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Operation
Reactor®
Reactor® 3 3 3 Proportioning
Reactor®
Electric, heated,
heated, plural
plural component
Electric,
Electric,
heated,
plural
coatings.
coatings.
coatings. For
For
For indoor
indoor
indoor use
(classified)
(classified) locations.
(classified)
locations.
locations. Only
Important
Important Safety
Important
Safety Instructions
Safety
Read all warnings and instructions in this manual and in
related manuals before using the equipment. Save these
instructions.
See page 4 for model information
including maximum working
pressure.
Proportioning Systems
Proportioning
component proportioner
proportioner for
component
proportioner
use
use only.
only. Not
only.
Not
Not approved
approved
approved for
Only use
Only
use with
use
with Reactor
with
Reactor 3 3 3 heated
Reactor
Instructions
Instructions
PROVEN QUALITY. LEADING TECHNOLOGY.
Systems
Systems
for spraying
spraying polyurethane
polyurethane foam
for
spraying
polyurethane
for
for use
use in in in explosive
use
explosive atmospheres
explosive
heated hoses.
heated
hoses. For
hoses.
For professional
For
professional use
professional
3A8500E
foam and
and polyurea
polyurea
foam
and
polyurea
atmospheres or or or hazardous
atmospheres
hazardous
hazardous
use only.
use
only.
only.
EN
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Table of Contents
Related Manuals for Graco Reactor 3 E-XP1
Summary of Contents for Graco Reactor 3 E-XP1
- Page 1 Operation Reactor® Reactor® Reactor® 3 3 3 Proportioning Proportioning Proportioning Systems Systems Systems 3A8500E Electric, heated, heated, plural plural component component proportioner proportioner for for spraying spraying polyurethane polyurethane foam foam and and polyurea polyurea Electric, Electric, heated, plural component proportioner spraying polyurethane...
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Page 2: Table Of Contents
Tools Required for Setup ......25 California Proposition 65 ....... 62 General Equipment Guidelines ....25 Connect Power ........26 Graco Extended Warranty for Reactor® Install Cell Module ........27 Components ........63 Supply Wet Cups With Throat Seal Liquid (TSL®)....... 28 Connect Heated Hose to Proportioner ....... -
Page 3: Supplied Manuals
Reactor. Refer to these manuals and quick guides for detailed Manuals are available at www.graco.com. equipment information. Description Description Description Manual Manual in in in Manual Manuals are also available at www.graco.com. English English English Description Manual Description Description Manual Manual... -
Page 4: Models
Models Models Models Models Reactor Reactor Reactor E E E - - - 20 Model Model Model E E E - - - 20 20 Standard Standard Standard 7 7 7 kW E E E - - - 20 20 Pro Pro 7 7 7 kW E E E - - - 20 20 Pro... - Page 5 Models Reactor Reactor Reactor E E E - - - 30 Model E E E - - - 30 30 Standard Standard 10 E E E - - - 30 30 Pro Pro 10 10 kW E E E - - - 30 30 Pro Pro 15 15 kW...
- Page 6 Models Reactor E E E - - - XP1 Reactor Reactor Model Model Model E E E - - - XP1 XP1 Standard Standard Standard 10 10 kW E E E - - - XP1 XP1 Pro Pro 10 10 kW E E E - - - XP1 XP1 Elite Elite 10...
- Page 7 Models Reactor Reactor Reactor E E E - - - XP2 Model E E E - - - XP2 XP2 Standard Standard 15 15 kW E E E - - - XP2 XP2 Pro Pro 15 15 kW E E E - - - XP2 XP2 Elite Elite 15 15 kW...
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Page 8: Approvals
Approvals Accessories Accessories Accessories Approvals Approvals Approvals Description Intertek approvals apply to proportioners Description Description without hoses. Number Number Number 20A677 Engine CAN Kit Proportioner Proportioner Approvals: Proportioner Approvals: Approvals: 24M174 Drum Level Sticks 20A676 Light Tower Kit 18E191 Off-Ratio Kits 18E192 18E154 Air Manifold Kit... -
Page 9: Warnings
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. - Page 10 Warnings WARNING WARNING WARNING SKIN INJECTION INJECTION HAZARD HAZARD SKIN 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 immediate surgical immediate...
- Page 11 Warnings WARNING WARNING WARNING THERMAL EXPANSION EXPANSION HAZARD HAZARD THERMAL THERMAL EXPANSION 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. •...
- Page 12 Warnings WARNING WARNING WARNING EQUIPMENT MISUSE MISUSE HAZARD HAZARD EQUIPMENT EQUIPMENT MISUSE 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 Technical Specifications Specifications in all equipment manuals.
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Page 13: Important Isocyanate Information
Important Isocyanate Information Important Important Important Isocyanate Isocyanate Information Isocyanate Information 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. •... - Page 14 Important Isocyanate Information Material Material Material Self Self - - - Ignition Self Ignition Ignition Moisture Moisture Sensitivity Moisture Sensitivity Sensitivity of of of Isocyanates Isocyanates Isocyanates Exposure to moisture (such as humidity) will cause ISO to partially cure, forming small, hard, abrasive crystals that become suspended in the fluid.
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Page 15: Typical Installation
Typical Installation Typical Installation Installation Typical Typical Installation Typical Typical Typical Installation Installation Installation without without without circulation circulation circulation Figure 1 Reactor Proportioner H � Agitator Air Supply Line Bleed Lines B *� J � P � Heated Hose Bundle Fluid Supply Lines Gun Fluid Manifold D �... -
Page 16: Typical Installation Without
Typical Installation Typical Typical Typical Installation Installation with Installation with with system system fluid system fluid manifold fluid manifold manifold to to to drum drum drum circulation circulation circulation Figure 2 Reactor Proportioner H � P � Agitator Air Supply Line Gun Fluid Manifold B* �... -
Page 17: Circulation
Typical Installation Typical Typical Typical Installation Installation with Installation with gun with gun fluid fluid manifold fluid manifold to to to drum manifold drum circulation drum circulation circulation Figure 3 Reactor Proportioner H � Agitator Air Supply Line Bleed Lines B* �... -
Page 18: Component Identification
Component Identification Component Component Component Identification Identification Identification Proportioner Proportioner Proportioner 3A8500E... - Page 19 Component Identification ISO Side Pressure Relief Outlet RES Side Pressure Relief Outlet ISO Side Inlet Pressure Gauge RES Side Inlet Pressure Gauge Advanced Display Module (ADM) Electrical Cord Strain Relief Electric Motor ISO Side Inlet Fitting RES Side Inlet Fitting Fluid Heaters ISO Side Pressure Gauge RES Side Pressure Gauge...
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Page 20: Electrical Enclosure
Component Identification Electrical Enclosure Enclosure Electrical Electrical Enclosure AAP * Temperature Control Module (TCM) Cellular Antenna AAR * GPS Antenna Motor Control Module (MCM) ADM LED Status Lights Wiring Terminal Blocks Reactor Connect Module Cable 24V Power Supply Connection Surge Protector ADM USB Port Transformer Breaker ADM CAN Cable Connection... -
Page 21: (Tcm)
Component Identification Temperature Control Control Module Module Temperature Temperature Control Module (TCM) (TCM) (TCM) ti36983b Description Ref. Description Description Ref. Ref. Main Power Input Heater Over-Temperature Inputs CAN Communications Connections A/B Inlet Temperatures and 24 VDC Power Supply Input A Heater Temperature Input B Heater Temperature Input A/B Hose Temperature Inputs A/B Heater Power Outputs... -
Page 22: Motor Control Module (Mcm)
Component Identification Motor Control Control Module Module (MCM) (MCM) Motor Motor Control Module (MCM) ti36982b Description Description Description Description Description Description Ref. Ref. Ref. Ref. Ref. Ref. Motor Fan CAN Communication Connections ISO Lube Pump Output Main Power Input A-Side Pump Outlet Pressure B-Side Pump Outlet Pressure Digital Inputs/Outputs A-Side Pump Inlet Pressure... -
Page 23: Installation
Installation Installation Installation Installation 3. Place the left and right wall mounting brackets (MB) as shown in Fig. Fig. 4. 4. 4. Insert the Fig. enclosure pivot arm screws (ES) through the brackets (MB) and tighten to secure the Location Location Location enclosure. -
Page 24: Mount The System
Installation Mount the the System System Mount Mount System 2. Use the four holes in the base of the system frame (BH) to secure the base to the floor. The bolts are not supplied. To prevent serious injury due to the system tipping over, ensure that the Reactor is properly secured to the wall. -
Page 25: Setup
Setup Setup Setup Setup General Equipment Equipment Guidelines Guidelines General General Equipment Guidelines NOTICE NOTICE NOTICE Grounding Grounding Grounding Failure to properly size the generator may result in damage. To avoid damage to the equipment, follow the guidelines listed below. •... -
Page 26: Connect Power
Setup Connect Connect Connect Power Power Power All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations. 1. Turn the main power switch (MP) OFF. 2. Open the electrical enclosure door. NOTE: The terminal jumpers are located NOTE: NOTE: inside the electrical enclosure door. -
Page 27: Install Cell Module
Setup Install Cell Cell Module Module Install Install Cell Module 5. Attach the cellular antenna cable (ZE) to the cellular module. Tighten by hand. NOTE: NOTE: Installation of the cell module is required NOTE: 6. Attach the GPS antenna cable (ZD) to the to use the Reactor Connect app. -
Page 28: Liquid (Tsl®)
If the reservoir is low or empty, Proportioner Proportioner Proportioner add new TSL to the fill line. When ordering pre-filled bottles from Graco, use a marker to draw a line at the top of the fluid line as it was NOTICE NOTICE NOTICE shipped. -
Page 29: Startup
Startup Startup Startup Startup 4. Use A and B Drum Level Sticks (24M174) to measure the material level in each drum. If desired, the level can be entered and tracked with the ADM. 5. Check the generator fuel level. To prevent serious injury, only operate Reactor with all covers and shrouds in place. - Page 30 Startup 11. Turn on the air compressor, air dryer, and breathing air (if applicable). Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination: • Never interchange component A and component B wetted parts.
- Page 31 Startup h. Turn off the transfer pumps. If If If you you are are using using using an an electric electric electric transfer transfer transfer pump: pump: pump: tap to turn off the Thermal expansion can cause overpressurization, resulting in A-side transfer pump and equipment rupture and serious injury, turn off the B-side transfer pump.
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Page 32: Operation
Operation Operation Operation Operation Pressure Pressure Pressure Relief Relief Procedure Relief Procedure Procedure 5. Close the gun fluid inlet valves A and B. Follow the Pressure Relief Procedure whenever you see this symbol. This equipment stays pressurized until pressure is manually relieved. To help prevent The Fusion AP gun is shown. -
Page 33: Jog Mode
Operation Jog Mode Mode Mode Jog the the Transfer Transfer Pumps Transfer Pumps Pumps Separately Separately Separately Pneumatic Transfer Transfer Pumps: Pumps: Manually turn Pneumatic Pneumatic Transfer Pumps: Jog mode has two purposes: on/off air to the pumps one at a time. See your pump manual, Related Manuals, page 3 •... -
Page 34: Purge Air Procedure
Operation Purge Air Air Procedure Procedure Purge Purge Procedure 8. Pump one gallon (3.8 L) of material through the system. 9. Set the pressure relief/spray valves (SA, SB) to spray NOTE: NOTE: NOTE: Perform this procedure any time air is introduced into the system. -
Page 35: Flush The Equipment
Operation Flush the the Equipment Equipment Flush Flush Equipment 4. Use jog mode to circulate fluid. Reactor systems allow the entire system to be in jog mode, or A and B-side transfer pumps to be put into jog mode separately. See Jog Mode, page 33. -
Page 36: Fluid Circulation
Operation Fluid Circulation Circulation Fluid Fluid Circulation Circulation Circulation Circulation Through Through Reactor Through Reactor Reactor 4. Tap +/- to set the temperature targets NOTICE NOTICE NOTICE for ISO and RES To prevent equipment damage, do not circulate fluid containing a blowing agent without consulting with your material supplier regarding fluid temperature limits. - Page 37 Operation Circulation Circulation Circulation Through Through Through Gun Gun Manifold Manifold Manifold 3. Follow Startup, page 4. Set temperature targets for ISO NOTICE NOTICE NOTICE To prevent equipment damage, do not circulate fluid containing a blowing agent and RES without consulting with your material supplier on the ADM screen.
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Page 38: Calibration
Operation Calibration Calibration Calibration Calibrate Calibrate the Calibrate the Transfer Transfer Pumps Transfer Pumps Pumps After installing a new electric transfer pump, Calibrate Calibrate Calibrate the the Heated Heated Heated Hose Hose Hose you must calibrate the transfer pump motor. NOTICE NOTICE NOTICE... -
Page 39: Spray
Operation Spray Spray Spray 6. Open the fluid inlet valve located at each pump inlet. 1. Engage the gun piston safety lock and close gun fluid inlet valves A and B. Pump Mode Mode button 7. Tap the Pump Pump Mode Fusion Fusion... - Page 40 Operation 12. Open the A and B gun fluid valves. 14. Pull the 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 affected by four variables: Fusion Fusion...
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Page 41: Shutdown
Operation Shutdown Shutdown Shutdown 7. Turn off the air compressor, air dryer, and breathing air. NOTICE NOTICE NOTICE 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 42: Advance Display Module (Adm)
Advance Display Module (ADM) Advance Display Display Module Module (ADM) (ADM) Advance Advance Display Module (ADM) Menu Menu Menu Bar Navigation The menu bar is located at the top of each screen of the ADM. The menu bar contains the Navigation Navigation menu (1), current screen (2), system notifications (3), and time (4). -
Page 43: Home Screen
Advance Display Module (ADM) Home Home Home Screen Screen Screen A A A and and B B B side side Supply side Supply Control Supply Control Panels Control Panels Panels The A and B Supply Control panels display the Use the Home screen to control the Reactor remaining material supply for A and B side system operation functions. - Page 44 Advance Display Module (ADM) Cycle Cycle Cycle Count Count Count Panel Panel Panel Ratio Ratio Monitoring Ratio Monitoring Monitoring Panel Panel Panel The Cycle Count panel contains information The Ratio Monitoring panel displays information regarding pump cycles and the equivalent regarding the A to B material ratio.
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Page 45: Diagnostic Screen
Advance Display Module (ADM) Diagnostic Diagnostic Screen Diagnostic Screen Screen Proportioner Proportioner Proportioner Control Control Panel Control Panel Panel This Proportioner Control panel contains Use the Diagnostic screen to view information controls for operation of the proportioner pump. for all system components. Icon Icon Icon... -
Page 46: Logs Screens
4. Close the electrical enclosure door. help.graco.com help.graco.com help.graco.com for error and troubleshooting 5. Turn the main power switch (MP) ON. The information. USB Download Download in in in Progress... -
Page 47: Setup Screens
Advance Display Module (ADM) Setup Setup Setup Screens Screens Screens Enable Flow Tap the checkbox to enable/disable Meters flow meters. Use the Setup screens screens to edit settings Enable Flow Meter Tap the checkbox to enable/disable for the Reactor system. Alarms flow meter alarms. - Page 48 Advance Display Module (ADM) Heat Heat Heat Enable Power Tap the checkbox to enable/disable Management power management. Tap the number to Use the Heat screen to calibrate hose heat and adjust the primary heater power limit. set the hose control mode. To calibrate the Power management allows users to system, see the Calibration, page...
- Page 49 Only appears when electric Air: select when using an Air: Air: transfer pumps are selected. air/pneumatic transfer pump (or other non-Graco Electric Transfer NOTE: After pressing the button, NOTE: NOTE: Pump). a notice will appear on the screen...
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Page 50: Advanced Screens
Pressure Units Display and USB download pressure After resetting your Reactor key, all operators units. using the Graco Reactor Connect app must Volume Units Display and USB download volume units. reconnect to the Reactor. For security of wireless control, change the... -
Page 51: Maintenance
Grease Circulation Valves Wet Cup Clean the grease circulation valves weekly. Check the wet cup daily. Keep it 3/4 full with Graco Throat Seal Liquid (TSL ) or compatible ® solvent. Do not over tighten packing nut/wet Desicant Desicant Dryer... -
Page 52: Flush Inlet Strainer Screen
Maintenance Flush Inlet Inlet Strainer Strainer Screen Screen Flush Flush Inlet Strainer Screen 4. After the fluid has drained, remove inlet cap (ZC) and inlet strainer screen (ZA) from the strainer manifold. Thoroughly flush the screen with compatible solvent and shake it dry. -
Page 53: Change Iso Pump Throat Seal Lubricant (Tsl) Fluid
Maintenance Change ISO ISO Pump Pump Throat Throat Seal Seal Change Change Pump Throat Seal 6. Thread the reservoir onto the cap (H) assembly and place it in the bracket. Lubricant (TSL) (TSL) Fluid Fluid Lubricant Lubricant (TSL) Fluid Check the condition of the TSL fluid daily. Change the TSL fluid if it becomes a gel, its color darkens, or it becomes diluted with isocyanate. -
Page 54: Troubleshooting
Errors sent directly to online troubleshooting for the active error code. Otherwise, go to help.graco.com help.graco.com help.graco.com and search for the active When an error occurs the error information error. screen displays the active error code and description. See Logs Screens, page... -
Page 55: Led Status Descriptions
Troubleshooting LED Status Status Status Descriptions Descriptions Descriptions The following tables describe the meaning of LED statuses for the TCM, MCM, ADM, and System. Table Table 1 1 1 TCM Table TCM Module Module Module LED LED Status Status Status Descriptions Descriptions Descriptions Temperature... -
Page 56: Performance Charts
Performance Charts Performance Performance Performance Charts Charts 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. - Page 57 Performance Charts Heater Heater Heater Performance Performance Chart Performance Chart Chart (60) (54.4) (48.9) (43.3) (37.8) (32.2) (26.7) a T in Power (7kW) degrees F (21.1) (degrees C) Power (10kW) Power (15kW) (15.6) (10) (4.4) (-1.1) (-6.7) (-12) (-17.8) (1.9) (3.8) (5.7) (7.6)
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Page 58: Technical Specifications
Technical Specifications Technical Technical Technical Specifications Specifications Specifications Reactor E E E - - - 20 Reactor Reactor Reactor 3 3 3 Proportioning Proportioning Systems, Systems, E E E - - - 20 Reactor Reactor Proportioning Systems, U.S. U.S. U.S. Metric Metric Metric... - Page 59 Technical Specifications Reactor Reactor Reactor E E E - - - 30 Reactor Reactor 3 3 3 Proportioning Reactor Proportioning Systems, Proportioning Systems, Systems, E E E - - - 30 U.S. Metric Metric Metric U.S. U.S. Maximum Fluid Working Pressure 2000 psi 140 bar, 14 MPa Maximum Fluid Temperature...
- Page 60 Technical Specifications Reactor E E E - - - XP1 Reactor Reactor Reactor 3 3 3 Proportioning Proportioning Systems, Systems, E E E - - - XP1 Reactor Reactor Proportioning Systems, U.S. U.S. U.S. Metric Metric Metric 3000 psi Maximum Fluid Working Pressure 207 bar, 20.7 MPa Maximum Fluid Temperature 180 °F...
- Page 61 Technical Specifications Reactor Reactor Reactor E E E - - - XP2 Reactor Reactor 3 3 3 Proportioning Reactor Proportioning Systems, Proportioning Systems, Systems, E E E - - - XP2 U.S. Metric Metric Metric U.S. U.S. Maximum Fluid Working Pressure 3500 psi 241 bar, 24.1 MPa Maximum Fluid Temperature...
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Page 62: California Proposition 65
California Proposition 65 California California California Proposition Proposition Proposition 65 CALIFORNIA CALIFORNIA CALIFORNIA RESIDENTS RESIDENTS RESIDENTS WARNING: WARNING: Cancer and reproductive harm — www.P65warnings.ca.gov. WARNING: 3A8500E... -
Page 63: Components
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 64 For the latest information about Graco products, visit www.graco.com. For patent information, see www.graco.com/patents. To place place place an an order, order, contact your Graco Distributor or call to identify the nearest distributor. order, Phone: 612-623-6921 or or or Toll Toll Free: Free: 1-800-328-0211 Fax: Fax: 612-378-3505...
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