure for the and enable or disable saved recipes. Enabled Pressure Imbalance Alarm and Deviation, enable or recipes can be selected at the Home Run Screen.

  • Page 35: Run Mode

    Advanced Display Module (ADM) Operation Run Mode The ADM will start in the Run screens at the “Home” screen. Press to navigate through the Run Mode screens. See Run Screens Navigation Diagram, page From the Run screens, press to access the Setup screens. 333023D Run Screens Navigation Diagram Figure 12...
  • Page 36 Advanced Display Module (ADM) Operation Home — System Off Home — System With Error This is the home screen when the system is off. Active errors are shown in the status bar. The error This screen displays actual temperatures, actual code, alarm bell, and description of the error will pressures at the fluid manifold, jog speed, coolant scroll in the status bar.
  • Page 37 Advanced Display Module (ADM) Operation Maintenance Events Use this screen to view daily and lifetime cycles or This screen shows the date, time, event code, and gallons that have been pumped and gallons or liters description of all events that have occurred on remaining in the drums.
  • Page 38 QR Codes To quickly view online help for a given error code, scan the displayed QR code with your smartphone. Alternately, visit http://help.graco.com and search for the error code to view online help for that code. 333023D...
  • Page 39 Advanced Display Module (ADM) Operation Diagnostic Job Data Use this screen to view information for all system Use this screen to enter a job name or number. components. Recipes The following information is displayed: Use this screen to select an enabled recipe. Use the Temperature up and down arrows to highlight a recipe and press •...
  • Page 40 Advanced Display Module (ADM) Operation System Events Use the table below to find a description for all system non-error events. All events are logged in the USB log files. Event Code Description Recipe Selected EACX EADA Heat On A EADB Heat On B EADH Heat On Hose...

  • Page 41: Startup

    Startup Startup 3. Check generator fuel level. NOTICE Running out of fuel will cause voltage To prevent serious injury, only operate Reactor fluctuations that can damage electrical with all covers and shrouds in place. equipment and void the warranty. Do not run out of fuel.
  • Page 42 Startup 8. Switch on the air compressor, air dryer, and e. Open fluid inlet valves (FV). Check for leaks. breathing air, if included. 9. For first startup of new system, load fluid with feed pumps. a. Check that all Setup steps are complete. Cross-contamination can result in cured Setup, page material in fluid lines which could cause...
  • Page 43 Startup 10. Press to activate ADM. Thermal expansion can cause overpressurization, resulting in equipment 11. If necessary, setup the ADM in Setup Mode. See rupture and serious injury, including fluid Advanced Display Module (ADM) Operation, injection. Do not pressurize system when page preheating hose.

  • Page 44: Fluid Circulation

    Fluid Circulation Fluid Circulation Circulation Through Reactor 3. Set PRESSURE RELIEF/SPRAY valves (SA, NOTICE SB) to PRESSURE RELIEF/CIRCULATION To prevent equipment damage, do not circulate fluid containing a blowing agent without consulting with your material supplier regarding fluid temperature limits. NOTE: Optimum heat transfer is achieved at lower fluid flow rates with temperature set points at desired drum temperature.

  • Page 45: Circulation Through Gun Manifold

    Jog Mode Circulation Through Gun Manifold pressure of this equipment. See Technical Specifications, page NOTICE 3. Follow procedures from Startup, page To prevent equipment damage, do not circulate fluid containing a blowing agent without consulting with your material supplier regarding fluid 4.

  • Page 46: Spraying

    Spraying Spraying 6. Open fluid inlet valve located at each pump inlet. The Fusion AP gun is shown. 1. Engage gun piston safety lock and close gun fluid inlet valves A and B. Fusion Probler 2. Attach gun fluid manifold. Connect gun air line. Open air line valve.

  • Page 47: Spray Adjustments

    Spraying Spray Adjustments 9. Open gun fluid inlet valves A and B. Flow rate, atomization, and amount of overspray are affected by four variables. • Fluid pressure setting. Too little pressure results in an uneven pattern, coarse droplet size, low flow, and poor mixing.

  • Page 48: Manual Hose Heat Mode

    Spraying Manual Hose Heat Mode 3. Select Enable Manual Hose Mode. Note If the system produces the T6DH sensor error hose alarm or the T6DT sensor error TCM alarm, use When manual hose mode is enabled, the manual hose heat mode until the hose RTD cable or manual hose mode advisory EVCH-V will appear.
  • Page 49 Spraying Disable Manual Hose Mode 5. Navigate back to the Run Mode Home screen. The hose now displays a current instead of a 1. Enter Setup Mode and navigate to System 2 temperature. Screen and deselect Enable Manual Hose Mode, or repair the hose RTD cable or FTS.

  • Page 50: Shutdown

    Shutdown Shutdown NOTICE 6. Turn off the air compressor, air dryer, and breathing air. Proper system setup, startup, and shutdown procedures are critical to electrical equipment reliability. The following procedures ensure steady voltage. Failure to follow these procedures will cause voltage fluctuations that can damage electrical equipment and void the warranty.
  • Page 51 Shutdown 9. Engage gun piston safety lock then close fluid inlet valves A and B. Fusion Probler 333023D...

  • Page 52: Pressure Relief Procedure

    Pressure Relief Procedure Pressure Relief Procedure 4. Route fluid to waste containers or supply tanks. Follow the Pressure Relief Procedure Turn PRESSURE RELIEF/SPRAY valves (SA, whenever you see this symbol. SB) to PRESSURE RELIEF/CIRCULATION . Ensure gauges drop to 0. This equipment stays pressurized until pressure is manually relieved.

  • Page 53: Flushing

    Flushing Flushing To flush feed hoses, pumps, and heaters separately from heated hoses, set PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE To help prevent fire and explosion: RELIEF/CIRCULATION . Flush through bleed lines (N). • Flush equipment only in a well-ventilated area. •...

  • Page 54: Maintenance

    Proportioner Maintenance ISO Lubricant Level Wet Cup Inspect ISO lubricant level and condition Check the wet cup daily. Keep it 2/3 full with Graco daily. Refill or replace as needed. See Throat Seal Liquid (TSL ) or compatible solvent. Do ®...

  • Page 55: Flush Inlet Strainer Screen

    Maintenance Flush Inlet Strainer Screen compatible solvent and shake it dry. Inspect the screen. No more than 25% of the mesh should be restricted. If more than 25% of the mesh is blocked, replace the screen. Inspect the gasket (B) and replace as required. 4.

  • Page 56: Pump Lubrication System

    Maintenance Pump Lubrication System 4. When the reservoir is flushed clean, fill with fresh lubricant. Check the condition of the ISO pump lubricant daily. 5. Thread the reservoir onto the cap assembly and Change the lubricant if it becomes a gel, its color place it in the bracket.

  • Page 57: Errors

    Otherwise, manually navigate to enough to stop the system at this time. http://help.graco.com and search for the active error. Advisories are indicated by . This condition indicates a parameter that is not immediately critical to the process.

  • Page 58: Troubleshooting

    ADM that have occurred on the system. Errors, page 57 for information about errors that can occur on the system. Error Codes and Troubleshooting See system repair manual or visit http://help.graco.com for causes and solutions to each error code. 333023D...

  • Page 59: Usb Data

    Follow Download Procedure, page 59, to retrieve log files. 6. Open GRACO folder. Each time a USB flash drive is inserted into the ADM 7. Instructions continue on next page. USB port, a new folder named DATAxxxx is created. 8. Open the system folder. If downloading data...

  • Page 60: System Configuration Settings

    The Blackbox log maintains a record of how the • Hose temperature system runs and the features that are used. This log • A side temperature setpoint will help Graco troubleshoot system errors. • B side temperature setpoint Diagnostics Log File • Hose temperature setpoint •...

  • Page 61: Custom Language File

    5. Open the system folder. If working with more Create Custom Language Strings than one system, there will be more than one folder within the GRACO folder. Each folder is The custom language file is a tab-delimited text file labeled with the corresponding serial number of that contains two columns.

  • Page 62: Performance Charts

    Performance Charts Performance Charts Use these charts to help identify the proportioner that will work most efficiently with each mix chamber. Flow rates are based on a material viscosity of 60 cps. NOTICE To prevent system damage, do not pressurize the system above the line for the gun tip size being used.
  • Page 63 Performance Charts Proportioners For Coatings Table 5 Fusion Air Purge, Round Pattern 3500 (241) 3000 (207) 2500 AR2020 E-XP2 (172) (000) PRESSURE AR2929 2000 (00) psi (bar) (138) 1500 (103) AR4242 (01) 1000 (69) (34) (1.9) (3.8) (5.7) (7.6) FLOW gal./min (l/min) Table 6 Fusion Air Purge, Flat Pattern 3500 (241, 24.1)
  • Page 64 Performance Charts Table 7 Fusion Mechanical Purge, Round Pattern 3500 (241, 24.1) E-XP2 3000 (207, 20.7) XR2323 (RTM040) 2500 (174, 17.4) XR2929 (RTM040) PRESSURE 2000 (138, 13.8) psi (bar) MR3535 (RTM040) 1500 MR4747 (103, 10.3) (RTM055) XR3535 (RTM055) XR4747 1000 (RTM055) (69, 6.9) (35, 3.5)

  • Page 65: Technical Specifications

    Technical Specifications Technical Specifications Reactor 2 E-30 and E-XP2 Proportioning System Metric U.S. Maximum Fluid Working Pressure E-30 2000 psi 14 MPa, 140 bar E-XP2 3500 psi 24.1 MPa, 241 bar Maximum Fluid Temperature E-30 150°F 66°C E-XP2 190°F 88°C Maximum Flow Rate E-30 30 lb/min...
  • Page 66 Technical Specifications Sound Power E-30 93.7 dBA Measured from 3.1 ft (1 m), at 1000 psi (7 MPa, 70 bar), 3 gpm (11.4 lpm) E-XP2 86.6 dBA Measured from 3.1 ft (1 m), at 3000 psi (21 MPa, 207 bar), 1 gpm (3.8 lpm) Fluid Inlets Component A ISO) and...

  • Page 67: Graco Extended Warranty For Reactor

    With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

  • Page 68: Graco Information

    Graco Information For the latest information about Graco products, visit www.graco.com. To place an order, contact your Graco Distributor or call to identify the nearest distributor. Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505 All written and visual data contained in this document reflects the latest product information available at the time of publication.

This manual is also suitable for:

Reactor 2 e-30

Table of Contents