Proportioner for automatic spray applications (122 pages)
Summary of Contents for Graco Reactor 2 E-30
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Operation Reactor® 2 2 2 E E E - - - 30 30 and and E E E - - - XP2 Reactor® Reactor® Proportioning Proportioning Proportioning Systems Systems Systems 333023M Electric, Heated, Heated, Plural Plural Component Component Proportioner Proportioner for for spraying spraying polyurethane polyurethane foam...
Warnings 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.
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Warnings WARNING WARNING WARNING SKIN SKIN SKIN INJECTION INJECTION INJECTION HAZARD HAZARD 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 Get immediate immediate immediate surgical...
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Warnings WARNING WARNING WARNING THERMAL THERMAL THERMAL EXPANSION EXPANSION HAZARD EXPANSION HAZARD HAZARD Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure due to the thermal expansion. Over-pressurization can result in equipment rupture and serious injury.
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Warnings WARNING WARNING WARNING EQUIPMENT EQUIPMENT EQUIPMENT MISUSE MISUSE HAZARD MISUSE HAZARD HAZARD Misuse can cause death or serious injury. • Do not operate the unit when fatigued or under the influence of drugs or alcohol. • Do not exceed the maximum working pressure or temperature rating of the lowest rated system component.
Important Isocyanate Information Important Isocyanate Isocyanate Information Information Important Important Isocyanate Information Isocyanates (ISO) are catalysts used in two component materials. Isocyanate Conditions Conditions Isocyanate Isocyanate Conditions Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and atomized particulates.
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Important Isocyanate Information Material Self Self - - - Ignition Ignition Moisture Sensitivity Sensitivity of of of Isocyanates Isocyanates Material Material Self Ignition Moisture Moisture Sensitivity Isocyanates Exposure to moisture (such as humidity) will cause ISO to partially cure, forming small, hard, abrasive crystals that become suspended in the fluid.
Models Models Models Models Reactor 2 2 2 E E E - - - 30 30 and and E E E - - - 30 30 Elite Elite Reactor Reactor Elite All elite systems include fluid inlet sensors, ratio monitoring, and Xtreme-Wrap 50 ft (15 m) heated hose. For part numbers, see Accessories, page E E E - - - 30...
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Models Reactor 2 2 2 E E E - - - XP2 XP2 and and E E E - - - XP2 XP2 Elite Elite Reactor Reactor Elite All elite systems include fluid inlet sensors and Xtreme-Wrap 50 ft (15 m) heated hose. For part numbers, see Accessories, page Model Model...
Air Manifold Kit (4 outlets) Proportioner Proportioner Approvals: Proportioner Approvals: Approvals: 24U314 Wheel and Handle 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) with RTD 9902471...
Manual Manual Manual Description Description Description 333023 Reactor 2 E-30 and E-XP2 Operation 333091 Reactor 2 E-30 and E-XP2 Startup Quick Guide 333092 Reactor 2 E-30 and E-XP2 Shutdown Quick Guide Related Manuals Manuals Related Related Manuals The following manuals are for accessories used with the Reactor.
Typical Installation, with system fluid manifold to drum circulation Typical Installation, Installation, with with system system fluid fluid manifold manifold to to to drum drum Typical Typical Installation, with system fluid manifold drum circulation circulation circulation Figure 2 * Shown exposed for clarity. Wrap with tape during operation. Reactor Proportioner Fluid Supply Lines Heated Hose...
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Component Identification ISO Side Pressure Relief Outlet Red Stop Button RES Side Pressure Relief Outlet ISO Side PRESSURE RELIEF/SPRAY Valve Advanced Display Module (ADM) RES Side PRESSURE RELIEF/SPRAY Valve Drive Gear Housing Heated Hose Power Termination Box Electrical Cord Strain Relief ISO Side Pressure Transducer (behind Electric Motor gauge GA)
Advanced Display Module (ADM) Advanced Display Display Module Module (ADM) (ADM) Advanced Advanced Display Module (ADM) The ADM display shows graphical and text NOTICE NOTICE NOTICE 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.
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Advanced Display Module (ADM) Table 1 1 1 : : : ADM ADM Keys Keys and and Indicators Indicators Table Table Keys Indicators Function Function Function Press to startup or shutdown the system. Startup/Shutdown Startup/Shutdown Startup/Shutdown Key and and Indicator Indicator Indicator Press to stop all proportioner processes.
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Advanced Display Module (ADM) 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 Table Table 2 2 2 ADM ADM LED LED Status Status Descriptions...
Advanced Display Module (ADM) ADM Display Display Details Details Display Details Alarm/Deviation Alarm/Deviation Alarm/Deviation The current system error is displayed in the middle of Power Up Up Screen Screen Power Power Screen the menu bar. There are four possibilities: The following screen appears when the ADM is Icon Icon Icon...
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Advanced Display Module (ADM) Icons Icons Icons Icons Softkeys Icons Icons Softkeys Softkeys Icon Icon Icon Function Function Function Icon Icon Icon Function Function 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.
Electrical Enclosure Electrical Enclosure Enclosure Electrical 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...
Not used Ref. Ref. Ref. Description Description 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 Not used...
Temperature Control Module (TCM) Cable Connections Temperature Control Control Module Module (TCM) (TCM) Cable Cable Connections Connections Temperature 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)
Installation Installation Installation Installation Setup Setup Setup From From From Shipping Shipping Configuration Shipping Configuration 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.
Setup Setup General Equipment Equipment Guidelines Guidelines Setup Setup General General Equipment Guidelines • Determine the correct size generator. Using the correct size generator and proper air compressor Grounding Grounding Grounding will enable the proportioner to run at a nearly constant RPM.
Setup Connect Power Power Connect Connect Power 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. 5. Connect incoming power wires as shown in image.
Liquid (TSL) (TSL) Liquid Liquid (TSL) 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. Pump rod and connecting rod move during operation.
Setup Connect Heated Heated Hose Hose to to to Proportioner Proportioner Connect Connect Heated Hose Proportioner 2. For proportioners with electrical splice connectors (S): See the heated hose manual for detailed instructions. a. Connect hose power wires to electrical splice connectors (S) from proportioner.
Advanced Display Module (ADM) Operation Advanced Display Display Module Module (ADM) (ADM) Operation Operation Advanced 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.
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Advanced Display Module (ADM) Operation Setup Mode Mode Setup 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 .
Advanced Setup Screens Advanced Setup Setup Screens Screens Advanced 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.
System 1 System 1 1 1 System 2 2 2 System System System System Use this screen to enable pressure imbalance alarms Use this screen to enable Manual Hose Mode, and deviations, set pressure imbalance values, Integrated Mode, and the diagnostic screen. This enable low chemical alarm, and enable inlet sensors.
Recipes Add Recipe Recipe Recipe 2. Use to highlight the next field and use the number pad to enter a value. Press to save. 1. Press and then use to select a recipe field. Press to enter a recipe name Enable or or or Disable Disable Recipes Recipes...
Run Mode Run Mode Mode 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. Run Screens Navigation Diagram Figure 14 333023M...
Run Mode Home — — — System System Off Home — — — System System Active Active Home Home System Home Home System Active This is the home screen when the system is off. When the system is active, the home screen displays This screen displays actual temperatures, actual actual temperature for heat zones, actual pressures pressures at the fluid manifold, jog speed, coolant...
Run Mode Targets Maintenance Targets Targets Maintenance Maintenance Use this screen to define the setpoints for the Use this screen to view daily and lifetime cycles or A Component Temperature, B Component gallons that have been pumped and gallons or liters Temperature, heated hose temperature, and remaining in the drums.
Run Mode Events Errors Events Events Errors Errors This screen shows the date, time, event code, and This screen shows the date, time, error code, and description of all events that have occurred on description of all errors that have occurred on the the system.
QR Codes Codes 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. 333023M...
Run Mode Diagnostic Diagnostic Diagnostic Note Maximum values based on maximum input Use this screen to view information for all system voltage. Values will lower with lower input components. voltage. Job Data Data Data Use this screen to enter a job name or number. The following information is displayed: Temperature Temperature...
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Run Mode System Events Events System 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. Description Event Event Code Event Code Code Description Description Recipe Selected EACX EADA Heat On A...
Startup Startup Startup Startup Check generator generator fuel fuel level. level. 4. Check Check generator fuel level. NOTICE NOTICE NOTICE Running out of fuel will cause voltage fluctuations that can damage electrical To prevent serious injury, only operate Reactor equipment and void the warranty. Do not run with all covers and shrouds in place.
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Startup 9. Switch on the air compressor, air dryer, and e. Open fluid inlet valves (FV). Check for leaks. breathing air, if included. For first first startup startup of of of new new system, system, load load fluid fluid with with 10.
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Startup 11. Press to activate ADM. Thermal expansion can cause overpressurization, resulting in equipment rupture and serious injury, including fluid 12. If necessary, setup the ADM in Setup Mode. See injection. Do not pressurize system when Advanced Display Module (ADM) Operation, preheating hose.
Fluid Circulation Fluid Circulation Circulation Fluid Fluid Circulation Circulation Through Through Reactor Reactor Circulation Circulation Through Reactor 3. Set PRESSURE RELIEF/SPRAY valves (SA, NOTICE NOTICE 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.
Jog Mode Circulation Through Through Gun Gun Manifold Manifold Circulation Circulation Through Manifold NOTICE NOTICE NOTICE 4. Turn main power switch on 5. Set temperature targets. See Targets, page To prevent equipment damage, do not circulate fluid containing a blowing agent without consulting 6.
Spraying 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 Fusion Fusion Probler Probler Probler 2.
Spraying 9. Open gun fluid inlet valves A and B. 11. Pull gun trigger to test spray onto cardboard. If necessary, adjust pressure and temperature to get desired results. Spray Adjustments Adjustments Spray Spray Adjustments Flow rate, atomization, and amount of overspray are Fusion Probler Fusion...
Manual Hose Mode Manual Hose Hose Mode Mode Manual Manual Hose Mode 3. Select Enable Manual Hose Mode. Note If the system produces the T6DH sensor error hose When manual hose mode is enabled, the alarm or the T6DT sensor error TCM alarm, use manual hose mode advisory EVCH-V Manual Hose Mode until the hose RTD cable or FTS will appear.
Manual Hose Mode Disable Manual Manual Hose Hose Mode Mode Disable Disable Manual Hose Mode 5. Navigate back to the Run Mode Home screen. The hose now displays a current instead of a temperature. Manual Hose Mode is automatically disabled when the system detects a valid FTS (Fluid Temperature Sensor) in the hose.
Shutdown Shutdown Shutdown Shutdown 6. Turn off the air compressor, air dryer, and NOTICE NOTICE NOTICE 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.
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Shutdown 9. Set PRESSURE RELIEF/SPRAY valves (SA, 10. Engage gun piston safety lock then close fluid inlet valves A and B. SB) to SPRAY to seal out moisture from drain line. Fusion Fusion Fusion Probler Probler Probler 333023M...
Purge Air Procedure Purge Air Air Procedure Procedure Purge Purge Procedure 5. Set the PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION NOTE: NOTE: Perform this procedure any time air is NOTE: introduced into the system. 1. Relieve pressure. Pressure Relief Procedure, page 6.
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Purge Air Procedure 11. To relieve air pressure from the feed pumps, 13. Set the PRESSURE RELIEF/SPRAY valves disconnect the air supply lines (G) from the feed (SA, SB) to PRESSURE RELIEF/CIRCULATION pumps (K). 14. Listen for a “spitting” sound from the bleed lines (N) or recirculation lines (R).
Pressure Relief Procedure Pressure Relief Relief Procedure Procedure Pressure Pressure Relief Procedure 3. Close gun fluid inlet valves A and B. Follow the Pressure Relief Procedure whenever you see this symbol. 4. Shut off feed pumps and agitator, if used. 5.
Flushing Flushing Flushing Flushing To flush feed hoses, pumps, and heaters separately from heated hoses, set PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION . Flush through bleed To help prevent fire and explosion: lines (N). • Flush equipment only in a well-ventilated area. •...
Proportioner Maintenance Maintenance Proportioner Proportioner Maintenance Clean gun check valve screens regularly. See gun manual. Wet Cup Check the wet cup daily. Keep it 2/3 full with Graco Dust Protection Protection Dust Dust Protection Throat Seal Liquid (TSL ® ) or compatible solvent. Do not overtighten packing nut/wet cup.
Maintenance Flush Inlet Inlet Strainer Strainer Screen Screen Flush Flush Inlet Strainer Screen 4. Ensure the pipe plug (D) is screwed into the strainer plug (C). Install the strainer plug with the screen (A) and o-ring (B) in place and tighten. Do not overtighten.
Maintenance Pump Lubrication Lubrication System System Pump Pump Lubrication System 5. Thread the reservoir onto the cap assembly and place it in the bracket. Check the condition of the ISO pump lubricant daily. 6. The lubrication system is ready for operation. No Change the lubricant if it becomes a gel, its color priming is required.
Otherwise, manually navigate to 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.
Refer to your Reactor 2 App manual for instructions. Error Codes Codes and and Troubleshooting Troubleshooting Error Error Codes Troubleshooting See system repair manual or visit help.graco.com for causes and solutions to each error code. 333023M...
Event Event Log Event Windows® Explorer. 6. Open GRACO folder. The event log file name is 1–EVENT.CSV and is 7. Open the system folder. If downloading data stored in the DATAxxxx folder. from more than one system, there will be more The event log maintains a record of the last 49,000 than one folder.
The Blackbox log maintains a record of how the system runs and the features that are used. This log • A side temperature setpoint will help Graco troubleshoot system errors. • B side temperature setpoint • Hose temperature setpoint Diagnostics Log...
The first column consists folder within the GRACO folder. Each folder is of a list of strings in the language selected at the labeled with the corresponding serial number of time of download.
Performance Charts Performance Charts Charts Performance 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 NOTICE NOTICE To prevent system damage, do not pressurize the system above the line for the gun tip size being used.
Technical Specifications Technical Specifications Specifications Technical Technical Specifications Reactor Reactor 2 2 2 E E E - - - 30 Reactor 30 and and E E E - - - XP2 XP2 Proportioning Proportioning System Proportioning System System U.S. U.S. U.S.
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Technical Specifications Sound Sound Pressure Sound Pressure Pressure, Sound Pressure measured per ISO-9614–2. Measured from 3.1 ft (1 m), 87.3 dBA E-30, at 1000 psi (7 MPa, 70 bar), 3 gpm (11.4 lpm) E-XP2, Measured from 3.1 ft (1 79.6 dBA m), at 3000 psi (21 MPa, 207 bar), 1 gpm (3.8 lpm) Sound...
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.
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Information For the latest information about Graco products, visit www.graco.com. To place place an an order, order, contact your Graco Distributor or call to identify the nearest distributor. place order, Phone: 612-623-6921 or or or Toll Toll Free: Free: 1-800-328-0211 Fax:...
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