Graco 332636D User Manual

Operation

Reactor® 2 Elite Integrated

Proportioning System

Electric, Heated, Integrated Plural Component Proportioning System With Integrated Generator. For
spraying polyurethane foam and polyurea coatings. For professional use only. Not approved for use in
explosive atmospheres or hazardous locations. Not for outdoor use.

Important Safety Instructions. Read all warnings and instructions in
this manual. Save these instructions.

332636D

EN

PROVEN QUALITY. LEADING TECHNOLOGY.

Contents

Warnings ........................................................... 3

Important Isocyanate Information......................... 8

Models............................................................... 10

Approvals........................................................... 12

Accessories........................................................12

Supplied Manuals............................................... 13

Related Manuals ................................................ 13

Typical Installation, without circulation.................. 14

Typical Installation, with circulation ......................15

Component Identification..................................... 16

Generator .................................................... 18

Proportioner Control Panel ........................... 19

Air Compressor............................................ 20

Advanced Display Module............................21

Electrical Enclosure......................................26

Electrical Cabinet......................................... 27

Motor Control Module (MCM)........................ 28

Engine Control Module................................. 29

Load Center ................................................ 30

Temperature Control Module (TCM) Cable

Connections................................... 31

Circuit Breakers........................................... 32

Overview............................................................34

Setup ................................................................. 37

Locate Reactor ............................................ 37

Trailer Setup Guidelines............................... 38

Install Wall (optional) .................................... 39

Connect Battery ........................................... 41

Add Fuel ..................................................... 41

General Equipment Guidelines ..................... 42

Electrical Connections.................................. 42

Connect Feed Pumps................................... 42

Breathing Air................................................ 42

Connect Pressure Relief Lines...................... 43

Install Fluid Temperature Sensor .................. 43

Connect Heated Hose.................................. 43

Close gun fluid manifold valves A and

B ................................................... 44

Connect Whip Hose to Gun Or Gun Fluid

Manifold......................................... 44

Pressure Check Hose .................................. 44

Connect Remote Display Module..................44

Grounding ................................................... 45

Supply Wet Cups With Throat Seal Liquid

(TSL) .............................................46

Operation........................................................... 47

Initial System Setup ..................................... 47

Register and Activate the Graco Insite........... 48

Advanced Setup Screens.............................50

System 1.....................................................51

System 2.....................................................51

Recipes....................................................... 51

Run Mode ................................................... 53

Startup............................................................... 57

Fluid Circulation..................................................61

Circulation Through Reactor.........................61

Circulation Through Gun Manifold................. 62

Jog Mode....................................................62

Spraying ............................................................63

Spray Adjustments....................................... 64

Manual Hose Heat Mode .............................. 65

Shutdown...........................................................67

Pressure Relief Procedure .................................. 69

Flushing............................................................. 70

System Errors .................................................... 71

Troubleshoot Errors ..................................... 72

Clear Alarm .................................................72

Maintenance ...................................................... 73

Preventative Maintenance Schedule ............. 73

Wetcup........................................................73

Fluid Inlet Strainer Screen ............................ 73

Coolant Filter............................................... 73

Grease Circulation Valves ............................ 73

ISO Lubrication Level ................................... 73

Wiring Connections...................................... 73

Dust Protection............................................ 73

Coolant Levels ............................................. 73

Compressor Maintenance............................. 73

Air Compressor Oil Level .............................. 73

Clean Heat Sink Fins....................................74

Engine Maintenance .................................... 74

Fuel Tank....................................................75

Flush Inlet Strainer Screen ........................... 75

Pump Lubrication System............................. 76

USB Data........................................................... 77

USB Logs.................................................... 77

System Configuration Settings...................... 78

Download Log Files...................................... 79

Custom Language File ................................. 79

Upload Procedure ........................................ 80

Appendix A: Engine Control Module..................... 81

Dimensions........................................................84

Performance Charts............................................ 87

Technical Specifications...................................... 90

Graco Extended Warranty for Integrated

Reactor® 2 Components ....................... 93

2

332636D

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. Product-specific hazard symbols and warnings not covered in this section may appear 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

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin,
inhaled, or swallowed.

• Read MSDSs to know the specific hazards of the fluids you are us ing.

• Store hazardous fluid in approved containers, and dispose of it according to applicable
guidelines.

• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning
equipment.

CARBON MONOXIDE HAZARD

Exhaust contains poisonous carbon monoxide, which is colorless and odorless. Breathing
carbon monoxide can cause death.

• Donotoperateinanenclosedarea.

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury,
including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective
equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent
manufacturer.

332636D 3

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.

treatment

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• 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.

• Follow the
or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damage d parts immediately.

FIRE AND EXPLOSION HAZARD

.

Pressure Relief Procedure

when you stop spraying and before cleaning, checking,

Get immediate surgical

Flammable fumes, such as solvent and paint fumes, in
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 the work area. See

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless
they are antistatic or conductive.

•

Stop operation immediately

equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

if static sparking occurs or you feel a shock.Do not use

Grounding

work area

instructions.

canigniteorexplode.Tohelp

4

332636D

Warnings

WARNING

THERMAL EXPANSION HAZARD

Fluidssubjectedtoheatinconfinedspaces,includinghoses,cancreatearapidriseinpressure
due to the thermal expansion. Over-pressurization can result in equipment rupture and serious
injury.

• Openavalvetorelievethefluidexpansionduringheating.

• Replace hoses proactively at regular intervals based on your operating conditions.

PRESSURIZED ALUMINUM PARTS HAZARD

Use of fluids that are incompatible with aluminum in pressurized equipme nt 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.

• Many other fluids may contain chemicals that can react with aluminum. Contact your material
supplier for compatibility.

PLASTIC

Many solvents can degrade plastic parts and cause them to fail, which could cause serious
injury or property damage.

• Use only compatible water-based solvents to clean plastic structural or pressure-containing
parts.

•See
solvent manufacturer’s MSDSs and recommendations.

PARTS CLEANING SOLVENT HAZARD

Technical Data

in this and all other equipment instruction manuals. Read flu id and

332636D 5

Warnings

WARNING

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 rated
system component. See

• 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 distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure.

• Turn off all e quipment and follow the

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals
and create safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• 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 surfaces.

• 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.

Technical Data

Pressure Relief Procedure

in all equipment manuals.

when equipment is not in use.

BATTERY HAZARD

The battery may leak, explode, cause burns, or cause an explosion if mishandled.

• Only use the battery type specified for use with the equipment. See

• Battery maintenance must only be p erformed or supervised by personnel knowledgeable of
batteries and the required precautions. Keep unauthorized personnel away from battery.

• When replacing the battery, use the same lead-acid automotive battery, with 800 CCA
minimum, specified for use with the equipment. See

• Do not dispose of battery in fire. The battery is capable of exploding.

• Follow local ordinances and/ or regulations for disposal.

• Do not open or mutilate the battery. Released electrolyte has been known to be harmful to
the skin and eyes and to be toxic.

• Remove watches, rings, or other metal objects.

• Only use tools with in sulated handles. Do not lay tools or metal parts on top of battery.

MOVING PARTS HAZARD

Moving parts can pinch, cut 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

Technical Data

and disconnect all power sources.

Technical Data

.

.

6 332636D

Warnings

WARNING

ENTAGLEMENT HAZARD

Rotating parts can cause serious injury.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Do not wear loose clothing, jewelry or long hair while operating equipment.

• Equipment can start without warning. Before checking, moving, or servicing equipment,
follow the

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.

CALIFORNIA PROPOSITION 65

The engine exhaust from this product contains a chemical known to the State of California to
cause cancer, birth defects or other reproductive harm.

Pressure Relief Procedure

and disconnect all power sources.

332636D

7

Important Isocyanate Information

Important Isocyanate Information

Isocyanates (ISO) are catalysts used in two component materials.

Isocyanate Conditions

Spraying or dispensing materials containing
isocyanates creates potentially harmful mi sts,
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 providing sufficient
ventilation in the work area. If sufficient ventilation
is not available, a supplied-air respirator is required
for everyone in the work area.

To prevent contact with isocyanates, appropriate
personal protective equipment, including
chemically impermeable gloves, boots, aprons,
and goggles, is also required for everyone in the
work area.

Keep Components A and B Separate

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.

• Never use solvent on one side if it has been
contaminated from the other side.

Moisture Sensitivity of Isocyanates

Exposure to moisture (such as humidity) will cause
ISO to partially cure; forming 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

Material Self-Ignition

Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings
and material MSDS.

NOTICE

Partially cured ISO will reduce performance and
the life of all wetted parts.

• Always use a sealed container with a desiccant
dryerinthevent,oranitrogenatmosphere.

Never

store ISO in an open container.

• Keep the ISO pump wet cup or reservoir (if
installed) filled with appropriate lubricant. The
lubricant creates a barrier between the ISO and
the atmosphere.

• Use only moisture-proof hoses compatible with
ISO.

• Never use reclaimed solvents, which may
contain moisture. Always keep solvent
containers closed when not in use.

• Always lubricate threaded parts with an
appropriate lubricant when reassembling.

8 332636D

Important Isocyanate Information

Foam Resins with 245 fa Blowing Agents

Some foam blowing agents will froth at temperatures
above 90°F (33°C) when not under pressure,
especially if agitated. To reduce frothing, minimize
preheating in a circulation system.

Changing Materials

NOTICE

Changing the material types used in your
equipment requires special attention to avoid
equipment damage and downtime.

• When changing materials, flush the equipment
multipletimestoensureitisthoroughlyclean.

• Always clean the fluid inlet strainers after
flushing.

• Check with your material manufacturer for
chemical compatibility.

• When changing between epoxies and urethanes
or polyureas, disassemble and clean all fluid
components and change hoses. Epoxies often
have amines on the B (hardener) side. Polyureas
oftenhaveaminesontheB(resin)side.

332636D 9

Models

Models

Reactor 2 E-30i

All base systems include fluid inlet pressure and temperature sensors and Graco InSite™. For part numbers,
see Accessories, page 12.

Model

Base Machine
Maximum Fluid

Working Pressure
psi (MPa, bar)

Approximate Output
per Cycle (A+B) gal.
(liter)

MaxFlowRatelb/min
(kg/min)

Total System Load †
(Watts)

Voltage (phase)
Available Auxiliary

Current at Volts, 60
Hz*





No Air Compressor/Dryer

E-30i E-30i with heat E-30i E-30i with heat

272079 272080 272089 272090
2000 (13.8, 138) 2000 (13.8, 138) 2000 (13.8, 138) 2000 (13.8, 138)

0.0272 (0.1034) 0.0272 (0.1034) 0.0272 (0.1034) 0.0272 (0.1034)

30 (13.5) 30 (13.5) 30 (13.5) 30 (13.5)

7,400 11,600 13,500 17,700

240 VAC (1) 240 VAC (1) 240 VAC (1) 240 VAC (1)
52 Amps (240) 35 Amps (240) 22 Amps (240)

9 Amps (120)



With Air Compressor/Dryer

5 Amps (240)
9 Amps (120)

Fusion AP Package

(Gun Part No.)

Fusion CS Package

(Gun Part No.)

Probler P2 Package

(Gun Part No.)

Heated Hose
50 ft (15 m)

Heated Whip Hose
10 ft (3 m)



Total system watts used by system, based on
maximum heated hose length of 310 ft (94.5 m)
for each unit.

* Full load amps available for auxiliary equipment

when all bare-system components are operating
at maximum capabilities. Available auxiliary
current is based on 310 ft (94.5 m) of heated hose.
An additional 3.0 amps (240 VAC) of auxiliary
current is available for each 50 ft (15.2 m) section
of heated hose that is not used.

liary current at 120 VAC is available on CB08,

Auxi

e 1 (circuit breaker pin 2), line 2 current at 120

lin

is used by the air dryer (circuit breaker pin 4).

VAC



AP2079

(246102)



CS2079

(CS02RD)

P22079



(GCP2R2)

24Y240 24Y240 24Y240 24Y240

246055 246055 246055 246055

AP2080

(246102)

CS2080

(CS02RD)

P22080

(GCP2R2)

AP2089

(246102)

CS2089

(CS02RD)

P22089

(GCP2R2)



Available auxiliary current will be less when the
engine is de-rated for site altitude. Reduce the
Available Auxiliary Current in the chart by 2.5
Amps (240 VAC) per 1000 ft (300 m) elevation
increments. If the available auxiliary current is
less than zero, the system configuration may not
support the full load at that altitude.



Includes Complete Air Compressor/Dryer Kit
24U176.

Refer to Circuit Breaker Configuration Options,

page 33.



See Approvals, page 12.



Packages include gun, heated hose, and whip
hose.

AP2090

(246102)

CS2090

(CS02RD)

P22090

(GCP2R2)

10 332636D

Models

Reactor 2 E-XP2i

All base systems include fluid inlet pressure and temperature sensors and Graco InSite™. For part numbers,
see Accessories, page 12.

Model

Base Machine
Maximum Fluid Working Pressure psi

(MPa, bar)
Approximate Output per Cycle (A+B)

gal. (liter)
Max Flow Rate gal/min (l/min)

Total System Load † (Watts)
Voltage (phase)
Available Auxiliary Current at Volts, 60

Hz*





No Air Compressor/Dryer

E-XP2i with heat E-XP2i with heat

272081 272091
3500 (24.1, 241) 3500 (24.1, 241)

0.0203 (0.0771) 0.0203 (0.0771)

2.0 (7.6) 2.0 (7.6)
11,600 17,700
240 VAC (1) 240 VAC (1)
35 Amps (240) 5 Amps (240)



With Air Compressor/Dryer

9 Amps (120)

Fusion AP Package

(Gun Part No.)

Probler

(Gun Par

Heated H
50 ft (15

Heated
10 ft (3

P2 Package

t No.)

ose

m)

Whip Hose
m)



Total sy
maximum
for each

* Full load amps available for auxiliary equipment

when all bare-system components are operating
at maximum capabilities. Available auxiliary
current is based on 310 ft (94.5 m) of heated hose.
An additional 3.0 amps (240 VAC) of auxiliary
current is available for each 50 ft (15.2 m) section
of heated hose that is not used.

Auxiliary current at 120 VAC is available on line 1
(circuit breaker pin 2), line 2 current at 120 VAC is
used by the air dryer (circuit breaker pin 4).





stem watts used by system, based on

heated hose length of 310 ft (94.5 m)

unit.

AP2081

(246101)

P22081
(GCP2R1)

24Y241 24Y241

246055 246055

AP2091

(246101)

P22091

(GCP2R1)









ble auxiliary current will be less when the

Availa

is de-rated for site altitude. Reduce the

engine

ble Auxiliary Current in the chart by 2.5

Availa
Amps (2
increm
less th
suppor

Includes Complete Air Compressor/Dryer Kit
24U176.

Refer to Circuit Breaker Configuration Options,

page 33.

See Approvals, page 12.
Packages include gun, heated hose, and whip

hose.

40 VAC) per 1000 ft (300 m) elevation

ents. If the available auxiliary current is

an zero, the system configuration may not

t the full load at that altitude.

332636D

11

Approvals

Approvals

Intertek approvals apply to proportioning systems
without hoses.

Model

272079
272089

272080
272081
272090
272091

Proportioning System Approvals:

9902471

Conforms to ANSI/UL Std. 73

Certified to CAN/CSA Std.

C22.2 No. 68

Note

Heated hoses provided with a system or sold
individually are not approved by Intertek.

Accessories

Kit Number Description

15M483 Remote Display Module Protective

Covers (10 pack)
15V551
24K207 Fluid Temperature Sensor (FTS)

24K333
24K336 Hose Rack
24K337 Light Tower Kit
24L911 Pallet Support Kit
24M174
24U174 Remote Display Module Kit
24U176
24U177

Cables

ADM Protective Covers (10 pack)

with RTD

Fuel Line and Cable Extension Kit

Drum Level Sticks

CompleteAirCompressorKit

Feed Pump Shutdown Kit

9902471

rms to ANSI/UL Std. 499

Confo

fiedtoCAN/CSAStd.

Certi

C22.2

No. 88

121006

24N365

24N449

150 ft (45 m) cable (for remote

display module)

RTD Test Cables (to aide resistance

measurements)

50ft(15m)CANcable(forremote

display module)

12

332636D

Supplied Manuals

Supplied Manuals

The following manuals are shipped with the Reactor.
Refer to these manuals for detailed equipment
information.

Manuals are also available at www.graco.com.

Manual Description

332636 Reactor 2 Elite Integrated

Proportioning System, Operation

333093 Reactor 2 Elite Integrated

Proportioning System, Startup
Instructions

333094 Reactor 2 Elite Integrated

Proportioning System, Shutdown
Instructions

SEBU8311–02Perkins® Engine, Repair-Parts

Access at www.perkins.com. Go
to Service and Support/manuals.
Select engine family and type code
“GN”.

-

ST
15825–00

33227482

Mecc Alte Self-Regulating Alternator
Series NPE, Repair-Parts

Access at www.meccalte.com.
Select “meccalte” logo / Download
/ Instruction Manuals. Select NPE
instruction manual on page 5. Go to
Support and enter serial n umber for
Parts List and Help Videos.

Contact Mecc Alte for warranty and
service

Air Compressor, Operation/Mainte-
nance & Parts list.

Access at www.hydrovaneprod-
ucts.com. Go to Warranty & Service
tab and select “contact us” to
request manuals.

Refrigerated Air Dryer, Instruction
manual
Access from Service
Department (724) 746–1100 or
www.spx.com/en/hankison.

Related Manuals

The following manuals are for accessories used with
the Reactor.

Component Manuals in English:

Manuals are available at www.graco.com.

System Manuals

332637 Reactor 2 Elite Integrated

Proportioning System, Repair-Parts

Displacement Pump Manual

309577 Electric Reactor Displacement Pump,

Repair-Parts

Feed System Manuals

309572 Heated Hose, Instructions-Parts
309852

309815 Feed Pump Kits, Instructions-Parts
309827

Spray Gun Manuals

309550
312666
313213

Accessory Manuals

332733

3A1905

3A1906 Light Tower Kit, Instructions-Parts
3A1904 Fuel Tank/Battery Move Kit,

3A1903 Hose Rack, Instructions-Parts
332738

3A1907 Remote Display Module,

3A2574

Circulation and Return Tube Kit,
Instructions-Parts

Feed Pump Air Supply Kit,
Instructions-Parts

Fusion ™ AP Gun
Fusion ™ CS Gun
Probler P2 Gun

AirCompressorandAirDryerKit,
Instructions-Parts
Feed Pump Shutdown Kit,
Instructions-Parts

Instructions-Parts

Booster Heat Retrofit Kit,
Instructions-Parts

Instructions-Parts
Pallet Support Kit, Instructions-Parts

332636D 13

Typical Installation, without circulation

Typical Installation,
without circulation

Figure 1

* Shown exposed for clarity. Wrap with tape during operation.

A Reactor Proportioner
BHeatedHose
C Fluid Temperature Sensor (FTS)
D Heated Whip Hose
E
F
G Feed Pump Air Supply Lines
H

14

Fusion Spray Gun
Gun Air Supply Hose

Agitator Air Supply Line

J
K Feed Pumps
L Agitator
M Desiccant Dryer
NBleedLines
P
S Remote Display Module Kit (optional)

Fluid Supply Lines

Gun Fluid Manifold (part of gun)

332636D

Typical Installation, with circulation

Typical Installation, with circulation

Figure 2

* Shown exposed for clarity. W rap with tape during operation.

A Reactor Proportioner
BHeatedHose
C Fluid Temperature Sensor (FTS)
D HeatedWhipHose
E
F
G Feed Pump Air Supply Lines
H

332636D 15

Fusion Spray Gun
Gun Air Supply Hose

Agitator Air Supply Line

J
K Feed Pumps
L Agitator
MDesiccantDryer
P
R Recirculation Lines
S Remote Display Module (optional)

Fluid Supply Lines

Gun Fluid Manifold (part of gun)

Component Identification

Component Identification

Figure

3 Front View

BA
BB
DG Drive Gear Housing

DB Electrical Enclosure
EM Electric Motor
FA
FB
FM
GA Component A Pressure Gauge
GB Component B Pressure Gauge
GG Generator, page 18
HA
HB

Component A Pressure Relief Outlet
Compon

Component A Fluid Manifold Inlet
Component B Fluid Manifold Inlet
Reactor Fluid Manifold

Component A Hose Connection
Component B Hose Connection

ent B Pressure Relief Outlet

HC Heated Hose Electrical Connectors
MP
PA
PB

PC Prop
PT Pallet
SA Comp

SB Component B PRESSURE

SC Fl
TA

TB Component B Pressure Transducer

Main Power Switch
Component A Pump
Component B Pump (behind Electrical

Enclosure)

ortioner Control Panel, page 19

onent A PRESSURE

EF/SPRAY Valve

RELI

RELIEF/SPRAY Valve

uid Temperature Sensor (FTS) Cable

mponent A Pressure Transducer

Co

ehind gauge GA)

(b

(behind gauge GB)

16 332636D

Component Identification

Figure 4 Back View

CP Circulation Pump
EC Electrical Cord Strain Relief
FF

FH

FV
HE

Y-strainer (includes pressure
gauge, temperature gauge, and
pressure/temperature sensor)

Booster Fluid Heater (not included with all
models)

FluidInletValve(Asideshown)
Heat Exchangers (heat e xchanger coolant

loop)

HM

LR ISO Pump Lubricant Reservoir
MM Motor Control Module (MCM), page 28
SG Sight Glass
VA Component A Control Valve
VB Component B Control Valve
VC Bypass Control Valve

Temperature Control Module (TCM) Cable
Connections, page 31

332636D

17

Component Identification

Generator

Figure 5

AF Air Filter
BE
DF Diesel Fuel Filter
EA
EB
EE Engine
ED
ER Radiator
EX Exhaust
FD
FH Filter Housing
FJ Fuel Injector
FP Fuel Pump
FS Diesel Fuel Fill Cap

18 332636D

Battery (not supplied)

12V Charge Alternator
Engine Coolant Expansion Bottle

Engine Oil Dipstick

Fuel Shutoff Solenoid

FT Diesel Fuel Tank
GD Generator Power Distribution Box
GL Glow Plugs
HB
HE Heat Exchanger
HF
OD Oil Drain
OF Oil Filter
OL Oil Fill
OS Oil Pressure Switch
RC Engine Coolant Radiator Cap
RF Radiator Fan
ST Starter
TR
WS Over-Temperature Switch

Heat Exchanger Coolant Expansion Bottle

Heat Exchanger Coolant Fill Bottle

Coolant Temperature Sensor

Component Identification

Proportioner Control Panel

Figure 6

PD
PE
PF* Component A Feed Pump Air Outlet
PG* Component B Feed Pump Air Outlet
PH* Agitator Air Outlet
PJ* Gun Air Outlet

PK
PL

PM Gun Air Regulator
PN Component A Feed Pump Pressure Gauge
PP Component B Feed Pump and Agitator

PR

* Not for breathing air use.

Advanced Display Module (ADM), page 21
Engine Control Module, page 29

Component A Feed Pump Air Regulator
Component B Feed Pump and Agitator Air

Regulator

Pressure Gauge
GunPressureGauge

332636D 19

Component Identification

Air Compressor

Select models are supplied with an air compressor
and air dryer.

CA Air Compressor
CB
CC Air Compressor and Dryer On/Off Switch
CD Refrigerated Air Dryer
CE Air Dryer Drain Tube (bottom of refrigerated

CF Air Compressor Pressure Gauge

Power Box

air dryer; not shown)

Figure 7

20 332636D

Component Identification

Advanced Display Module

The ADM display shows graphic al and text
information related to setup and spray operations.

For detail on the display and individual screens, see

Run Mode, page 53, or Setup Mode.

Use the USB port on the ADM to download or upload
data. For more information about the USB data, see

USB Data, page 77.

NOTICE

To prevent damage to the softkey buttons, do not
press buttons with sharp objects such as pens,
plastic cards, or fingernails.

Figure 8 Front View

332636D

21

Component Identification

Table 1 : ADM Keys and Indicators

Key Function

Press to startup or shutdown the system.

Startup/Shu

Key and Indic

Soft Keys

Navigation Keys

Numeric Keypad

tdown

ator

Stop

Press to stop all proportioner processes. This Is not a safety o r emergency stop.

Press to select the specific screen or operation shown on the display directly next to
each key.

•

Left/Right Arrows:

•

Up/Down Arrows:

menu, or multiple screens within a function.

Use to input values.
Use to cancel a data entry field.

Usetomovefromscreentoscreen.

Usetomoveamongfieldsonascreen,itemsonadropdown

22

Cancel

Press to enter or exit Setup mode.

Setup

Press to choose a field to update, to make a selection, to save a selection or value, to
enter a screen, or to acknowledge an event.

Enter

332636D

Component Identification

Figure 9 Back View

CJ Flat Panel Mount (VESA 100)
CK Model and Serial Number
CL USB Port and Status LEDs
CM CAN Cable Connection

Table 2 ADM LED Status Descriptions

LED
System Status

USB Status (CL)

ADM Status (CN)

CN Module Status LEDs
CP Accessory Cable Connection
CR Token Access Cover
CS Battery Access Cover

Conditions

Green Solid Run Mode, System On
Green Flashing Setup Mode, System On
Yellow Solid Run Mode, System Off
Yellow Flashing

Green Flashing
Yellow Solid Downloading information to USB
Green and Yellow Flashing ADM is busy, USB cannot transfer

Green Solid
Yellow Solid Active Communication

Description

Setup Mode, System Off
Data recording in progress

informationwheninthismode
Power applied to module

Red Steady Flashing Software upload from token in

progress

Red Random Flashing or Solid

332636D 23

Module error exists

Component Identification

ADM Display Details

Power Up Screen

The following screen appears when the ADM is
powered up. It remains on while the ADM runs
through initialization and establishes communication
with other modules in the system.

Menu Bar

The menu
(The fol

bar appears at the top of each screen.

lowing image is only an example.)

System Mode

The current system mode is displayed at the lower
left of the menu bar.

Alarm/Deviation

The current system error is displayed in the middle of
the menu bar. There are four possibilities:

Icon Function

No Icon

Status

The current system status is displayed at the lower
right of the menu bar.

No information or no error has occurred
Advisory

Deviation
Alarm

Navigating the Screens

There are two sets of screens:

• The Run screens control spraying operations and
display system status and data.

• The Setup screens control system parameters and
advanced features.

Date and Time

The date and time are always displayed in one of
the following formats. The time is always displayed
as a 24-hour clock.

• DD/MM/YY HH:MM

• YY/MM/DD HH:MM

• MM/DD/YY HH:MM

Arrows

The left and right arrows indicate screen navigation.

Screen Menu

The screen menu indicates the currently active
screen, which is highlighted. It also indicates the
associated screens that are available by scrolling left
and right.

Press
screens. If the system has a password lock, the
Password screen displays. If the system is not locked
(password is set to 0000), System Screen 1 displays.

Press
Home screen.

Press the Enter soft key
function on any screen.

Press the Exit soft key

Use the other softkeys to select the function adjacent
to them.

on any Run screen to enter the Setup

on any Setup screen to return to the

to activate the editing

to exit any screen.

24

332636D

Icons

Screen Icons

Component Identification

Softkey Icons

These are frequently used icons on the screens.
The following descriptions explain wha t each icon
represents.

Icon Description

Component A

Component B

Estimated Supply Material

Hose Temperature

Jog Mode Speed

Engine Coolant Temperature

Pressure

Cycle Counter (press and
hold)

Advisory. See

System Errors, page 71 for

more information.

The following icons appear in the ADM, directly to
theleftorrightofthesoftkeywhichactivatesthat
operation.

Icon Function

Start Proportioner

Start and Stop Proportioner in Jog Mode

Stop Proportioner

Turn on specified heat zone.

Park component A pump

Enter Jog Mode. See Jog Mode, page 62

Cycle Counter

Reset

sandhold)

(pres
Select Recipe

Search

Move Cursor Left One Character

Move Cursor Right One Character

Deviation. See

System Errors, page 71 for

more information
Alarm. See

System Errors, page 71 for

more information

Toggle between upper-case, lower-case,
and numbers and special characters.

Backspace

ncel

Ca

Clear

Troubleshoot Selected Error

Increase value

Decrease value

Next screen

Previous screen

Return to first screen

332636D 25

Component Identification

Electrical Enclosure

AAA Temperature Control Module (TCM)

AAB Motor Control Module (MCM)

AAC Enclosure Fan

AAD Circuit Breakers

MP Main Power Switch

26 332636D

Electrical Cabinet

AAM Hose Breaker

AAN Transformer

AAP Load Center

Component Identification

AAS Fan

AAU Wiring Terminal Blocks

332636D

27

Component Identification

Motor Control Module (MCM)

Figure 10

Description

MB
1
2
3
4
5
6
7
8
9

Table 3 MCM Module LED (MB) Status Descriptions

LED Conditions Description
MCM Status

Module St
CAN Comm
Motor Temperature
Engine Coolant Temperature
Heat Exchanger A Temperature
Heat Exchanger B Temperature
A Pump Output Pressure
B Pump Output Pressure
A Fluid
BFlui

atus LEDs see LED Stat us Table

unication Connections

Inlet Sensor

d Inlet Sensor

Green Solid
Yellow Solid Active Communication
Red Steady Flashing Software upload from token in

10
11 Load Center
12
13 Not Used
14 Graco Insite
15
16

MCM Rotary Switch Positions

0=E-30i

1=E-XP2i

Accessor

Pump Cyc

Motor Power Output
Main Pow

yOutput

le Counter

™

er Input

Power applied to module

progress

Red Random Flashing or Solid

28 332636D

Module error exists

Component Identification

Engine Control Module

NOTICE

To prevent damage to the softkey buttons, do not
press buttons with sharp objects such as pens,
plastic cards, or fingernails.

For more information about the engine control module,
see Appendix A: Engine Control Module, page 81.

Icon Description Function

On Start Engine

Auto

Off Stop all system

Scroll Scroll through the

Page Select

Error Lamp Indicates error

Auto mode (not
used)

processes. Is
not a safety or
emergency stop.

instruments or
recorded events
on the currently
displayed page

Toggle between
the information
page and the error
log page

is present on
generator

Figure 11

332636D 29

Component Identification

Load Center

F3 Radiator Fan Fuse
F4
K1 Fuel Relay
K2
K3
K4 Radiator Fan Relay
MV

Load Center Power Fuse

Starter Relay
Glow Plug Relay

Manual Valve Switch

LED

D1

D2

D3

D4

D10 A Coolant Valve Red

D12 B Coolant Valve Blue

D14

D23

Related
Component

Fuel Shutoff
Solenoid (FS)

Starter (ST)
Glow Plugs

(GL)
Radiator Fan
(RF)

Bypass Coolant
Valve

Manual Valve
Switch (MV)

Color

Green

Red

Green

Green

Green

Red

ON-State
Description

Fuel shutoff
solenoid on the
engine is open.
Starter is
cranking.
Glow plugs are
heating.
Radiator fan is
on.
A-side (red)
coolant valve is
open.
B-side (blue)
coolant valve is
open.
Bypass coolant
valve is open.
Manual valve
switch is in the
ON position.

30 332636D

Temperature Control Module (TCM) Cable Connections

Component Identification

Figure 12

1 Power Input
2 Heater Overtemperature
3 CAN Communications Connections

4
5
6

Power Out (ISO)
Power Out (Res)
Power Out (Hose)

7

8

9

10 Hose T

ModuleStatusLEDs(see

Advanced Display Module (ADM), page 21,

Boost Heater A Temperature (ISO)

(CN) for conditions

Boost Heater B Temperature (RES)

emperature

332636D 31

Component Identification

Circuit Breakers

CM 24N750

T

24R754

MCM 24N953

P100 - Green/Y
P010 - Black
P020 - Red
P030 - Black
P040 - Red
P050 - Black
P060 - Red

P070 - Black
P090 - Green/Y
P080 - Red

ellow

ellow

ess
rn

a
r H

e

k
ea
Br

w
o

l

l

e
/Y

n
ee

r
G

­090

P

w
o

ll

e
/Y

n
ee

r
G

­00
P1

Disconnect

CT01

k
ac

- Bl
00
K1

w
o

ll

e
/Y

n
ee

r
G

­0

P11

ed

- R
0

K11

P110 - Green/Y

k

wn
o

lac

lue

B

Br

B

ellow

FAN

Red
Black

PS1

1

NEUTRAL

0
B
C

2

0
B
C

03

il

B

a

C

4
0
B
C

r DIN R

e

k

B11T
T

ea

2
1

Br

B

05
B
C

6

0
B
C

7

0
B
C

08
B
C

A

P010 - Black
P020 - Red

te

- Whi

0

K12

P030 - Black
P040 - Red
P050 - Black
P060 - Red

P070 - Black
P080 - Red

5

A
5
1

A
5
1

A
30

A
0

2

A2
40

A
0

15 A

Blulkhead Connector

Figure 13 Circuit Breaker Connections Inside
Electrical Enclosure (DB)

Note

Not all wires are shown.

Ground Bar

Ref. Size Component

CB01

CB02
CB03
CB04
CB05

Ground T

erminal

5A

Power Supply, Fan,

Coolant Pump
15 A Boost Heat A
15 A Boost Heat B
30 A Hose Heat
20 A

Motor Control

CB06* 40 A Air Compressor/Open
CB07*
CB08*

20 A
15 A

Open

Air Dryer/Open

* Contact Graco for circuit breaker options.

32 332636D

Component Identification

Circuit Breaker Configuration Options

Improper configuration can result in electric shock.
All electrical wiring must be done by a qualified
electrician and comply with all local codes and
regulations. See page 27 and 28 for correct circuit
breaker configuration.

Figure 14 Circuit Breakers Ins ide Proportioner
Cabinet

Ref. Size Component

CB20

Figure 15 Circuit Breakers Inside Alternator
Assembly

Ref. Size Component

CB10 90 A 120/240V Alternator

50 A Heated Hose

See Circuit Breakers, page 32 for recommended
circuit breaker configuration.

Sub-Panel Options

Some customer changes are acceptable to
accommodate larger loads from auxiliary equipment
or a sub-panel. It is suggested that circuit breakers
CB07 be substituted to accommodate larger loads
or a sub-panel. The total auxiliary equipment
loads added to the configuration must be limited
to the system’s available auxiliary current. See

Models, page 10, for available auxiliary current at

240V, 60Hz.

See the Reactor repair manual for optional circuit
breakers and their current ratings. Circuit breakers
used must meet UL489 specifications.

Auxiliary Wiring Diagram Options.

The generator supplies power in a 3-wire,
single-phase, mid-point neutral wiring configuration.
For 240 VAC loads, wire the load across the output
terminals of the circuit breaker. For 120 VAC loads,
wire the load between the neutral terminal blocks
below the circuit breaker to one pole of the circuit
breaker. See electrical diagrams in Reactor repair
manual.

Disable Booster Heat

Disable booster heat to allow use of power for
additional auxiliary power.

To replace or repair a circuit breaker, see the Reactor
2 Integrated Repair manual.

332636D 33

Overview

Overview

The system uses two coolant loops to use heat
released from the engine to heat the A and B
component material to the target temperatures
defined on the ADM (PD).

The engine coolant loop (gray) circulates heated
coolant from the engine (EE), through the heat
exchanger (HE), radiator (ER), and back to the
engine. Coolant in the proportioner c oolant loop
(black) captures heat from the engine coolant loop
inside the heat exchanger (HE) near the radiator.

Figure 16 Engine Coolant Loop and Proportioner
Coolant Loop

34 332636D

Overview

The proportioner coolant loop circulates coolant
through secondary heat exchangers (HE) located
on the back of the proportioner to heat the A
and B component material before the material is
pressurized in the proportioner pumps (PA, PB). After
the A and B material has been heated in the heat
exchangers, the material enters the fluid manifold
(FM) and heated hose.

For models with a booster heater, the A and B
material enters the booster heater after the material
is pressurized in the proportioning pumps to heat the
material higher than 140°F (60°C).

Figure 17 A and B Component Material Flow

332636D 35

Overview

Coolant only flows through the secondary heat
exchangers when the heat exchanger control valves
(VA, VB) are open and the A and B component
temperatures are below the target temperatures set
on the ADM. See Fig 18.

When the control valves (VA, VB) close, the A
and B material has reached target temperature.
Coolant flows through the bypass control valve (VC),
circulation pump (CP), sight glass (SG), proportioner
coolant fill bottle (HF), and back to the heat exchanger
in the engine coolant loop. See Fig. 19.

Figure 1
Valves O

8 Proportioner Coolant Loop — A and B

pen (heating material)

Figure 19 Proportioner Coolant Loop — A and B
Valves Closed (not heating material)

36 332636D

Setup

Setup

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.

Do not remove or separate the proportioner, engine
assembly, or power distribution box from the pallet.
Failure to leave the component mounting intact will
cause heating efficiency degradation, and potential
unsafe wiring and grounding.

Locate Reactor

1. Install hose rack, if ordered. See manual 3A1903
for detailed instructions.

2. Locate Reactor on a level surface that is
nonporous and diesel resistant, such as diamond
plate.

Note

3. Do not expose Reactor to rain or below 20°F
(-7°C).

NOTICE

To ensure the heat exchanger control valves
open and close properly, do not store Reactor
below 20°F (-7°C).

4. If a wall will be installed between the proportioner
and generator, remove the fuel tank and battery
bracket. See Trailer Setup Guidelines, page 38.

5. To mount in a trailer, use forklift to move Reactor
by inserting the forks through the Reactor pallet
frame. It is recommended to lift from the engine
side. Bolt pallet directly to trailer frame.

Note

Use Pallet Support K it 24L911 (rollers not
included) to relocate pallet to mounting
location when forks are unavailable. See
kit manual for instructions.

NOTICE

Keep the vent holes in the bottom of the
proportioner cabinet open. Make sure there is
unobstructed incoming air for the cooling fan at the
top of the proportioner cabinet that blows air up into
the electric motor. Failure to provide unobstructed
incoming air can cause the motor to overheat.

Leave at least 1 ft. (0.3m) distance from
the engine side of the pallet to any wall
for engine maintenance access.

332636D 37

Setup

Trailer Setup Guidelines

Route exhaust system away from combustible
materials to prevent materials from igniting or gas
recirculation into a wall, ceiling, or a concealed
space. Provide exhaust system guards to prevent
burns.

NOTICE

Provide recommended size louvers. Failure to do
so can damage the engine and void the engine
warranty.

Exhaust pipes that pass through flammable ceilings
must be guarded by vented metal thimbles that
extend at least 9 in. (228.6 mm) below and above
the roof and are at least 6 in. (152.4 mm) i n diameter
larger than the exhaust pipe.

Exhaust pipes that pass through flammable walls
must be guarded by either:

2. Provide radiator exhaust for Reactor. Use a 400

2

in.

(258, 0 6 4 mm2) minimum louver.

3. Provide air duct to connect radiator exhaust to
louver.

4. Provide a 400 in.
air intake louver near the generator.

5. Remove red exhaust cap.

6. Provide a minimum 2 in. (50.8 mm) diameter
engine exhaust outlet with flexible pipe element.
Provide rain cap, or equivalent routing, to prevent
moisture from entering the metal exhaust pipe.

2

( 258,064 mm2) minimum fresh

• Metal ventilated thimble at least 12 in. (305 mm)
larger than the diameter of the exhaust pipe.

• Metal or other approved fireproofing materials
that provides at least 8 in. (203 mm) of insulation
between the exhaust pipe and flammable material.

Exhaust pipes not covered above must have at least
9 in. (228.6 mm) of clearance from the outside of the
exhaust pipe to adjacent flammable materials.

1. Provide sufficient lighting to safely operate and

maintain system equipment.

Radiator Exhaust and Air Intake Louvers
Figure 20

38 332636D

Setup

Install Wall (optional)

It is only possible to install a wall between the
proportioner and generator for systems without an air
compressor.

Benefits:

• Temperature condition the trailer space where
chemical is stored. Check with chemical
manufacturer for chemical storage temperatures.

• Reduce noise for the operator while the Reactor
is running.

The supplied fuel lines and battery cable may need
to be replaced if a wall i s installed between the
proportioner and generator. Purchase the Fuel Line
and Battery Cable Extension Kit 24K333.

1. If necessary drain coolant from system. See

Reactor repair manual for complete instructions.
Coolant lines do not need to be disconnected to
install a wall.

Note

Battery must be connected to starter to
drain coolant from system.

2. Remove screws and battery bracket from the

pallet.

3. Remove fuel tank from the pallet.

a. Remove the mounting screws, supports, and

spacers.

b. Disconnect inlet and outlet fuel lines from the

fuel tank.

c. Use two people to lift fuel tank off of the pallet

and place where the fuel fill spout is easily
accessible.

Note

Do not mount fuel tank in front of
the generator air intake or where it
will limit opening and access to the
electrical enclosure (DB).

4. Install wall (IW) where the fuel tank was located.
Ensure there is at least 1.25 in. (31.75 mm)
between the wall and exhaust muffler. See

Fig. 22.

Note

To prevent an air pocket from forming
inside the coolant lines between the
proportioner and generator, ensure
there is a constant rise in elevation if
the coolant lines are adjusted. Failure
tohaveaconstantriseinelevationwill
reduce heating efficiency. See Fig. 23.

Remove Battery Bracket and Fuel Tank
Figure 21

5. Reconnect inlet and outlet fuel lines.

6. Install spacers, supports, and screws through
the fuel tank and tighten to the floor. Torque to
40 ft-lbs (54 N•m).

7. Place battery bracket over fuel tank or near the
Reactor. Remove existing battery cables from
engine and replace with the cables provided from
the fuel line and battery cable extension kit.

8. Install mounting bolts through battery bracket and
tighten to the floor. Torque to 40 ft-lbs (54 N•m ).

Note

Pads under the battery bracket help
stabilize the fuel tank during operation.

332636D 39

Setup

Figure 22 Top View With Wall

Figure 23 Side View With Wall

40 332636D

Connect Battery

Improper battery installation or maintenance
may result in electric shock, chemical burns,
or explosion. Battery maintenance must only
be performed or supervised by personnel
knowledgeable of batteries and the required
precautions. Keep unauthorized personnel away
from batteries.

See Technical Specifications, page 90 for battery
requirements and recommended battery size.

1. Secure battery (not supplied) to bracket with
strap.

Setup

Engine Starter Connections
Figure 25

3. Cover battery terminals with plastic caps (PC)
attached to supplied battery cables.

4. Verify battery was connected properly by
pressing OFF

(PE) to “wake up” the controller screen. Do not
attempt to start the engine until all Setup steps
are complete. See Repair manual if engine
control module does not light up.

on the engine control module

Add Fuel

Battery Connections
Figure 24

2. Connect battery cable from the engine starter
(ST) and chassis to the battery. Connect the
black cable to battery negative (-) and the red
cable to battery positive (+).

NOTICE

Always connect the red battery cable to battery
positive (+) and the black battery cable to the
battery negative (-). Failure to properly connect
the battery cable to the battery will damage the
fusible link when the engine control module is
turned ON. Do not bypass the fus ible link when
damaged. The fusible link prevents damage
to other system components. See the system
repair manual for repair instructions.

1. Remove fuel cap (FS) and fill fuel tank with n o
more than 20 gallons (75 liters) of diesel fuel.
Replace cap. See Perkins engine manual for
approved diesel fuels.

2. Squeeze prime bulb (P) to prime engine. Press
the prime bulb repeatedly until fuel begins to
return to the fuel tank.

332636D

Figure 26

41

Setup

General Equipment Guidelines

Maintain and inspect the generator, air compressor,
and other equipment per the manufacturer
recommendations to avoid an unexpected shutdown.
Unexpected equipment shutdown will cause voltage
fluctuations that can damage electrical equipment.

Electrical Connections

Connect air compressor, breathing air, and auxiliary
power electrical connections to the specified circuit
breakers. See Circuit Breakers, page 32.

1. Remove one or more knock-outs on side
of electrical enclosure, as required, and
route wires through for air compressor,
breathing air, and auxiliary equipment. See

Circuit Breaker Configuration Options, page 33,

for more information.

Connect Feed Pumps

For illustrations of a system with feed pumps, see

Typical Installation, with circulation, page 15 and
Typical Installation, without circulation, page 14.

1. Install feed pumps (K) in component A and B
supply drums.

2. Seal component A drum and use desiccant dryer
(M) in vent.

3. Install agitator (L) in component B drum, if
necessary.

4. Connect supply hoses from feed pumps to the
component A and component B material inlets
on the system. Ensure A and B inlet valves are
closed.

5. Connect air lines to proportioner. Ensure
components are properly connected to correct
location.

Ref Air Outlet

PF A Pump
PG
PH Agitator
PJ Gun

Note

Agitator air supply (PH) includes a small
internalrestrictionorificetolimittheair
flow to minimize air compressor load.
Maximum supplied air flow is 2.0 scfm
(0.1 m3/min) at 100 psi (0.7 MPa, 7 bar).
Designed for use with Twistork agitator

224854. Do not use the agitator air outlet
(PH) for any other component.

BPump

Breathing Air

42

Breathing the air from the compressed air supply
can cause serious injury if inhaled.

• Only use an independent and approved
breathing air system with adequate air flow to
provide clean breathable air.

Note

Supply hoses from feed pumps should
be 3/4 in. (199 mm) ID.

332636D

Setup

Connect Pressure Relief Lines

Do not operate Reactor without all covers and
shrouds in place.

1.

Recommended:

hose (R) to relief fittings (BA, BB) of both
PRESSURE RELIEF/SPRAY valves. Route
hose back to component A and B drums. See

Typical Installation, with circulation, page 15.

2.

Alternately:

in grounded, sealed waste containers (H). See

Typical Installation, without circulation, page 14.

Connect high pressure

Secure supplied bleed tubes (N)

Install Fluid Temperature Sensor

The Fluid Temperature Sensor (FTS) is supplied.
Install FTS between main hose and whip hose. See
Heated Hose manual for instructions.

2. Assemble heated hose sections, FTS, and whip
hose.

3. Connect A and B hoses to A and B outlets on
Reactor fluid manifold (FM). Hoses are color
coded: red for component A (ISO), blue for
component B (RES). Fittings are sized to prevent
connection errors.

Note

Manifold hose adapters (HA, HB) allow
use of 1/4 in. and 3/8 in. ID fluid hoses.
To use 1/2 in. (13 mm) ID fluid hoses,
remove adapters from fluid manifold and
install as needed to connect whip hose.

Connect Heated Hose

See Heated Hose manual for detailed instructions on
connecting heated hoses.

Note

TheFTS(C)andwhiphose(D)mustbeused
with heated hose. Hose length, including
whip hose, must be 60 ft (18.3 m) minimum.

NOTICE

Apply grease on all system and hose fluid fittings.
This lubricates the threads and prevents mate rial
from hardening on the threads.

1. Turn main power switch OFF .

Figure 27

4. Connect cables (C). Connect electrical
connectors (V). Follow procedures in heated
hose manual. B e sure cables have slack
when hose bends. Wrap cable and electrical
connections with electrical tape.

332636D 43

Setup

5. Connect quick-disconnect pin fitting to 4 ft air
hose, shipped loose. Connect other hose end to
the gun air hose in the heated hose bundle. Push
pin fitting into the lowest air panel outlet (PJ).

Figure 28

Close gun fluid manifold valves A and
B

Connect Whip Hose to Gun Or Gun Fluid Manifold

See hose manual for proper connections.

Pressure Check Hose

See hose manual. Pressure check for leaks. If
no leaks, wrap hose and electrical connections to
protect from damage.

Connect Remote Display Module

See Remote Display Module kit manual for
installation instructions.

44

332636D

Grounding

The equipment must be grounded to reduce the
risk of static sparking and electric shock. Electric
or static sparking can cause fumes to ignite or
explode. Improper grounding can cause electric
shock. Grounding provides an escape wire for the
electric current.

•

Reactor System:

an appropriately sized conductor to the trailer
or vehicle chassis or, if stationary, to true earth
ground. Remove bolt and braided cable from
pallet. Install grounding cable terminated with a
ring terminal (cable and terminal not supplied)
under braided cable. Reinstall bolt and torque
to minimum 25 ft-lbs (34 N∙m). An alternate
grounding location is to the ground bar in the
electrical enclosure. Follow all National, State, and
Local safety and fire codes.

System must be grounded with

•

Spray gun:

See Install Fluid Temperature Sensor, page 43.
Do not disconnect ground wire or spray without
whip hose.

•

Fluid supply containers:

•

Object being sprayed:

connect whip hose ground wire to FTS.

follow your local code.

follow your local code.

Setup

•

Solvent pails used when flushing:

code. Use only metal pails, which are conductive,
placed on a grounded surface. Do not place pail
on a nonconductive surface, such as paper or
cardboard, which interrupts grounding continuity.

•

To maintain grounding continuity when flushing or
relieving pressure,

firmly to the side of a grounded
trigger gun.

hold a metal part of spray gun

follow your local

metal

pail, then

332636D 45

Setup

Supply Wet Cups With Throat Seal Liquid (TSL)

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 during operation.

To prevent the pump from moving, turn the main
power switch OFF.

•

Component A (ISO) Pump:

filled with clean Graco Throat Seal Liquid (TSL),
Part 206995. Wet-cup piston circulates TSL
through wet-cup, to carry away isocyanate film on
displacement rod.

Keep reservoir (R)

•

Component B (Resin) Pump:

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.

Component B Pump

Check felt washers

Figure 30

Figure 29 Component A Pump

46 332636D

Operation

Operation

1. Turn the main power switch ON. The Graco logo

will display until communication and initialization
is complete.

2. Press the on/off button .

3. Verify the machine is active and the System
Status LED is illuminated green, see

Advanced Display Module (ADM), page 21.If

the System Status LED is not green, press the
ADM Power On/Off (A) button

Status LED will illuminate yellow if the machine
is disabled.

. The System

Initial System Setup

Perform the following tasks to fully setup your system.

1. Select pressure for the Pressure Imbalance
Alarm to activate. See System Screen , page 51.

2. Enter, enable, or disable recipes. See

Recipes Screen, page 56.

3. Set general system settings. See

Advanced Screen 1 — General, page 50.

4. Set units of measure. See

Advanced Screen 2 — Units, page 50.

5. Set USB settings. See

Advanced Screen 3— USB, page 50.

6. Set target temperatures and pressure. See

Targets, page 53.

7. Set component A and component B supply
levels. See Maintenance, page 54.

8. Ensure engine is at operating temperature on the
home screen.

332636D

47

Operation

Register and Activate the Graco Insite

1. Go to www.GracoInSite.com, click on “InSite
Login, then follow the instructions on the screen.

2. Find and record the 15 digit serial number from
the cellular box below.

Serial No.

Verify Module Status

To check the status of the cellular module, locate the status LEDs on the module then refer to the following
chart.

LED Status Description

Green flashing Finding GPS location
Green solid GPS location identified
Orange flashing Cellular connection in process
Orange solid Cellular connection established
Green and orange off Reactor power is OFF

48 332636D

Operation

Setup Mode

The ADM will start in the Run screens at the Home screen. From the Run screens, press to access the
Setup screens. The system defaults with no password, entered as 0000. Enter the current password then

press

.Press to navigate through the Setup Mode screens.

Set Password

Set a password to allow Setup screen access, see Advanced Screen 1 — General, page 50.Enterany
number from 0001 to 9999. To remove the password, enter the current password in the Advanced Screen –
General screen and change the password to 0000.

From the Setup screens, press to return to the Run screens.

332636D 49

Operation

Advanced Setup Screens

Advanced setup screens enable users to set units, adjust values, set formats, and view software information
for each comp
Advanced setup screen, press

to exit edit mode.

Note

Users must be out of edit mode to scroll
through the Advanced setup screens.

onent. Press

to scroll through the Advanced setup screens, Once in the desired

to access the fields and make changes. When changes are complete press

Advanced Screen 1 — General

Use this screen to set the language, date format,
current date, time, setup screens password (0000 –
for none) or (0001 to 9999), and screen saver delay.

Advanced Screen 3 — USB

Use this screen to disable USB downloads/uploads,
disable USB log errors, enter the maximum number
of days to download data, and how frequently USB
logs are recorded. See USB Data, page 77.

Advanced Screen 4— Software

Advanced Screen 2 — Units

Use this screen to set the temperature units, pressure
units, volume units, and cycle units (pump cycles or
volume).

This screen displays the software part number and
software version for the Advanced Display Module,
USB Configuration, Motor Control Module, and
Temperature Control Modules.

50 332636D

Operation

System 1

Use this screen to set the activation pressure for the
Pressure Imbalance Alarm and Deviation, enable or
disable diagnostic screens, set the maximum and
minimum drum volume, and enable drum alarms.

System 2

Use this screen to enable Manual Hose Mode and
inlet sensors, as well as setting the inlet sensor
low pressure alarm and low temperature deviation.
Manual Hose Mode disables the hose temperature
RTD sensor so the system can operate if the sensors
were to malfunction. Default settings are 10 psi (0.07
MPa, 0.7 bar) for low inlet pressure alarm and 50˚F
(10˚C) for low inlet temperature deviation.

Recipes

Use this screen to add recipes, view saved recipes,
and enable or disable saved recipes. Enabled
recipes can be selected at the Home Run Screen. 24
recipescandisplayedonthethreerecipescreens.

332636D 51

Operation

Add Recipe

1. Press and then use to select a
recipe field. Press

(maximum 16 characters). Press
old recipe name.

to enter a recipe name

to clear the

2. Use to highligh
number pad to enter a value. Press

t the next field and use the

to save.

Enable or Disable Recipes

1. Press and then use to select the
recipe that needs to be enabled or disabled.

2. Use
Press

to highlight the enabled check box.

to enable or disable the recipe.

52 332636D

Operation

Run Mode

The ADM will start in the Run screens at the “Home” screen. Press to navigate through the Run
Mode screens. .

Or press

to access the Setup screens.

Home — System Off

This is the home screen when the system is off.
This screen displays actual temperatures, actual
pressures at the fluid manifold, jog speed, coolant
temperature, and number of cycles.

Home — System Active

When the system is active, the home screen displays
actual temperature for heat zones, actual pressures
at the fluid manifold, coolant temperature, jog speed,
the number of cycles, along with all associated
control soft keys.

Use this screen to turn on heat zones, view
coolant temperature, start the proportioner, stop the
proportioner, park the component A pump, enter jog
mode, and clear cycles.

Home — System With Error

Active errors are shown in the status bar. The error
code, alarm bell, and description of the error will
scroll in the status bar.

1. Press

2. See Troubleshoot Errors, page 72 for corrective

action.

to acknowledge the error.

Targets

Usethisscreentodefinethesetpointsforthe
A Component Temperature, B Component
Temperature, heated hose temperature, and
pressure.

Maximum A and B temperature for systems without
booster heat:

Maximum A and B temperature for systems with
booster heat:

Maximum heated hose temperature:

above the highest A or B temperature setpoint or
180°F (82°C).

Note

If the remote display module kit is used,
these setpoints can be modified at the gun.

150°F (65°C)

180°F (82°C)

10°F (5°C)

332636D 53

Operation

Maintenance

Use this screen to view daily and lifetime cycles or
gallons that have been pumped and g allons or liters
remaining in the drums.

The lifetime value is the number of pump cycles or
gallons since the first time the ADM was turned on.

The daily value automatically resets at midnight.
The manual v alue is the counter that can be manually
reset. Press

and hold to reset manual counter.

All events and errors listed on this screen can be
downloaded on a USB flash drive. To download logs,
see Download Log Files, page 79.

Cycles

This screen shows daily cycles and gallons that have
been sprayed for the day.

All information listed on this screen can be
downloaded on a USB flash drive.

Events

This screen shows the date, time, event code, and
description of all events that have occurred on
the system. There are 10 pages, each holding 10
events. The 100 most recent events are shown. See

System Events

for event code descriptions.

54 332636D

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

EACX
EADA
EADB
EADH
EAPX
EARX
EAUX
EB0X
EBDA
EBDB
EBDH
EBPX
EBRX
EBUX
EC0X
ECDA

ECDB
ECDH
ECDP
ECDX

EL0X

EM0X

EP0X
EQU1
EQU2
EQU3
EQU4
EQU5

ER0X
EVUX

Recipe Selected
Heat On A
Heat On B
Heat On Hose
Pump On
Jog On
USB Drive Inserted
ADM Red Stop Button Pressed
Heat Off A
Heat Off B
Heat Off Hose
Pump Off
Jog Off
USB Drive Removed
Setup Value Changed
A Temperature Setpoint Changed
B Temperature Setpoint Changed
Hose Temperature Setpoint Changed
Pressure Setpoint Changed
Recipe Changed
System Power On
System Power Off
Pump Parked
System Settings Downloaded
System Settings Uploaded
Custom Language Downloaded
Custom Language Uploaded
Logs Downloaded
User Counter Reset
USB Disabled

332636D 55

Operation

Errors

This screen shows the date, time, error code, and
description of all errors that have occurred on the
system.

All errors listed on this screen can be downloaded on
a USB flash drive.

Job Data

Recipes

Use this screen to add recipes, view saved recipes,
and enable or disable saved recipes. Enabled
recipes can be selected at the Home Run Screen. 24
recipes can displayed on the three recipe screens.

Use this screen to enter a job name or number.

56 332636D

Startup

Startup

To prevent serious injury, only operate Reactor
with all covers and shrouds in place.

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.

1. Check generator fuel level.

Running out of fuel will cause v oltage fluctuations
that can damage electrical equipment.

3. Check fluid inlet filter screens.

Before daily startup, ensure that the
fluid inlet screens are clean. See

Flush Inlet Strainer Screen, page 75.

A

B

C

D

4. Check ISO lubrication reservoir.

Check level and condition of ISO lube daily. See

Pump Lubrication System, page 76.

2. Check coolant levels.

Inspect the level of coolant inside the engine
coolant expansion bottle (EB) and heat
exchanger coolant expansion bottle (HB).

HOT

COLD

HOT

COLD

5. Confirm main power switch is OFF before starting
generator.

332636D 57

Startup

6. Press start button on the engine control
module twice to start the generator. Verify
voltages are displayed on engine control module
before moving to next step.

The controller will automatically begin glow plug
warming and crank operations. Allow engine to
reach full operating speed.

Note

Engine will not start if main power switch
is in the ON position.

8. For first startup of new system, set system
settings on ADM in Setup Mode.

See Initial System Setup, page 47.

9. For first startup of new system, adjust air settings
to zero:

a. Close the main air shutoff valve (CK).

b. Ensure all three air regulators are turned fully

counterclockwise.

7. Turn main power switch ON.

The ADM will display the following screen until
communication and initialization is complete.

58 332636D

Startup

10. Start the air compressor, air dryer, breathing
air, and other accessories. For systems with a
supplied air compressor: start the air compressor
by pressing start on the air c ompressor START
box (CB).

11. Open the main air shutoff valve (CK).

Circulation Through Reactor, page 61.

Ifyouneedtocirculatematerialthrough
theheatedhosetothegunmanifold,see

Circulation Through Gun Manifold, page 62.

d. Turn both PRESSURE RELIEF/SPRAY

valves (SA, SB) to SPRAY

e. Adjust A and B feed pump air regulators to

desired air pressure, on front of proportioner,
to start the feed pumps. Do not exceed 130
psi (0.2 MPa, 2 bar) to the A and B feed
pumps.

f. Open fluid inlet valves (FV). Check for leaks.

.

12. For first startup of new system, adjust all three air
regulators to desired pressures.

13. For first startup of new system, load fluid with
feed pumps.

a. Check that all

See Setup, page 37.

b. If an agitator is used, open the agitator’s air

inlet valve.

c. If you need to circulate fluid through the

system to preheat the drum supply, see

Setup

steps are complete.

Cross-contamination can result in cured
material in fluid lines which could cause
serious injury or damage equipment. To
prevent cross-contamination:

•

Never

component B wetted parts.

• Never use solvent on one side if it has
been contaminated from the other side.

Always provide two grounded waste
containers to keep component A and
component B fluids separate.

interchange component A and

332636D 59

Startup

g. Hold gun fluid manifold over two grounded

waste containers. Open fluid valves A and B
until clean, air-free fluid comes from valves.
Close valves.

The Fusion AP gun manifold is shown.

Thermal expansion can cause
overpressurization, resulting in equipment
rupture and serious injury, including fluid
injection. Do not pressurize system when
preheating hose.

a. Press to turn on hose heat zone.

14. Press

15. Preheat the system:

This equipment is used with heated fluid which
can cause equipment surfaces to become very
hot. To avoid severe burns:

• Do not touch hot fluid or equipment.

• Do not turn on hose heat without fluid in
hoses.

• Allow equipment to cool completely before
touching it.

• Wear gloves if fluid temperature exceeds
110°F (43°C).

to activate the system.

b. Wait for the engine to reach operating

temperature, indicated when the black arrow
is under the green area of the temperature
bar. The radiator fan will turn on when
operating temperature is reached.

c. Wait for the hose to reach set point

temperature.

d. Press to turn on A and B heat zones.

60 332636D

Fluid Circulation

Fluid Circulation

Circulation Through Reactor

NOTICE

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. Low temperature
rise deviation errors may result.
To circulate through gun
manifold and preheat hose, see

Circulation Through Gun Manifold, page 62.

1. Follow Startup, page 57.

3. Set PRESSURE RELIEF/SPRAY valves (SA,

SB) to PRESSURE RELIEF/CIRCULATION

4. Set temperature targets. See Targets, page 53.

5. Press
AandBtemp

Jog Mode, p

jog mode.

6. Press

7. Turn on the A and B heat zones. Wait until the
fluid inlet valve temperature gauges (FV) reach
the minimum chemical temperature from the
supply drums.

rculate fluid in jog mode until

to ci

eratures reach targets. See

age 62 for more information about

to turn on the hose heat zone.

.

To avoid injection injury and splashing, do not
install shutoffs downstream of the PRESSURE
RELIEF/SPRAY valve outlets (BA, BB). The
valves function as overpressure relief valves

when set to SPRAY
open so valves can automatically relieve
pressure when machine is operating.

2. See Ty
Route
comp
rate
equi

pical Installation, with circulation, page 15.

circulation lines back to respective

onent A or B supply drum. Use hoses

d at the maximum working pressure of this

pment.

.Linesmustbe

8. Exit jog mode.

9. Set PRESSURE RELIEF/SPRAY valves (SA,
SB) to SPRAY

.

332636D 61

Fluid Circulation

Circulation Through Gun Manifold

NOTICE

To prevent equipment damage, do not circulate
fluid containing a blowing agent without consulting
with your material supplier regarding fluid
temperature limits.

Note

Circulating fluid through the gun manifold
allows rapid preheating of the hose.

1. Install gun fluid manifold (P) on accessory
circulation kit (CK). Connect high pressure
circulation lines (R) to circulation manifold.

rated at the maximum working pressure of this
equipment.

3. Follow procedures from Startup, page 57.

4. Turn main power switch on

5. Set temperature targets. See Targets, page 53.

6. Press
A and B temperatures reach targets. See

Jog Mode, page 62 for more information about

jog mode.

to circulate fluid in jog mode until

.

Jog Mode

Jogmodehastwopurposes:

• Speed fluid heating during circulation.

• Ease system flushing and priming.

1. Turn main power switch on

.

The Fusion AP gun manifold is shown.

CK Gun Manual

246362 Fusion AP 309818
256566

2. Route circulation lines back to respective
component A or B supply drum. Use hoses

Fusion CS

313058

2. Press circulate

3. Press up or down
(J1 through J20).

Note

Jog speeds correlate to 3-60% of motor
speed, but will not operate over 700 psi
(4.9 MPa, 49 bar) for either A or B.

4. Press

5. To stop the motor and exit jog mode press
or .

to start motor.

to enter jog mode.

to change jog speed

62 332636D

Spraying

Spraying

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.

6. Verify that the engine temperature is at least up
to the minimum operation temperature range.
The fan will start running when the engine has
reached maximum temperature.

7. Open fluid inlet valves.

8. Press to start motor and pumps.

3. Adjust the gun air regulator on the proportioner
control panel to desired gun air pressure. Do not
exceed 130 psi (0.2 MPa, 2 bar).

4. Set PRESSURE RELIEF/SPRAY valves (SA,

SB) to SPRAY

5. Check that heat zones are on and
temperatures and pressures are on target, see

Home screen, page 53

.

9. Check fluid pressure gauges (GA, GB) to
ensure proper pressure balance. If imbalanced,
reduce pressure of higher component by

slightly

valve for that component toward PRESSURE

RELIEF/CIRCULATION
balanced pressures.

turning PRESSURE RELIEF/SPRAY

until gauges show

332636D 63

Spraying

10. Open gun fluid inlet valves A and B.

Fusion Probler

NOTICE

To prevent crossover on impingement guns,

never

open fluid manifold valves or trigger gun

if pressures are imbalanced.

11. Disengage gun piston safety lock.

Fusion Probler

12. Pull gun trigger to test spray onto cardboard. If
necessary, adjust pressure and temperature to
get desired results.

Spray Adjustments

Flow rate, atomization, and amount of overspray are
affected by four variables.

•

Fluid pressure setting.

in an uneven pattern, coarse droplet size, low
flow, and poor mixing. Too much pressure results
in excessive overspray, high flow rates, difficult
control, and excessive wear.

•

Fluid temperature.

setting. The A and B temperatures can be offset to
help balance the fluid pressure.

•

Mix chamber size.

on desired flow rate and fluid viscosity.

•

Clean-off air adjustment.

resultsindropletsbuildinguponthefrontofthe
nozzle, and no pattern containment to control
overspray. Too much clean-off air results in
air-assisted atomization and excessive overspray.

Toolittlepressureresults

Similar effects to fluid pressure

Choice of mix chamber is based

Too little clean-off air

64 332636D

Manual Hose Heat Mode

If the system produces the T6DH sensor error hose
alarm or the T6DT sensor error TCM alarm, use
manual hose heat mode until the hose RTD sensor
can be repaired.

Do not use Manual Hose Mode for extended periods
of time. The system performs best when the hose
has a valid RTD and can operate in temperature
control mode. If a hose RTD breaks, the first priority
is to fix the RTD. Manual Hose Mode can help finish
a job while waiting for repair parts.

Spraying

4. Enter Run Mode and navigate to the Target

screen. Set the desired hose current.

Enable Manual Hose Mode

1. Disconnect the hose RTD sensor from the TCM.

2. Enter Setup Mode and navigate to System
Screen 2.

3. Select Enable Manual Hose Mode.

Note

When manual hose mode is enabled, the
manual hose mode advisory EVCH-V
will appear.

Hose Current Settings Hose Current

Default
Maximum 37A

Note

Until the RTD sensor is repaired, the
T6DH sensor error alarm will display
each time the system is powered up.

5. Navigate back to the Run Mode Home screen.
The hose now displays a current instead of a
temperature.

20A

332636D 65

Spraying

Disable Manual Hose Mode

1. Enter Setup Mode and navigate to System 2
Screen and deselect Enable Manual Hose Mode,
or repair the hose RTD.

2. Manual hose mode is automatically disabled
when the system detects a valid RTD sensor in
the hose.

66 332636D

Shutdown

Shutdown

Immediate Shutdown

NOTICE

To avoid system damage, follow daily shutdown
procedure. Use only for immediate shutdown.

For immediate shutdown, press:

Daily Shutdown

3. Set PRESSURE RELIEF/SPRAY valves (SA,

SB) to PRESSURE RELIEF/CIRCULATION

4. Relieve pressure. See

Pressure Relief Procedure, page 69.

5. Press

park operation is complete when green dot goes
out. Verify the park operation is complete before
moving to next step.

6. Press to deactivate the system.

to park the Component A Pump. The

.

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.

1. Press to stop the pumps.

2. Turn off all heat zones.

7. Turn off the air compressor, air dryer, and

breathing air.

332636D 67

Shutdown

8. Close the main air shutoff valve.

9. Turn main power switch OFF. Allow engine
cooling dwell time prior to shutting down the
engine.

10. Press to stop the engine.

11. Close all fluid supply valves.

To prevent electric shock do not remove any
shrouds or open the electrical enclosure door.
240 V is still present in the system until the
engine has stopped.

NOTICE

Allow engine cooling dwell time, per
manufacturer recommendations, prior to
shutdown. Dwell time will help engine
properly cool down after running at operating
temperature for any period of time. Stopping
the engine immediately after running it at
full load for an extended period of time can
cause the engine to overheat due to the lack of
coolant flow. See engine manual.

12. Engage gun piston safety lock then close fluid
inlet valves A and B.

Fusion Probler

68 332636D

Pressure Relief Procedure

Pressure Relief Procedure

Follow the Pressure Relief Procedure
whenever you see this symbol.

This equipment stays pressurized until pressure
is manually relieved. To help prevent serious
injury from pressurized fluid, such as skin injection,
splashing fluid and moving parts, follow the
Pressure Relief Procedure when you stop spraying
and before cleaning, checking, or servicing
equipment.

The Fusion AP gun is shown.

1. Relieve pressure in gun and perform gun
shutdown procedure. See gun manual.

2. Close gun fluid inlet valves A and B.

4. Route fluid to waste containers or supply tanks.
Turn PRESSURE RELIEF/SPRAY valves (SA,
SB) to PRESSURE RELIEF/CIRCULATION

. Ensure gauges drop to 0.

5. Engage gun piston safety lock.

Fusion Probler

6. Disconnect gun air line and remove gun flui d
manifold.

Fusion Probler

3. Shut off feed pumps and agitator, if used.

332636D 69

Flushing

Flushing

To help prevent fire and explosion:

• Flush equipment only in a well-ventilated area.

• Do not spray flammable fluids.

• Do not turn on heaters while flushing with
flammable solvents.

• Flush out old fluid with new fluid, or flush out old
fluid with a compatible solvent before introducing
new fluid.

• Use the lowest possible pressure when flushing.

• All wetted parts are compatible with common
solvents. Use only moisture-free solvents.

To flush feed hoses, pumps, and heaters
separately from heated hoses, set PRESSURE
RELIEF/SPRAY valves (SA, SB) to PRESSURE

RELIEF/CIRCULATION
lines (N).

To flush entire system, circulate through gun fluid
manifold (with manifold removed from gun).

To prevent moisture from reacting with
isocyanate, always leave the system filled
with a moisture-free plasticizer or oil. Do not
use water. Never leave the system dry. See

Important Isocyanate Information, page 8 .

. Flush through bleed

70 332636D

System Errors

System Errors

System errors alert you of a problem and help
prevent off-ratio spraying. When an error occurs the
error information screen displays the active error
code and description.

The error code, alarm bell, and active errors will scroll
in the status bar. For a list of the ten most recent
errors see Errors, page 56.

There are three types of errors that can occur. Errors
are indicated on the display as well as by the light
tower (optional).

Error Description
Alarms

Deviations

Advisories

To troubleshoot the active error, see

Troubleshoot Errors, page 72. See system

repair manual for non-error based troubleshooting.

A parameter critical to
the processhas reached
a level requiring the
system to stop. The
alarm needs to be
addressed immediately.

A parameter critical
to the process has
reachedalevel requiring
attention, but not
sufficient enough to
stop the system at this
time.

A parameter that is
not immediately critical
to the process. The
advisory needs attention
to prevent more serious
issues in the future.

332636D

71

System Errors

Troubleshoot Errors

See system repair manual or visit help.graco.com for
causes and solutions to each error code.

To troubleshoot the error:

1. Press the soft key next to “Help With This Error”
for help with the active error.

Note

Press or to return to the
previously displayed screen.

3. If no internet connection is available, see Error
Code Troubleshooting in the system repair
manual for causes and solutions for each error
code.

2. The QR code screen will be displayed. Scan
the QR code with your mobile device to be sent
directly to online troubleshooting for the active
error code. Otherwise, manually navigate to

help.graco.com and search for the active error.

Clear Alarm

When a de
determi

Note

If you forget which code occurred, go to

Errors, page 56, to view the last 200 errors

with date and time stamps.

If an a
resum
see Tr

To acknowledge a deviation or clear an alarm, press

.

viation or alarm occurs, be sure to

netheerrorcodebeforeresettingit.

larm has occurred, correct the cause before

ing operation. For error code troubleshooting,

oubleshoot Errors, page 72.

72

332636D

Maintenance

Maintenance

Prior to performing any maintenance procedures,
follow Pressure Relief Procedure, page 69.

Preventative Maintenance Schedule

The operating conditions of your particular system
determine how often maintenance is required.
Establish a preventive maintenance schedule by
recording when and what kind of maintenance is
needed, and then determine a regular schedule for
checking your system.

Wetcup

Check the wet cup daily. Keep it 2/3 full with Graco
Throat Seal Liquid (TSL
not overtighten packing nut/wet cup.

Fluid Inlet Strainer Screen

®

) or compatible solvent. Do

Wiring Connections

Tighten all screw-type wiring connections in the
Electrical Enclosure (DB), Reactor cabinet, and air
compressor control box (if supplied) monthly.

Dust Protection

Use clean, dry, oil-free compressed air to prevent
dust buildup on control modules, control boards,
fans, and motor (under shield).

Coolant Levels

Check coolant level inside both overflow tanks daily.

Flush and refill the coolant on both the engine and
heat exchanger coolant loop onc e a year. See
system repair manual for instructions.

Compressor Maintenance

Check that the oil level is visible in sight glass
weekly. Use only Hydrovane approved oil such as
Hydrovane Fluid Force Red 2000 oil or CompAir
CS-300. One gallon container (171101) is available
as an accessory.

Inspect fluid inlet strainer screens daily, see

Flush Inlet Strainer Screen, page 75.

Coolant Filter

Inspect filter in coolant filter housing monthly.
Replace filter semi-annually. See Repair manual.

Grease Circulation Valves

Grease circulation valves (SA, SB) with Fusion
grease (117773) weekly.

ISO Lubrication Level

Inspect ISO lubricant level and condition
daily. Refill or replace as needed. See

Pump Lubrication System, page 76.

Refer to the Hydrovane User Handbook for all service
schedule information.

Every 2000 hours or 1 year:

Hydrovane kit KO52 (includes air filter and two
gaskets).

Every 4000 hours:

Kit KM52 (includes air filter, oil separator and
miscellaneous seals).

Every 10000 hours:

(recommended for a complete rebuild completed by
a Hydrovane Service Center).

Change oil and install Hydrovane

Hydrovane Top-Up kit KT53

Change oil and install

Air Compressor Oil Level

• Daily check air compressor oil level through sight
glass.

332636D 73

Maintenance

Clean Heat Sink Fins

Keep heat sink fins clean at all times. Clean them
using a dry cloth or compressed air.

Note

Do not use conductive cleaning solvents on
the module.

Figure 31 MCM Heat Fins

Engine Maintenance

The engine instructions that accompany your
unit detail specific procedures for maintenance of
the engine. Following the engine manufacturer’s
recommendations will extend engine work life.

Daily

• Cooling System Coolant Level — Check

• Engine Air Cleaner Service Indicator — Inspect

• Engine Oil Level — Check

Every 500 Service Hours or 1 Year

• Engine Air Cleaner Element (Dual Element) —
Clean/Replace

• Engine Oil and Filter — Change

• Fuel System Filter — Replace

• Battery Voltage — Check. See

Appendix A: Engine Control Module, page 81.

Contact an Authorized Perkins Dealer or Distributor
for replacement filter elements. Refer to Perkins
engine part number GN66141N for compatible parts.

Figure 32 TCM Fins

Air Dryer Water Separator

• Clean ambient air filter monthly or more often if air flow across the condenser is blocked.

• Clean inlet strainer monthly or more often if rapid clogging occurs.

• Replace separator/filter element yearly or more often if pressure drop across the dryer is excessive.

• Check automatic condensate drain daily.

74

332636D

Maintenance

Fuel Tank

Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel tank
can cause excessive wear to the fuel system. See
the supplied Perkins engine manual for fuel tank
maintenance recommendations.

Flush Inlet Strainer Screen

The inlet strainers filter out particles that can plug the
pump inlet check valves. Inspect the screens daily as
part of the startup routine, and clean as required.

Isocyanate can crystallize from moisture
contamination or from freezing. If the chemicals used
are clean and proper storage, transfer, and operating
procedures are followed, there should be minimal
contamination of the A-side screen.

Note

3. Remove the screen (A) from the strainer
manifold. Thoroughly flush the screen with
compatible solvent and shake it dry. Inspect the
screen. Nomorethan25%ofthemeshshould
berestricted. Ifmorethan25%ofthemeshis
blocked, replace the screen. Inspect the gasket
(B) and replace as required.

4. Ensurethepipeplug(D)isscrewedintothe
strainer plug (C). Install the strainer plug with the
screen (A) and gasket (B) in place and tighten.
Do not overtighten. Let the gasket make the seal.

5. Open the fluid inlet valve, ensure that there are
no leaks, and wipe the equipment clean. Proceed
with operation.

Clean the A-side screen only during
daily startup. This minimizes moisture
contamination by immediately flushing
out any isocyanate residue at the start of
dispensing operations.

1. Close the fluid inlet valve at the pump inlet and
shut off the appropriate feed pump. This prevents
material from being pumped while cleaning the
screen.

2. Place a container under the strainer base to catch
drain off when removing the strainer plug (C).

A

B

C

D

Figure 33

332636D 75

Maintenance

Pump Lubrication System

Check the condition of the ISO pump lubricant daily.
Change the lubricant if it becomes a gel, its color
darkens, or it becomes diluted with isocyanate.

Gel formation is due to moisture absorption by the
pump lubricant. The interval between changes
depends on the environment in which the equipment
is operating. The pump lubrication system minimizes
exposure to moisture, but some contamination is still
possible.

Lubricant discoloration is due to continual seepage of
small amounts of isocyanate past the pump packings
during operation. If the packings are operating
properly, lubricant replacement due to discoloration
should not be necessary more often than every 3 or
4weeks.

To change pump lubricant:

1. Follow Pressure Relief Procedure, page 69.

2. Lift the lubricant reservoir (R) out of the bracket
and remove the container from the cap. Holding
the cap over a suitable container, remove the
check valve and allow the lubricant to drain.
Reattach the check valve to the inlet hose.

4. When the reservoir is flushed clean, fill with fresh
lubricant.

5. Thread the reservoir onto the cap assembly and
place it in the bracket.

6. The lubrication system is ready for operation. No
priming is required.

Pump Lubrication System
Figure 34

3. Drain the reservoir and flush it with clean
lubricant.

76 332636D

USB Data

USB Data

Each time a USB flash drive is inserted into the ADM
USB port, a new folder named DATAxxxx is created.
The number at the end of the folder name increases
each time a USB flash drive is inserted and data is
downloaded or uploaded.

Note

TheADMcanread/writetoFAT(File
Allocation Table) storage devices. NTFS,
used by 32 GB or greater storage devices,
is not supported.

USB Logs

During operation, the ADM stores system and
performance related information to memory in the
form of log files. The ADM maintains four log files:

• Event Log

• Job Log

ly Log

•Dai

• System Software Log

• Blackbox Log

• Diagnostics Log
Follow Download Procedure, page 79, to retrieve

log files.

Event Log

The event log file name is 1–EVENT.CSV and is
stored in the DATAxxxx folder.

The event log maintains a record of the last 49,000
events and errors. Each event record contains:

• Date of event code

• Time of event code

• Event code

• Event type

• Action taken

• Event Description

Event codes include both error codes (alarms,
deviations, and advisories) and record only events.

Actions Taken includes setting and clearing event
conditions by the system, and acknowledging error
conditions by the user.

Job Log

The job log file name is 2–JOB.CSV and is stored
in the DATAxxxx folder.

The job log maintains a record of data points
based on the USB Log Frequency defined
in the Setup screens. The ADM stores the
last 237,000 data points for download. See

Setup - Advanced Screen 3 — USB, page 50, for

informationonsettingtheDownloadDepthandUSB
Log Frequency.

• Data point date

• Data point time

• A side heat exchanger temperature

• A side boost heater temperature

• B side heat exchanger temperature

• B side boost heater temperature

•Hosetemperature

• Engine coolant temperature

• A side temperature setpoint

• B side temperature setpoint

• Hose temperature setpoint

• Inlet A side pressure

• Inlet B side pressure

• Pressure setpoint

• System lifetime pump cycle counts

• Pressure, volume, and temperature units

• Job name/number

332636D

77

USB Data

Daily Log

The daily log file name is 3–DAILY.CSV and is stored
in the DATAxxxx folder.

The daily log maintains a record of the total cycle
and volume sprayed on any day that the system is
powered up. The volume units will be the same units
that were used in the Job Log.

The following data is stored in this file:

• Date that material was sprayed

• Time — unused column

• Total pump cycle count for day

• Total volume sprayed for day

System Software Log

The system software file name is 4–SYSTEM.CSV
andisstoredintheDATAxxxxfolder.

The system software log lists the following:

• Date log was created

• Time log was created

• Component name

• Software version loaded on the above component

Blackbox Log File

The black box file name is 5–BLACKB.CSV and is
stored in the DATAxxxx folder.

The Blackbox log maintains a record of how the
system runs and the features that are used. This log
will help Graco troubleshoot system errors.

Diagnostics Log File

The diagnostics file name is 6–DIAGNO.CSV and is
stored in the DATAxxxx folder.

The Diagnostics log maintains a record of how the
system runs and the features that are used. This log
will help Graco troubleshoot system errors.

System Configuration Settings

The system configuration settings file name is
SETTINGS.TXT and is stored in the DOWNLOAD
folder.

A system configuration settings file automatically
downloads each time a USB flash drive is inserted
into the ADM. Use this file to back up system
settings for future recovery or to easily replicate
settings across multiple systems. Refer to the

Upload Procedure, page 80 for instructi ons on how

to use this file.

78 332636D

USB Data

Download Log Files

Note

System configuration setting files and custom
language files can be modified if the files
are in the UPLOAD folder of the USB flash
drive. See System Configuration Settings
File, Custom Language File, and Upload
Procedure sections.

Note

If needed, set the number of days to
download on the Advanced Setup Screen
3–USB in the ADM. USB log frequency can
only be changed before logging occurs.

1. Insert USB flash drive into USB port.

2. The menu bar and USB indicator lights “USB

Busy” to indicate that the USB is downloading
files. USB activity is complete when the “USB
Busy” screen prompt disappears or the flash
drive LED stops flashing.

Note

Normal system spraying can continue
while download is in progress.

3. Remove USB flash drive from USB port.

4. Insert USB flash drive into USB port of computer.

5. The USB flash drive window automatically opens.

If it does not, open USB flash drive from within
Windows® Explorer.

6. Open GRACO folder.

7. Open the system folder. If downloading data

from more than one system, there will be more
than one folder. Each folder is labeled with the
corresponding serial number of the ADM (The
serial number is on the back of the ADM.)

9. Open DATAxxxx folder.

10. Open DATAxxxx folder labeled with the highest
number. The highest number indicates the most
recent data download.

11. Open log file. Log files open in Microsoft® Excel
by default as long as the program is installed.
However,theycanalsobeopenedinanytext
editor or Microsoft® Word.

Note

All USB logs are saved in Unicode
(UTF-16) format. If opening the log
file in Microsoft Word, select Unicode
encoding.

Custom Language File

The custom language file name is DISPTEXT.TXT
andisstoredintheDOWNLOADfolder.

A custom language file automatically downloads
eachtimeaUSBflashdriveisinsertedintotheADM.
If desired, use this file to create a user-defined set of
custom language strings to be displayed within the
ADM.

ThesystemisabletodisplaythefollowingUnicode
characters. For characters outside of this set,
the system will display the Unicode replacement
character, which appears as a white question mark
inside of a black diamond.

• U+0020 - U+007E (Basic Latin)

• U+00A1 - U+00FF (Latin-1 Supplement)

• U+0100 - U+017F (Latin Extended-A)

• U+0386 - U+03CE (Greek)

• U+0400 - U+045F (Cyrillic)

8. Open DOWNLOAD folder.

332636D 79

USB Data

Create Custom Language Strings

The custom language file is a tab-delimited text file
that contains two columns. The first column consists
of a list of strings in the language selected at the
time of download. The second column can be used
to enter the custom language strings. If a custom
language was previously installed, this column
contains the custom strings. Otherwise the second
column is blank.

Modify the second column of the custom language file
as needed and the follow Upload Procedure, page 80 ,
to install the file.

The format of the custom language file is critical.
The following rules must be followed in order for the
installation process to succeed.

• Define a custom string for each row in the second
column.

Note

If the custom language file is used, you
must define a custom string for each
entry in the DISPTEXT.TXT file. Blank
second-column fields will be displayed
blank on the ADM.

• The file name must be DISPTEXT.TXT.

1. If necessary, follow the
automatically generate the proper folder structure
on the USB flash drive.

2. Insert USB flash drive into USB port of computer.

3. The USB flash drive window automatically opens.
If it does not, open USB flash drive from within
Windows Explorer.

4. Open GRACO folder.

5. Open the system folder. If working with more
than one system, there will be more than one
folder within the GRACO folder. Each folder is
labeled with the corresponding serial number of
theADM.(Theserialnumberisonthebackof
the module.)

6. If installing the system configuration settings
file, place SETTINGS.TXT file into the UPLOAD
folder.

7. If installing the custom language file, place
DISPTEXT.TXT file into th e UPLOAD folder.

8. Remove USB flash drive from the computer.

9. Install USB flash drive into the ADM USB port.

10. The menu bar and USB indicator lights indicate
that the USB is downloading files. Wait for USB
activity to complete.

Download Procedure

to

• The file format must be a tab-delimited text file
using Unicode (UTF-16) character representation.

• The file must contain only two columns, with
columns separated by a single tab character.

• Do not add or rem ove rows to the file.

• Do not change the order of the rows.

Upload Procedure

Use this procedure to install a system configuration
file and/or a custom language file.

11. Remove USB flash drive from USB port.

Note

If the custom language file was installed,
users can now select the new language
from the Language drop-down menu in

Advanced Screen 1 — General, page 50.

80 332636D

Appendix A: Engine Control Module

Run Screens

There are seven run screens on the engine control module:

• Line-to-neutral voltage

• Line-to-line voltage

• Frequency

• Engine Speed

• Engine lifetime counter

• Battery voltage

Appendix A: Engine C ontrol Module

Press

to scroll through the run screens. Press to enter the Information screens.

Run Screen Layout

Inst

Icon

Instrumentation Units

Alarm

Icon

Mode

Icon

Information Screens

From the Run Screen, press to enter the information screens. P ress to scroll through the last five
generator events.

Press

to return to the Run Screens.

Information Screen Layout

Alarm

Icon

Mode

Icon

Event

#

Time of Event (Engine

Run Hours)

Units

332636D 81

Appendix A: Engine Control Module

Mode Icons

Icon Description Details

Stopped

Auto Engine is at rest and the unit is in auto mode.

Manual Engine is at rest and the unit is in manual run mode.

Timer animation Engine is starting up.

Running animation Engine is running.

Engine is at rest and the unit is in stop mode.

Instrumentation Icons

A small icon is displayed in the instrumentation icon area to indicate w hat value is currently being displayed.

Icon Description Details

Generator Generator voltage and frequency screen

Engine Speed Engine speed screen

Engine Lifetime
Counter

Event Log Event is being displayed.

Unit Time Unused feature

Hours run

82 332636D

Appendix A: Engine C ontrol Module

Alarms

There are two types of alarms that can occur on the system. Alarms are indicated by an icon the Run and
Information screens. See the information screen to see the latest alarm.

Warning

When present on system, a warning alarm will stop the generator.

Shutdown

When present on system, a shutdown alarm will stop the generator.

Warning

Icon Description Details

Battery High
Voltage

Battery Low
Voltage

Fail To Stop The module detected a condition that indicates that the engine is running when

Flexible Sensor The flexible sensor warning alarm has been triggered.

The DC Supply has risen above the high volts setting level for the duration of
the high battery volts timer.

The DC Supply has fallen below the low volts setting level for the duration
of the low battery volts timer.

it has been instructed to stop.

Shutdown

Clear the alarm and remove the fault. Then press the stop button to reset the module.

Icon Description Details

Fail To Start The engine has not fired after the preset number of start attempts.

Generator High
Voltage Shutdown

Generator Low
Voltage Shutdown

High Coolant
Temperature
Shutdown

The generator output voltage has risen above the preset level.

The generator output voltage has fallen below the preset level.

The module detects that the engine coolant temperature has exceeded the hi gh
engine temperature shutdown setting after the Safety On timer has expired.

Low Oil Pressure
Shutdown

Over Frequency
Shutdown

Under Frequency
Shutdown

332636D 83

The engine oil pressure has fallen below the low oil pressure trip setting level
after the Safety On timer has expired.

The generator output frequency has risen above the preset l evel.

The generator output frequency has fallen below the preset level.

Dimensions

Dimensions

Figure

35

84 332636D

Dimensions

Figure 36

Figure 37

332636D 85

Dimensions

38 Floor Mount Hole Pattern

Figure

86 332636D

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.

Proportioners For Foam

2000

(138)

AR4242

(01)

PRESSURE

psi (bar)

150 0

(103)

100 0

(69)

500

(34)

05

(2.3)

AR5252

(02)

10

(4.5)

15

(6.8)

20

(9.1)

FLOW lbs/min (kg/min)

AR6060

(03)

AR7070

(04)

25

(11.3)

E-30i

30

(13.6)

35

(15.9)

40

(18.1)

332636D 87

Performance Charts

Proportioners For Coatings

Table 4 Fusion Air Purge, Round Pattern

3500

(241)

3000

(207)

2500

(172)

PRESSURE

psi (bar)

2000

(138)

150 0

(103)

100 0

(69)

500

(34)

0 0.5

Table 5 Fusion Air Purge, Flat Pattern

3500

(241, 24.1)

3000

(207, 20.7)

2500

(174, 17.4)

PRESSURE

2000

(138, 13.8)

psi (bar)

1500

(103, 10.3)

1000

(69, 6.9)

AR2020

(000)

AR2929

(00)

(1.9)

1.0

(3.8)

FLOW gal./min (l/min)

AF2020

(FTXX24 TIP)

AR4242

(01)

AF2929

(FTXX38 TIP)

AF4242

(FTXX38 TIP)

AF5252

(FTXX48 TIP)

E-XP2i

1.5

(5.7)

E-XP2i

2.0

(7.6)

500

(35, 3.5)

0 0.5

(1.9)

1.0

(3.8)

1.5

(5.7)

2.0

(7.6)

FLOW gal./min (l/min)

88 332636D

Table 6 Fusion Mechanical Purge, Round Pattern

3500

(241, 24.1)

3000

PRESSURE

(207, 20.7)

2500

(174, 17.4)

2000

(138, 13.8)

XR2323

(RTM040)

psi (bar)

1500

(103, 10.3)

1000

(69, 6.9)

500

(35, 3.5)

0 0.5

(1.9)

(RTM040)

XR3535

(RTM055)

E-XP2i

XR2929

1

(3.8)

MR3535

(RTM040)

XR4747

(RTM055)

MR4747

(RTM055)

1.5

(5.7)

Performance Charts

2.0

(7.6)

FLOW gal./min (l/min)

Table 7 Fusion Mechanical Purge, Flat Pattern

3500

(241, 24.1)

(1.5)

XF2323

(FTM424)

MF2929

(FTM424)

XF2929

(FTM424)

XF3535

(FTM638)

0.6

(2.3)

PRESSURE

psi (bar)

3000

(207, 20.7)

2500

(174, 17.4)

2000

(138, 13.8)

1500

(103, 10.3)

1000

(69, 6.9)

500

(35, 3.5)

0 0.4

XF1313

(FTM424)

(FTM424)

XF1818

(FTM424)

0.2

(0.7)

MF1818

FLOW gal./min (l/min)

MF3535

(FTM638)

0.8

(3.0)

(3.8)

1

MF4747

(FTM638)

XF5757

(FTM638)

MF5757

(FTM638)

1.2

(4.5)

1.4

(5.3)

1.6

(6.0)

E-XP2i

1.8

(6.8)

2.0

(7.6)

332636D 89

Technical Specifications

Reactor 2 Elite Integrated Proportioning Systems

U.S.

Maximum Fluid Working Pressure

E-30i 2000 psi 14 MPa, 140 bar
E-XP2i 3500 psi 24.1 MPa, 24

Maximum Fluid Temperature

E-30i
E-30i with booster heater
E-XP2i 180°F 82°C

Maximum

E-30i 30 lb/min 13.5 kg/min
E-XP2i 2 gpm 7.6 lpm

Maxim

Length

Output per Cycle

AandB

E-30i 0.0272 gal. 0.1034 liter
E-XP2i 0.0203 gal. 0.0771 liter

Operating Ambient Temperature Range

Output

um Heated Hose Length

150°F 65°C
180°F 82°C

310 ft

Metric

1bar

94 m

mperature

Te

Auxiliary Power Available

Voltage 120 Vac or 240 Vac, 60 Hz

Engine

Model Perkins 404–22G, 2.2 L, 29 HP

Alternat or

Model Mecc Alte 22 kW, 240 V, 1 PH, 60 Hz, pancake style

Battery Requirements

Voltage 12 Vdc
Minimum Cold Cranking Amps 800 CCA

Connection Type Post Style

20° to 120°F -7° to 49°C

Recommended Battery Size

BC Group Number

34

Length 10.25 in. 260 mm
Width 6.81 in. 173 mm
Height 7.88 in. 200 mm

Booster Heater Power

E-30i None
E-30i with booster heat 4000 Watts
E-XP2i 4000 Watts

Rotary Vane Air Compressor
Hydrovane Model V04 (PURS type), continuous run

Part No.

025CK10

Pressure 140 psi 0.9 MPa, 9.6 bar)

Specifications 16 cfm

Thermal overload switchRequired Features

Safety Relief Valve

Motor: Baldor

o.

Part N

ifications

Spec
Required Features

1735 RPM, 240 V, 1 Phase, OPSB

5HP,

EL1410–CUS

C face, lift rings,

Refrigerated Air Dryer

Hankison Model H1T20
Specifications 115VAC, 1 Phase, 60 Hz, 22 scfm at 150 psi (1 MPa, 10.3 bar)
Required Features Pilot valve unloader

Noise

Sound Pressure measured per ISO-9614–2.

SoundPressuremeasuredfrom

91.0 dBA

3.1 ft (1 m), at 1500 psi (10 MPa,
103 bar), 2 gpm (7.6 lpm)

Fluid Inlets

Component A (ISO) and

3/4NPT(f)with3/4NPSM(f)union

Component B (RES)

Fluid Outlets

Component A (ISO) #8 (1/2 in.) JIC, with #5 (5/16 in.) JIC adapter
Component B (RES) #10 (5/8 in.) JIC, with #6 (3/8 in.) JIC adapter

Fluid Circulation Ports

Size 1/4 NPSM(m), with sst braided tubing
Maximum Pressure 250 psi 1.75 MPa, 17.5 bar

Weight

E-30i 1750 lb 794 kg
E–30i with compressor and dryer 2200 lb 998 kg
E-30i with booster heat 1800 lb 816 kg
E–30i with bo

compressor,

oster heat,

and dryer

2250 lb 1021 kg

E-XP2i 1800 lb 816 kg
E–XP2i with compressor and

2200 lb 998 kg

dryer

Wetted Parts

Material Aluminum

, stainless steel, zinc plated carbon steel, brass,

carbide, chrome, chemically resistant o-rings, PTFE, ultra-high

molecular weight polyethylene

Graco Extended Warranty for Integrated Reactor

®

2 Components

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its
name to be free from defects in material and workmanship on the date of sale to the original purchaser for use.
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 accor dance
with Graco’s written recommendations.

Graco Part Number

24U050 Electric Motor
24U051 Electric Motor
24U831
24U832
24U855
24U854 Advanced Display Module
All other Reactor 2 parts 12 Months

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction,
damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper
maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco
be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures,
accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation,
operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized
Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace
free of charge any defective parts. The equipment will be returned to the original purchaser transportation
prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be
made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS
FORAPARTICULARPURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The
buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost
profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available.
Any action for breach of warranty hereunder must be brought within the latter of two (2) years of the date of
sale, or one (1) year the warranty period expires.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT,
MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO.

manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of
their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of
these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco
supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold
hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices

and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be
drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en
Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou
en rapport, directement ou indirectement, avec les procédures concernées.

Description Warranty Period

36 Months or 3 Million Cycles

36 Months or 3 Million Cycles
Motor Control Module 36 Months or 3 Million Cycles
Motor Control Module 36 Months or 3 Million Cycles
Heater Control Module 36 Months or 3 Million Cycles

36 Months or 3 Million Cycles

These items sold, but not

Graco Information

For the latest information about Graco products, visit www.graco.com.

To place an order,
Phone:

612-623-6921

All written and visual data contained in this document reflects the latest product information available at the time of publication.

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

contact your Graco Distributor or call to identify the nearest distributor.

or Toll Free:

Graco reserves the right to make changes at any time without notice.

Original Instructions. This manu al contains English. MM 332636

Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

1-800-328-0211

For patent information, see www.graco.com/patents.

Graco Headquarters:

International Offices:

Revision D, July 2014

Fax:

612-378-3505

Minneapolis

Belgium, China, Japan, Korea

www.graco.com