Graco Reactor 2 E-30, Reactor 2 E-30 Elite, Reactor 2 E-XP2, Reactor 2 E-XP2 Elite Operation

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

Warnings ........................................................... 3
Important Isocyanate Information......................... 7
Models............................................................... 9
Approvals........................................................... 11
Accessories........................................................11
Supplied Manuals............................................... 12
Related Manuals ................................................ 12
Typical Installation, without circulation.................. 13
Typical Installation, with system uid manifold
to drum circulation................................. 14
Typical Installation, with gun uid manifold to
drum circulation.....................................15
Component Identication..................................... 16
Advanced Display Module (ADM) ........................ 18
ADM Display Details .................................... 21
Navigating the Screens ................................ 21
Electrical Enclosure ............................................ 23
Motor Control Module (MCM) .............................. 24
Temperature Control Module (TCM) Cable
Connections..........................................25
Installation.......................................................... 26
Setup................................................................. 27
Grounding ................................................... 27
Close gun fluid manifold valves A and
B ................................................... 27
General Equipment Guidelines ..................... 27
Connect Power............................................ 28
Supply Wet Cups With Throat Seal Liquid
(TSL).............................................29
Install Fluid Temperature Sensor .................. 29
Connect Heated Hose to Proportioner...........30
Registerand Activate the Graco InSite........... 30
Advanced Display Module (ADM)
Operation..............................................31
Advanced Setup Screens .................................... 34
Advanced Screen 1 General..................... 34
Advanced Screen 2 Units......................... 34
Advanced Screen 3 USB.......................... 34
Advanced Screen 4 Software .................... 34
System 1 ............................................................ 35
System 2 ............................................................ 35
Recipes ............................................................. 35
Add Recipe..................................................35
Enable or Disable Recipes............................35
Run Mode..........................................................36
Home System Off .................................... 37
Home System Active................................ 37
Home System With Error..........................37
Targets........................................................ 37
Maintenance................................................ 38
Cycles......................................................... 38
Events......................................................... 38
Errors.......................................................... 38
Troubleshooting........................................... 39
Diagnostic ................................................... 40
Job Data ..................................................... 40
Recipes....................................................... 40
Startup............................................................... 42
Fluid Circulation..................................................45
Circulation Through Reactor ......................... 45
Circulation Through Gun Manifold ................. 46
Jog Mode ........................................................... 46
Spraying ............................................................ 47
Spray Adjustments....................................... 48
Manual Hose Heat Mode.....................................49
Enable Manual Hose Mode........................... 49
Disable Manual Hose Mode .......................... 50
Shutdown...........................................................51
Pressure Relief Procedure .................................. 53
Flushing............................................................. 54
Maintenance ...................................................... 55
Preventative Maintenance Schedule ............. 55
Proportioner Maintenance ............................ 55
Flush Inlet Strainer Screen ........................... 56
Pump Lubrication System............................. 57
Errors ................................................................ 58
View Errors.................................................. 58
Troubleshoot Errors ..................................... 58
Troubleshooting..................................................59
Error Codes and Troubleshooting..................59
USB Data........................................................... 60
Download Procedure.................................... 60
USB Logs.................................................... 60
System Conguration Settings...................... 61
Custom Language File ................................. 62
Upload Procedure ........................................ 62
Performance Charts............................................ 63
Technical Specications...................................... 66
Notes ............................................................... 68
Graco Extended Warranty for Reactor® 2
Components ......................................... 69
2
333023G

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 or installing 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.
Do not expose to rain. Store indoors.
TOXIC FLUID OR FUMES
Toxic uids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled or swallowed.
Read Safety Data Sheet (SDS) for handling instructio ns and to know the s pecic hazards of the uids you are using, including the effects of long-term exposure.
When spraying, servicing equipment, or when in the work area, always keep work area well ventilated and always wear appropriate personal protective equipment. See
Protective Equipment
Store hazardous uid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
Always wear appropriate personal protective equipment and cover all skin when spraying, servicing equipment, or when in the work area. Protective equipment helps prevent serious injury, including long-term exposure; inhalation of toxic fumes, mists or vapors; allergic reaction; burns; eye injury and hearing loss. This protective equipment incl udes but is not limited to:
A properly fitting respirator, which may include a supplied-air respirator, chemically impermeable gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory authority.
Protective eyewear and hearing protection.
warnings in this manual.
Personal
333023G 3
Warnings
WARNING
SKIN INJECTION HAZARD
High-pressure uid 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 y our 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 uid connections before operating the equipment.
Check hoses and couplings daily. Replace worn or damaged 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 re 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 ammable fumes are present.
Ground all equipment in the work area. See
Use on ly grounded hoses.
Hold gun rmly 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.
THERMAL EXPANSION HAZARD
Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure due to the thermal expansion. Over-pressurization can result in equipment rupture and serious injury.
Open a valve to relieve the fluid expansion during heating.
Replace hoses proactively at regular intervals based on your operating conditions.
if static sparking occurs or you feel a shock.Do not use
Grounding
work area
instructions.
canigniteorexplode.Tohelp
4
333023G
Warnings
WARNING
PRESSURIZED ALUMINUM PARTS HAZARD
Use of uids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result i n death, serious injury, or property damage.
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or uids containing such sol vents.
Many other fluids may contain chemicals that can react with alumi num. Contact your material supplier for compatibility.
PLASTIC PARTS CLEANING SOLVENT HAZARD
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
Technical Data
solvent manufacturer’s MSDSs and recommendations.
in this and all other equipment instruction manuals. Read uid and
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
Do not operate the unit when fat igued 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 uids and solvents that are compatible with equipment wetted parts. See Te chnical Data in all equipment manuals. Read uid 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 equipment 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 mo d ify equipment. Alterations or modifications may void agency approvals and create safety hazards.
Make sure all equipment is rated and approv ed for the environm ent 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.
MOVING PARTS HAZARD
Technical Data
Pressure Relief Procedure
in all equipment manuals.
when equipment is not in use.
Moving parts can pinch, cut or amputate ngers and other body parts.
Keep clear of moving parts.
Do not operate equipment with protective guards or covers removed.
Pressurized equipment c an start without warning. Before checking, moving, or servicing equipment, follow the
333023G 5
Pressure Relief Procedure
and disconnect all power sources.
Warnings
WARNING
BURN HAZARD
Equipment surfaces and uid that is heated can become very hot during operation. To avoid severe burns:
Do not touch hot uid or equipment.
6 333023G

Important Isocyanate Information

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

Isocyanate Conditions

Spraying or dispensing uids that contain isocyanates creates potentially harmful mists, vapors, and atomized particulates.
Read and understand the uid manufacturer’s warnings and Safety Data Sheet (SDS) to know specic hazards and precautions related to isocyanates.
Use of isocyanates involves potenti a lly hazardous procedures. Do not spray with this equipment unless you are trained, qualified, and have read and understood the information in this manual and in the uid manufacturer’s application instructions and SDS.
Use of incorrectly maintained or mis-adjusted equipment may result in improperly cured material, which could cause off gassing and offensive odors. Equipment must be carefully maintained and adjusted according to instructions in the manual.
To prevent inhalation of isocyanate mists, vapors and atomized particulates, everyone in the work area must wear appropriate respiratory protection. Always wear a properly tting respirator, which may include a supplied-air respirator. Ventilate the work area according to instructions in the uid manufacturer’s SDS.
Avoid all skin contact with isocyanates. Everyone in the work area must wear chemically impermeable gloves, protective clothing and foot coverings a s recommended by the uid manufacturer and local regulatory authority. Follow all uid manufacturer recommendations, including those regarding handling of contaminated clothing. After spraying, wash hands and face before eati ng or drinking.
Hazard from exposure to isocyanates continues after spraying. Anyone without appropriate persona l protective equipment must stay out of the work area during application and after application for the time period specied by the uid manufacturer. Generally this time period is at least 24 hours.
Warn others who may enter work area of hazard from exposure to isocyanates. Follow the recommendations of the uid manufacturer and local regulatory authority. Posting a placard such as the following outside the work area is recommended:
333023G
7
Important Isocyanate Information

Material Self-Ignition

Some materials may become self-igniting if applied too thick. Read material manufacturers warnings and SDS.

Keep Components A and B Separate

Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage to equipment. To prevent cross-contamination:
Never
interchange component A and component
Bwettedparts.
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 that become suspended in the uid. Eventually a lm will form on the surface and the ISO willbegintogel,increasinginviscosity.
NOTICE
Partially cured ISO will reduce performance and the life of all wetted parts.
Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere.
Never
store ISO in an open container.
Keep the IS O 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.

Changing Materials

NOTICE
Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime.
When chan ging materials, flush the equipment multiple times to ensure it is thoroughly clean.
Always clean the uid inlet strainers after flushing.
Check with your material manufacturer for chemical compatibility.
When changing between epoxies and urethanes or polyureas, disassemble and clean all uid components and change hoses. Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the B (resin) side.
Always lubricate threaded parts with an appropriate lubricant when reassembling.
NOTE:
crystallization varies depending on the blend of ISO, the humidity, and the temperature.
The amount of lm formation and rate of

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.
8 333023G

Models

Models

Reactor 2 E-30 and E-30 Elite

All elite systems include uid inlet sensors, Graco InSite, and Xtreme-Wrap 50 ft (15 m) heated hose. For part numbers, see Accessories, page 11
Model
Proportioner
272010 272011 272110 272111
Maximum Fluid Working Pressure psi (MPa, bar) Approximate Output per Cycle (A+B) gal. (liter) Max Flow Rate lb/min (kg/min) Total System Load
(Watts) Configurable Voltage Phase
Full Load Peak Current*
Fusion AP Package
(Gun Part No.)
Fusion CS Package
(Gun Part No.)
Probler P2 Package
(Gun Part No.)
d Hose
Heate
15 m)
50 ft (
40 (scuff guard)
24K2
40 (Xtreme-Wrap)
24Y2
Heated Whip Hose 10 ft (3 m)
Graco Insite Fluid Inlet Sensors (2)
E-30 Model E-30 Elite Model
10 kW 15 kW 10 kW 15kW
2000 (14, 140) 2000 (14, 140) 2000 (14, 140) 2000 (14, 140)
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)
17,900 23,000 17,900 23,000
230230
400 Y
230230
400 Y
230230
400 Y
230230
400 3ØY
78 50 34 100 62 35 78 50 34 100 62 35
AP2010
(246102)
CS2010
(CS02RD)
P22010
(GCP2R2)
24K24
Qty:
246050 246050 246050 246050
0
1
AH2010
(246102)
CH2010
(CS02RD)
PH2010
(GCP2R2)
0
24K24
Qty:
5
AP2011
(246102)
CS2011
(CS02RD)
P22011
(GCP2R2)
0
24K24
Qty:
1
AH2011
(246102)
CH2011
(CS02RD)
PH2011
(GCP2R2)
0
24K24
Qty:
5
AP2110
(246102)
CS2110
(CS02RD)
P22110
(GCP2R2)
24Y24
Qty:
✓✓ ✓✓
0
1
AH2110
(246102)
CH2110
(CS02RD)
PH2110
(GCP2R2)
0
24Y24
Qty:
5
AP2111
(246102)
CS2111
(CS02RD)
P22111
(GCP2R2)
24Y24024Y24
Qty:
1
AH2111
(246102)
CH2111
(CS02RD)
PH2111
(GCP2R2)
Qty:
0
5
Full load amps with all devices operating at
*
maximum capabilities. Fuse requirements at various ow rates and mix chamber sizes may be less.
Total system watts used by system, based on maximum heated hose length for each unit.
E30 and E–XP2 series: 310 ft (94.5 m) maximum heated hose length, including whip hose.
See Approvals, page 11.
Packages include gun, heated hose, and whip hose. Elite packages also include Graco InSite and uid inlet sensors.
Low line input voltage will reduce power available and heaters will not perform at full capacity.
Voltage Configurations Key
Phase
Ø
DELTA
YWYE
333023G 9
Models

Reactor 2 E-XP2 and E-XP2 Elite

All elite systems include fluid inlet sensors, Graco InSite, and Xtreme-Wrap 50 ft (15 m) heated hose. For part numbers, see Accessories, page 11
Model
Proportioner Maximum Fluid Working
Pressure psi (MPa, bar) Approximate Output per
Cycle (A+B) gal. ( liter) Max Flow Rategpm/min
(l/min) Total System Load
(Watts) Congurable Voltage
Phase Full Load Peak Current
(amps)
Fusion AP Package
(Gun Part No.)
Probler P2 Package
(Gun Part No.)
Heated Hose 50 ft (15 m)
Heated Whip Hose 10 ft (3 m)
Graco Insite Fluid Inlet Sensors (2)
272012 272112
E–XP2 Model EXP2 Elite Model
15 kW 15 kW
3500 (24.1, 241) 3500 (24.1, 241)
0.0203 (0.0771) 0.0203 (0.0771)
2 (7.6) 2 (7.6)
23,000 23,000
230 1Ø 230 3Ø 400 3ØY 230 230 3Ø∆ 400 Y
100 62 35 100 62 35
AP2012
(246100)
P22012
(GCP2R0)
24K241 (scuff guard)
246055 246055
AP2112
(246100)
P22112
(GCP2R0)
24Y241 (Xtreme-Wrap)
Full load amps with all devices operating at
*
maximum capabilities. Fuse requirements at various ow rates and mix chamber sizes may be less.
Total system watts used by system, based on maximum heated hose length for each unit.
E30 and EXP2 series: 310 ft (94.5 m) maximum heated hose length, including whip hose.
See Approvals, page 11.
10 333023G
Packages include gun, heated hose, and whip hose. Elite packages also include GracoInSiteanduidinletsensors.
Low line input voltage will reduce power available and heaters will not perform at full capacity.
Voltage Configurations Key
Phase
Ø
DELTA
YWYE

Approvals

Approvals
Intertek approvals apply to proportioners without hoses.
Proportioner Approvals:
9902471
Conforms to ANSI/UL Std. 499
Certied to CAN/CS A Std. C22.2 No. 88

Accessories

Kit Number Description
24U315 24U314 Wheel and Handle Kit 24T280 16X521
24N449 50 ft (15 m) CAN cable (for remote
24K207
24U174 Remote Display Module Kit 15V551 15M483 Remote Display Module Protective
24M174 121006
Air Manifold Kit (4 outlets)
GracoInSiteKit GracoInSiteExtensioncable24.6ft
(7.5 m)
display module) Fluid Temperature Sensor (FTS)
with RTD
ADM Protective Covers (10 pack)
Covers (10 pack) Drum Level Sticks 150 ft (45 m) CAN cable (for remote
display module)
24N365
RTD Test Cables (to aide resistance measurements)
333023G
11

Supplied Manuals

Supplied Manuals
The following manuals are shipped with the Reactor
2. Refer to these manuals for detailed equipment information.
Manuals are also available at www.graco.com.
Manual Description
333023 Reactor 2 E-30 and E-XP2
Operation
333091
333092 Reactor 2 E-30 and E-XP2
Reactor 2 E-30 and E-XP2 Startup Quick Guide
Shutdown Quick Guide

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
333024 Reactor 2 E-30 and E-XP2,
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
3A1905
3A1906 Light Tower Kit, Instructions-Parts 3A1907 Remote Display Module Kit,
332735 332736 Handle and Wheel Kit,
333276
Circulation and Return Tube Kit, Instructions-Parts
Feed Pump Air Supply Kit, Instructions-Parts
Fusion AP Gun Fusion CS Gun
®
Probler
Feed Pump Shutdown Kit, Instructions-Parts
Instructions-Parts Air Manifold Kit, Instructions-Parts
Instructions-Parts Graco InSite Kit, Instructions-Parts
P2 Gun
12
333023G

Typical Installation, without circulation

Typical Installation, without circulation
H
K
G
J
M
K
G
L
J
A
F
N
(RES)
N
(ISO)
D
S
Figure 1
* Shown exposed for clarity. Wrap with tape during operation.
A Reactor Proportioner BHeatedHose C Fluid Temperature Sensor (FTS) D HeatedWhipHose E F G Feed Pump Air Supply Lines H
Fusion Spray Gun Gun Air Supply Hose
Agitator Air Supply Line
E
P
C*
J K Feed Pumps L Agitator MDesiccantDryer NBleedLines P S Remote Display Module Kit (optional)
B
Fluid Supply Lines
Gun Fluid Manifold (part of gun)
333023G 13
Typical Installation, with system uid manifold to drum circulation
Typical Installation, with system fluid manifold to drum circulation
M
K
H
G
J
R
M
K
G
J
A
L
R
(RES)
F
(ISO)
D
S
Figure 2
* 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
Fusion Spray Gun Gun Air Supply Hose
Agitator Air Supply Line
E
P
C*
J K Feed Pumps L Agitator M Desiccant Dryer P R Recirculation Lines S Remote Display Module (optional)
B
Fluid Supply Lines
Gun Fluid Manifold (part of gun)
14
333023G
Typical Installation, with gun uidmanifoldtodrumcirculation
Typical Installation, with gun fluid manifold to drum circulation
Figure 3
* Shown exposed for clarity. Wrap with tape during operation.
A Reactor Proportioner BHeatedHose C Fluid Temperature Sensor (FTS) CK Circulation Block (accessory) D HeatedWhipHose F G Feed Pump Air Supply Lines H
333023G 15
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 Identication
Component Identification
Figure 4
16 333023G
Key
BA BB
CD Advanced Disp DG Drive Gear Hou EC Electrical C EM Electric Motor FA FB FH FM FV GA ISO Side Pre GB RES Side Pr HA HB MP PA PB RR
ISO Side Pressure Relief Outlet RES Side Pressure Relief Outlet
ord Strain Relief
ISO Side Flui RES Side Flui Fluid Heate Reactor Flu Fluid Inlet
ISO Side Ho RES Side H Main Powe ISO Side P RES Side P Graco InS
only)
rs (behind shroud)
id Manifold
Valve(RESsideshown)
rSwitch
ump
ite Cellular Module (Elite models
lay Module (ADM)
sing
d Manifold Inlet
d Manifold Inlet
ssure Gauge essure Gauge se Connection
ose Connection
ump
Component Identication
RS Red Stop Button SA ISO Side PRESSURE RELIEF/SPRAY
SB RES Side PRESSURE RELIEF/SPRAY
T Heated Hose Power Termination Box TA
TB
XA
XB Fluid Inlet Sensor (RES side, Elite models
Valve
Valve
ISO Side Pressure Transducer (behind gauge GA)
RES Side Pressure Transducer (behind gauge GB)
Fluid Inlet Sensor (ISO side, Elite models only)
only)
333023G
17

Advanced Display Module (ADM)

Advanced Display Module (ADM)
The ADM display shows graphical and text information related to setup and spray operations.
NOTICE
To prevent damage to the softkey buttons, do not press buttons with sharp objects such as pens, plastic cards, or ngernails.
Figure 5 Front View
18 333023G

Table 1 : ADM Keys and Indicators

Key Function
Press to startup or shutdown the system.
Advanced Display Module (ADM)
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 or emergency stop.
Press to select the specic 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. Usetocanceladataentryeld.
Usetomovefromscreentoscreen.
Usetomoveamongeldsonascreen,itemsonadropdown
Cancel
Press to enter or exit Setup mode.
Setup
Press to choose a eld to update, to make a selection, to save a selection or value, to enter a screen, or to acknowledge an event.
Enter
333023G 19
Advanced Display Module (ADM)
Figure 6 Back View
CJ Flat Panel Mount (VESA 100) CK Model and Serial Num ber 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
20 333023G
Module error exists
Advanced Display Module (ADM)

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 bar appears at the top of each screen. (The following image is only an example.)
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
Soft Keys
Icons next to the soft keys indicate which mode or action is associated with each soft key. Soft keys that do not have an icon next to them are not active in the current screen.
NOTICE
To prevent damage to the soft key buttons, do not press buttons with sharp objects such as pens, plastic cards, or ngernails.
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.
MM/YY HH:MM
DD/ /MM/DD HH:MM
•YY
/DD/YY HH:MM
•MM
Arrows
The left and right arrows indicate screen navigation.
creen Menu
S
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.
System Mode
The current system mode is displayed at the lower left of the menu bar.

Navigating the Screens

Therearetwosetsofscreens:
The Run s creens control spraying operations and display system status and data.
The Setup screens control system parameters and advanced features.
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.
333023G
21
Advanced Display Module (ADM)

Icons

Icons
Icon Function
Component A
Component B
Estimated Supply Material
Hose Temperature
Jog Mode Speed
Pressure
Cycle Counter (press and hold)
Advisory. See Errors, page 38 for more information.
Deviation. See Errors, page 38 for more information
Alarm. See Errors, page 38 for more information
Softkeys
Icon Function
Start Proportioner
Start and Stop Proportioner in Jog Mode
Stop Proportioner
Turn on or off the specified heat zone.
Park pump
Enter Jog Mode. See Jog Mode, page 46
Reset Cycle Counter (press and hold)
Select Recipe
Search
Move Cursor Left One Character
Move Cursor Right One Character
Toggle between upper-case, lower-case, and numbers and special characters.
Backspace
22
Cancel
Clear
Troubleshoot Selected Error
Increase value
Decrease value
Next screen
Previous screen
Return to first screen
333023G

Electrical Enclosure

Electrical Enclosure
AAA Temperature Control Module (TCM)
AAB Motor Control Module (MCM)
AAC Enclosure Fan
AAD Wiring Terminal Blocks
AAE Power Supply
AAF Surge Protector
AAG Hose Breaker
AAH Motor Breaker
AAJ A Side Heat Breaker
AAK B Side Heat Breaker
AAL Transformer Breaker
MP Main Power Switch
333023G 23

Motor Control Module (MCM)

Motor Control Module (MCM)
Base Model Elite Model
Figure 7
Description
MS Module Status LEDs see LED Status Table 1 2 Motor Temperature 3 Not used 4 Not used 5 Not used 6 7 8 9

Table 3 MCM Module LED (MS) Status Descriptions

LED MCM Status
CAN Communication Connections
A Pump Output Pressure B Pump Output Pressure A Fluid Inlet Sensor (Elite only) B Fluid Inlet Sensor (Elite only)
Conditions
Green Solid Yellow Flashing Red Steady Flashing Software upload from token in
10 Accessory output 11 Not used 12 14 15 16 Main Power Input
*
RS Rotary Switch
* MCM Rotary Switch Positions
2=E-30
3=E-XP2
Pump Cycle Counter Graco Insite Motor Power Output
Description
Power applied to module Active Communication
progress
24
Red Random Flashing or Solid
Module error exists
333023G

Temperature Control Module (TCM) Cable Connections

Temperature Control Module (TCM) Cable Connections
Figure 8
1 Power Input 2 3 4 5 6 7 8 9 10 Hose Temperature

Table 4 TCM Module LED (7) Status Descriptions

LED TCM Status
Heater Overtemperature CAN Communications Connections Power Out (ISO) Power Out (Res) Power Out (Hose) Module Status LEDs Heater A Temperature (ISO) Heater B Temperature (RES)
Conditions
Green Solid Yellow Flashing Red Steady Flashing Software upload from token in
Red Random Flashing or Solid
Description
Power applied to module Active Communication
progress Module error exists
333023G 25

Installation

Installation
Setup From Shipping Conguration
1. Remove bolts (A) and nuts.
2. Swing up the electrical enclosure and reins tal l bolt (A) with nut. Tighten bolt (B) and nut.
3. Position cable bundles against the frame and attach to the frame with loose wire tie (C) on each side.
1. Use the supplied bolts to install the sup plied L-brackets onto the system frame in the top-most square holes. Install brackets on both the left and right side of system frame.
2. Secure the L-brackets to the wall. If L-brackets donotlineupwiththewallstudspacing,bolta piece of wood to the studs then secure L -brackets to wood.
3. Use the four holes in the base of the system frame to secure base to the floor. Bolts not supplied.
To prevent serious injury due to system tipping over, ensure Reactor is properly secured to wall.
Note
Mounting brackets and bolts are included in the box of loose parts, shipped with your system.
26 333023G

Setup

Setup

Grounding

The equipment must be grounded to reduce the risk of static sparking. Static sparking can cause fumes to ignite or explode. Grounding provides an escape wire for the electric current.
Reactor:
cord.
Spray gun:
See Install Fluid Temperature Sensor, page 29. Do not disconnect ground wire or sp ray without whip hose.
Fluid supply containers:
Object being sprayed:
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 ushing or relieving pressure,
rmly to the side of a grounded trigger gun.
System is grounded through the power
connect whip hose ground wire to FTS.
follow your local code.
follow your local code.
follow your local
hold a metal part of spray gun
metal
pail, then

General Equipment Guidelines

Determine th e correct size generator. Using the
correct size generator and proper air compressor will enable the proportioner to run at a nearly constantRPM.Failuretodosowillcausevoltage uctuations that can damage electrical equipment.
Use the following procedure to determine the correct size generator.
1. List system components that use peak load
requirements in watts.
2. Add the wattage required by the system
components.
3. Perform the following equation:
Total watts x 1.25 = kVA (kilovolt-am peres )
4. Select a generator size that is equal to or greater
than the determined kVA.
Use proportioner power cords that meet or exceed
therequirementslistedinTable4.Failuretodoso will cause voltage uctuations that can damage electrical equipment.
Use an air compressor with continuous run head
unloading devices. Direct online air compressors that start and stop during a job will cause voltage uctuations that can damage electrical equipment.
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.
Close gun fluid manifold valves A and B
333023G
Use a wall power supply with enough current
to meet system requirements. Failure to do so will cause voltage uctuations that can damage electrical equipment.
27
Setup

Connect Power

All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.
1. Turn main power switch (MP) OFF.
2. Open electrical enclosure door.
NOTE:
Terminal jumpers are located inside the
electrical enclosure door.
3. Install supplied terminal jumpers in the positions shown in image for the power source used.
4. Route power cable through strain relief (EC) in electrical enclosure.
5. Connect incoming power wires as shown in image. Gently pull on all connections to verify they are properly secured.
6. Verify all items are connected properly as shown in image then close electrical enclosure door.

Table 5 Power Cord Requirements

Model Input Power
E-30, 10 kW
200–240 VAC, 1Phase
200–240 VAC, 3 Phase, DELTA
350–415 VAC, 3 Phase, WYE
E-30, 15 kW
200–240 VAC, 1Phase
200–240 VAC, 3 Phase, DELTA
350–415 VAC, 3 Phase, WYE
Cord Specications AWG (mm
2
)
4 (21.2), 2 wire + ground
6(13.3),3wire +ground
8 (8.4), 4 wire +ground
4 (21.2), 2 wire + ground
6(13.3),3wire +ground
8 (8.4), 4 wire +ground
Model Input Power
E-XP2, 15 kW
200–240 VAC, 1Phase
200–240 VAC, 3Phase, DELTA
350–415 VAC, 3 Phase, WYE
Cord Specifications AWG (mm
2
)
4 (21.2), 2 wire + ground
6(13.3),3wire +ground
8(8.4),4wire +ground
28 333023G

Supply Wet Cups With Throat Seal Liquid (TSL)

Pump rod and connecting rod m ove 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:
with 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) filled
Setup
Component B (Resin) Pump:
in packing nut/wet-cup (S) daily. Keep saturated with Graco Throat Seal Liquid (TSL), Part No. 206995, to prev en t material from hardening on displacement rod. Replace felt washers when worn or contaminated with hardened material.
Figure 10 Component B Pump
Check felt washers

Install Fluid Temperature Sensor

Figure 9 Component A Pump
The Fluid Temperature Sensor (FTS) is supplied. Install FTS between main hose and whip hose. See Heated Hose manual for instructions.
333023G 29
Setup

Connect Heated Hose to Proportioner

See the heated hose manual for detailed instructions.
1. For proportioners with termination box (TB):
a. Connect hose power wires to terminal block
(T) on termination box (TB). Remove box cover and loosen lower strain relief (E). Route hose wires (V) through the box strain relief and fully insert into terminal block (T). A and B hose wire positions are not important. Torque to 2630 in-lbs (2.9–3.3 N·m).
b. Fully tighten strain relief screws and replace
cover.
a. Connect hose power wires to electrical splice
connectors (S) from proportioner. Wrap connections with electrical tape.
Figure 12 Electrical Splice Connectors
3. Connect FTS cable connectors (R). Fully tighten RTD connectors, if provided.
Figure 11 Termination Box
2. For proportioners with elec tric al splice connectors (S):

Register and Activate the Graco InSite

Note
Elite systems only.
1. Go to www.GracoInSite.com, then follow the instructions on the screen.
2. Find and record the 15 di gi t serial numb er from the cellular module below.
30 333023G

Advanced Display Module (ADM) Operation

Advanced Display Module (ADM) Operation
When main power is turned on by turning the main power switch (MP) to the ON position, the power up screen will be displayed until communication and initialization is complete.
Then the power key icon screen will display until the ADM power on/off button (A)
rst time after system power-up. To begin using the ADM, the machine must be active.
To verify the machine is active, verify that the System Status Indicator Light (B) is illuminated green, see
Advanced Display Module (ADM), page 18.Ifthe
System Status Indicator Light is not green, press the ADM Power On/Off (A) button
Status Indicator Light will illuminate yellow if the machine is disabled.
is pressed for the
. The System
Perform t
1. Set pressure values for the Pressure Imbalance
2. Enter, enable, or disable recip es. See
3. Set general system settings. See
4. Set units of measure. See
5. Set USB settings. See
6. Set target temperatures and pressure. See
7. Set component A and component B supply
he following tasks to fully setup your system.
Alarm to activate. See System Screen 1, page 35.
Recipes Screen, page 35.
Advanced Screen 1 General, page 34.
Advanced Screen 2 Units, page 34.
Advanced Screen 3— USB, page 34.
Targets, page 37.
levels. See Maintenance, page 38.
333023G 31
Advanced Display Module (ADM) Operation

Setup Mode

The ADM will start i n 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
Setup Screens Navigation Diagram, page 45.
.Press to navigate through the Setup Mode screens. See
Set Password
Set a password to allow Setup screen access, see Advanced Screen 1 General, page 34. Enter any 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.
32 333023G
Advanced Display Module (ADM) Operation
Setup Screens Navigation Diagram Figure 13
333023G 33

Advanced Setup Screens

Advanced Setup Screens
Advanced setup screens enable users to set units, adjust values, set formats, and view software information for each component. Press Advanced setup screen, press
to exit edit mode.
Note
Users must through th
be out of edit mode to scroll
e Advanced setup screens.
to scroll through the Advanced setup screens, Once i n the desired
to access the elds and make changes. When changes are complete press

Advanced Screen 1 — General

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

Advanced Screen 3 — USB

UsethisscreentoenableUSBdownloads/uploads, enable a logs 90% full advisory, enter the maximum number of days to download data, enable specifying date range of data to download, and how frequently USB logs are recorded. See USB Data, page 60.

Advanced Screen 2 — Units

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

Advanced Screen 4— Software

This screen displays the software part number and software version for the Advanced Display Module, USB Configuration, Motor Control Module, and Temperature Control Modules.
34 333023G

System 1

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

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.
Add Reci
pe
Use this screen to enable Manu al Hose Mode and inlet sensors, as well as setting the i nlet 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.
1. Press and then use to select a
recipe field. Press (maximum 16 characters). Press
oldrecipename.
2.Use to highlight the next eld and use the
number pad to enter a value. Press
toenterarecipename
to clear 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
333023G 35
to highlight the enabled check box.
to enable or disable the recipe.

Run Mode

Run Mode
The ADM will st screens. See R
From the Run sc
to access the Setup screens.
art in the Run screens at the Home screen. Press
un Screens Navigation Diagram, page 44.
reens, press
to navigate through the Run Mode
36 333023G
Run Screens Navigation Diagram
Run Mode

Home — System Off

This is the home screen when the system is off. This screen displays actual temperatures, actual pressures at the uid 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 uid manifold, coolant temperature, jog speed, the number of cycles, along with all associated control soft keys.

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.SeeTroubleshooting, page 59 for corrective
action.
to acknowledge the error.

Targets

Usethisscreentodenethesetpointsforthe A Component Temperature, B Component Temperature, heated hose temperature, and pressure.
Maximum A and B temperature:
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 modied at the gun.
190°F (88°C)
10°F (5°C)
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.
NOTE:
temperatures and pressures. These will not be shown on models without inlet sensors.
Screen shown displays inlet sensor
333023G 37
Run Mode

Maintenance

Use this screen to view daily and lifetime cycles or gallons that have been pumped and gallons or liters remaining in the drums.
The lifetime value is the number of pump cycles or gallons since the rst time the ADM was turned on.
The daily value automatically resets at midnight.
The manual value is the counter that can be manually reset. Press
and hold to reset manual counter.

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. See Error Codes and Troubleshooting, page 59 for error code descriptions.
All events and errors listed on this screen can be downloaded on a USB flash drive. To download logs, see Download Procedure, page 60.

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 ash drive.

Errors

This sc descr syste
All errors listed on this screen can be downloaded on a USB flash drive.
reen shows the date, time, error code, and
iption of all errors that have occurred on the
m.
38 333023G

Troubleshooting

This screen displays the last ten errors that occurred on the system. Use the up and down
Run Mode
arrows to select an error and press the QR code for the selected error. Press
to access the QR code screen for an error code that is not listed on this screen. See
Error Codes and Troubleshooting, page 59,formore
information on error codes.
to view
QR Codes
Toquicklyviewonlinehelpforagivenerrorcode, scan the displayed QR code with your smartphone. Alternately, visit http://help.graco.com and search for the error code to view online help for that code.
333023G 39
Run Mode

Diagnostic

Use this screen to view information for all system components.
The following information is displayed:
Temperature
A C hemical
B C hemical
•HoseChemical
TCM PCB temperature control module temperature
Amps
•ACurrent 15 kW heater)
•BCurrent 15 kW heater)
Hose Current
Volts
•MCMBus motor controller, which is the DC voltage that has been converted from the AC voltage supplied to the system (275400 VAC typical full range)
Hose Voltage (90V)
(0–25 A for 10kW heater, 0–38 A for
(0–25 A for 10kW heater, 0–38 A for
(0–45 A typical)
displays the voltage supplied to the
Note
Maximum values based on maximum input
voltage. Values will lower with lower input voltage.

Job Data

Use this screen to enter a job name or number.

Recipes

Use thi up and d
by a green box.
sscreentoselectanenabledrecipe.Usethe
own arrows to highlight a recipe and press
to load. The currently loaded recipe is outlined
Note
This screen will not display if there are not any enabled recipes. To enable or disable recipes, see Recipes Setup Screen, page 35.
Pressure
Pressure A chemical
Pressure B chemical
Cycles
CPM cycles per minute
Total Cycles lifetime cycles
40 333023G
Run Mode

System Events

Use the table below to find a description for all system non-error events. All events are logged in the USB log les.
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
333023G
41

Startup

Startup
desired, the level can be entered and tracked in the ADM. See Advanced Setup Screens, page 34.
4.
Check generator fuel level.
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 uctuations that can damage electrical equipment and void the warranty.
1.
Check uid inlet lter screens.
Before daily startup, ensure that the fluid inlet screens are clean. See
Flush Inlet Strainer Screen, page 56
NOTICE
Running out of fuel will cause voltage fluctuations that can damage electrical equipment and void the warranty. Do not run out of fuel.
5.
Confirm main power switch is OFF before starting generator.
6. Ensure the main breaker on the generator is in the off position.
7. Start the generator. Allow it to reach full operating temperature.
2.
Check ISO lubrication reservoir.
Check level and condition of ISO lube daily. See
Pump Lubrication System, page 57.
3. Use A and B Drum Level Sticks (24M174) to measure the material level in each drum.. If
42
8.
Turn main power switch ON.
The ADM will display the following screen until communication and initialization is complete.
333023G
Startup
9. Switch on the air compressor, air dryer, and
breathing air, if included.
10.
For first startup of new system, load fluid with feed pumps.
a. Check that all
See Setup, page 27.
b. If an agitator is used, open the agitator’s air
inlet valve.
c. If you need to circulate uid through the
system to preheat the drum supply, see
Circulation Through Reactor, page 45.
If you need to circulate material through the heat hose to the gun manifold, see
Circulation Through Gun Manifold, page 46.
d. Turn both PRESSURE RELIEF/SPRAY
valves (SA, SB) to SPRAY
Setup
steps are complete.
.
e. Open uid inlet valves (FV). Check for leaks.
Cross-contamination can result in cured material in uid 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.
Always provide two grounded waste containers to keep component A and component B uids separate.
f. Hold gun uid manifold over two grounded
waste containers. Open uid valves A and B until clean, air-free uid comes from valves. Close valves.
The Fusion AP gun manifold is shown.
333023G 43
Startup
11. Press to activate ADM.
12. If necessary, setup the ADM in Setup Mode. See
Advanced Display Module (ADM) Operation, page 31.
13. Preheat t he system:
a. Press
to turn on hose heat zone.
Thermal expansion can cause overpressurization, resulting in equipment rupture and serious injury, including fluid injection. Do not pressurize system when preheating hose.
b. If you need to circulate fluid through the
system to preheat the drum supply, see
Circulation Through Reactor, page 45.
If you need to circulate material through theheathosetothegunmanifold,see
Circulation Through Gun Manifold, page 46.
c. Wait for the hose to reach set point
temperature.
This equipment is used with heated uid which can cause equipment surfaces to become very hot. To avoid severe burns:
Do not touc h hot uid or equipment.
Do not turn on hose heat without uid in hoses.
Allow equipment to cool completely before touching it.
Wear gloves if uid temperature exceeds 110°F (43°C).
d. Press
Note
Hose heat-up time may increase at voltages less than nominal 230 VAC when maximum hose length is used.
to turn on A and B heat zones.
44
333023G

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 rega rding uid temperature limits.
NOTE:
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 46.
1. Follow Startup, page 42.
Optimum heat transfer is achieved at lower
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.
.Linesmustbe
3. Set PRESSURE RELIEF/SPRAY valves (SA,
SB) to PRESSURE RELIEF/CIRCULATION
4. Set temperature targets. See Targets, page 37.
5. Press A and B temperatures reach targets. See
Jog Mode, page 46 for more information about
jog mode.
6. Press
7. Turn on the A and B heat zones. Wait until the uid inlet valve temperature gauges (FV) reach the minimum chemical temperature from the supply drums.
8. Exit jog mode.
9. Set PRESSURE RELIEF/SPRAY valves (SA, SB) to SPRAY
to circulate uid in jog mode until
to turn on the hose heat zone.
.
.
2. See Typical Installation, with system fluid
manifold to drum circulation, page 14.Route
circulation lines back to respective component A or B supply drum. Use hoses rated at the maximum working pressure of this equipment. See Technical Specifications, page 66.
333023G 45

Jog Mode

Circulation Through Gun Manifold

NOTICE
To prevent equipment damage, do not circulate uid containing a blowing agent without consulting with your material supplier regarding uid temperature limits.
NOTE:
uid flow rates with temperature set points at desired drum temperature. Low temperature rise deviation errors may result. Circulating uid through the gun manifold allows rapid preheating of the hose.
1. Install gun fluid manifold (P) on accessory
Optimum heat transfer is achieved at lower
circulation kit (CK). Connect high press u re circulation lines (R) to circulation manifold.
hoses rated at the maximum working pressure of this equipment. See
Technical Specifications, page 66.
3. Follow procedures from Startup, page 42.
4. Turn main power switch on
5. Set temperature targets. See Targe ts, page 37.
6. Press A and B temperatures reach targets. See
Jog Mode, page 46 for more information about
jog mode.
to circulate uid in jog mode until
.
Jog Mode
Jogmodehastwopurposes:
It can speed uid heating during circulation.
It can ease system flushing and priming.
The Fusion AP gun manifold is shown.
CK Gun
246362 Fusion AP 309818 256566
2. Route circu lat ion lines ba ck to respect iv e component A or B supply drum. Use
Fusion CS
Manual
313058
1. Turn main power switch on
2. Press circulate
3. Press up or down (J1 through J20).
Note
Jog speeds correlate to 3-30% of motor power, 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
.
46 333023G

Spraying

The Fusion AP gun is shown.
1. Engage gun piston safety lock and close gun fluid inlet valves A and B.
Fusion Probler
2. Attach gun uid manifold. Connect gun air line. Open air line valve.
Spraying
6. Open uid inlet valve located at each pump inlet.
7. Press to start motor and pumps.
3. Adjust the gun air regulator to desired gun air pressure. Do not exceed the maximum rated air pressure.
4. Set PRESSURE RELIEF/SPRAY valves (SA,
SB) to SPRAY
5. Verify heat zones are on and temperatures and pressures are on target, see
Home screen, page 37.
.
8. Check uid pressure gauges (GA, GB) to ensure proper pressure balance. If imbalanced, reduce pressure of hi gher component by
slightly
valve for that component toward PRESSURE
RELIEF/CIRCULATION balanced pressures.
turning PRESSURE RELIEF/SPRAY
until gauges show
333023G
47
Spraying
9. Open gun uid inlet valves A and B.
Fusion Probler
NOTICE
To prevent material crossover on impinge ment guns,
never
open uid manifold valves or
trigger gun if pressures are imbalanced.
10. Disengage gun piston safety lock.
Fusion Probler
11. 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 ow, and poor mixing. Too much pressure results in excessive overspray, high ow 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 ow rate and uid 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
48 333023G

Manual Hose Heat Mode

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 cable or FTS temperature 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 i n temperature control mode. If a hose RTD breaks, the rst priority is to fix the RTD. Manual Hose Mode can help finish a job while waiting for repair parts.
3. Select Enable Manual Hose Mode.
Note
When manual hose mode is enabled, the manual hose mode advisory EVCH-V will appear.
4. Enter Run Mode and navigate to the Target
screen. Use the up and down arrows to set the desiredhosecurrent.

Enable Manual Hose Mode

1. Disconnect the hose RTD sensor from the TCM.
2. Enter Setup Mode and navigate to System Screen 2.
Hose Current Settings Hose Current
Default Maximum 37A
20A
333023G 49
Manual Hose Heat Mode
5. Navigate back to the Run Mode Home screen. The hose now displays a current instead of a temperature.
Note
Until the RTD sensor is repaired, the T6DH sensor error alarm will display each time the system is powered up.

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 cable or FTS.
2. Manual hose mode is automatically disabled when the system detects a valid RTD sensor in the hose.
50 333023G

Shutdown

Shutdown
NOTICE
Proper system setup, startup, and shutdow n procedures are critical to electrical equipment reliability. The following procedures ensure steady voltage. Failure to follow these procedures will cause voltage uctuations that can damage electrical equipment and void the warranty.
1. Press to stop the pumps.
2. Turn off all heat zones.
6. Turn off the air compressor, air dryer, and
breathing air.
7. Turn main power switch OFF.
3. Relieve pressu re. See
Pressure Relief Procedure, page 53.
4. Press to park the Component A Pump. The park operation is complete when green dot goes out. Verify the park operation is complete be fore moving to next step.
5. Press to deactivate the system.
To prevent electric shock do not remove any shrouds or open the electrical enclosure door.
8. Close all uid supply valves.
333023G 51
Shutdown
9. Set PRESSURE RELIEF/SPRAY valves (SA,
SB) to SPRAY
to seal out moisture from
drain line.
10. Engage gun piston safety lock then close uid inlet valves A and B.
Fusion Probler
52 333023G

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 uid, such as skin injection, splashing uid 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. Engage gun piston safety lock.
3. Close gun uid inlet valves A and B.
4. Shut off feed pumps and agitator, if used.
5. Route uid to waste containers or supply tanks. Turn PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION
. Ensure gauges drop to 0.
333023G 53

Flushing

Flushing
To flush feed hoses, pumps, and heaters separately from heated hoses, set PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESS URE
To help prevent re and explosion:
Flush equipment only in a well-ventilated area.
Do not spray ammable uids.
Do not turn on heaters while ushing with flammable solvents.
Flush out o ld uid with new fluid, or ush out old uid with a compatible solvent before introducing new uid.
Use the lowest possible pressure when flushing.
All wetted parts are compatible with common solvents. Use only moisture-free solvents.
RELIEF/CIRCULATION lines (N).
To ush entire system, circulate through gun uid manifold (with manifold removed from gun).
To prevent moisture from reacting with isocyanate, always leave the system lled with a moisture-free plasticizer or oil. Do not use water. Never leave the system dry. See Important Isocyanate Information.
. Flush through bleed
54 333023G

Maintenance

Prior to performing any maintenance procedures, follow Pressure Relief Procedure, page 53.

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.

Proportioner Maintenance

Maintenance
Grease Circulation Valves
Grease circulation valves (SA and SB) with Fusion grease (117773) weekly.
ISO Lubricant Level
Wet Cup
Check the wet cup daily. Keep it 2/3 full with Graco Throat Seal Liquid (TSL not overtighten packing nut/wet cup.
®
) or compatible solvent. Do
Packing Nuts
Do not overtighten packing nut/wet cup. Throat u-cup is not adjustable.
Fluid Inlet Strainer Screens
Inspect uid inlet strainer screens daily, see
Flush Inlet Strainer Screen, page 56.
Inspect ISO lubricant level and condition daily. Refill or replace as needed. See
Pump Lubrication System, page 57.
Moisture
To prevent crystallization, do not expose component Atomoistureinair.
Gun Mix Chamber Ports
Clean gun mix chamber ports regularly. See gun manual.
Gun Check Valve Screens
Clean gun check valve screens regularl y. See gun manual.
Dust Protection
Use clean, dry, oil-free compressed air t o prevent dust buildup on control modules, fans, and motor (under shield).
Vent Holes
Keep vent holes on bottom of electrical cabinet open.
333023G 55
Maintenance

Flush Inlet Strainer Screen

The inlet strainers lter 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
Clean the A-side screen only during daily startup. This minimizes moisture contamination by immediately ushing out any isocyanate residue at the start of dispensing operations.
1. Close the uid inlet valve at the pump inlet and shut off the appropriate feed pump. This prevents material from being pumped while cleaning the screen.
compatible solvent and shake it dry. Inspect the screen. No more than 25% of the mesh should be restri ct ed. If more than 25% of the mesh is blocked, replace the screen. Inspect the gasket (B) and replace as required.
4. Ensure the pipe plug (D) is screwed into the strainer plug (C). Install the strainer plug with the screen(A)ando-ring(B)inplaceandtighten.Do not overtighten. Let the gasket make the seal.
5. Open the uid inlet valve, ensure that there are no leaks, and wipe the equipment clean. Proceed with operation.
2. Place a containerunderthe strainerbase to catch drain off when removing the strainer plug (C).
3. Remove the screen (A) from the strainer manifold. Thoroughly ush the screen with
Figure 15
56 333023G
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 t he 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 53.
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.
3. Drain the reservoir and ush it with clean
lubricant.
4. When the reservoir is flushed clean, ll 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 16
333023G 57

Errors

Errors

View Errors

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 Troubleshooting, page 59. Error codes arestoredintheerrorloganddisplayedontheError and Troubleshooting screens on the ADM.
There are are indic tower (op
Alarms are indicated by a parameter critical to the process has reached a level requiring the system to stop. The alarm needs to be addressed immediately.
Deviations are indicated by indicates a parameter critical to the process has reached a level requiring attention, but not sufficient enough to stop the system at this time.
Advi
cates a parameter that is not immediately critical
indi to th prev
three types of errors that can occur. Errors
ated on the display as well as by the light
tional).
. This condition indi cates
. This condition
sories are indicated by
e process. The advisory needs attention to ent more serious issues in the future.
. This condition

Troubleshoot Errors

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.
2. The QR c ode screen will be dis pl ay ed. Scan the QR code with your smart phone to be sent directly to online troubleshooting for the active error code. Otherwise, manually navigate to http://help.graco.com and search for the active error.
To diagnose the active error, see
Troubleshoot Errors, page 58.
3. If no internet connection is available, see
Error Codes and Troubleshooting, page 59 for
causes and solutions for each error code.
58 333023G

Troubleshooting

See Errors, page 58 for information about e rrors that can occur on the system.

Error Codes and Troubleshooting

See system repair manual or visit http://help.graco.com for causes and solutions to each error code.
Troubleshooting
See Troubleshooting, page 39 for the ten most recent errors that have occurred on the system. See
Troubleshoot Errors, page 58 to diagnose errors on
the ADM that have occurred on the system.
333023G 59

USB Data

USB Data

Download Procedure

Note
System configuration setting les and custom language files can be modified if the les are in the UPLOAD folder of the USB ash drive. See System Configuration Settings File, Custom Language File, and Upload Procedure sections.
1. Insert USB ash drive into USB port.
2. The menu bar and USB indi ca tor lights in dic ate that the USB is downloading les. Wai t for USB activity to complete.
3. Remove USB ash drive from USB port.
4. Insert USB ash drive into USB port of computer.
5. The USB ash drive window automatica lly opens. If it does not, open USB ash drive from within Windows® Explorer.
6. Open GRACO folder.
7. Instructions continue on next page.
8. 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 DOWNLOAD folder.
10. Open DATAxxxx folder.
11. Open DATAxxxx folder labeled with the highest number. The highest number indicates the most recent data download.
12. Open log file. Log les 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 le in Microsoft Word, select Unicode encoding.

USB Logs

Note
The ADM can read/write to FAT (File Allocation Table) storage devices. NTFS, used by 32 GB or greater storage devices, is not supported.
During operation, the ADM stores system and performance related information to memory in the form of log les. The ADM maintains six log les:
•EventLog
Job Log
•DailyLog
System Software Log
Blackbox Log
Diagnostics Log Follow Download Procedure, page 60,toretrieve
log les.
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.
Event Log
The event log le 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
•Eventtype
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.
60 333023G
USB Data
Job Log
Thejoblogfilenameis2JOB.CSVandisstored in the DATAxxxx folder.
The job log maintains a record of data points based on the USB Log Frequency dened in the Setup screens. The ADM stores the last 237,000 da ta points f or d ownloa d. See
Setup - Advanced Screen 3 USB, page 34,for
informationonsettingtheDownloadDepthandUSB Log Frequency.
Data point date
Data point time
A side temperature
B side temperature
Hose temperature
A side temperature setpoint
B side temperature setpoint
Hose temperature setpoint
A side inlet pressure
B side inlet pressure
Inlet pressure setpoint
System Software Log
The system software le 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 le 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
Thediagnosticslenameis6DIAGNO.CSVandis 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 lifetime pump cycle counts
Pressure, volume, and temperature units
Job name/number
Daily Log
The daily log le 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—unusedcolumn
Total pump cycle count for day
Total volume sprayed for day
System Configuration Settings
The system configuration settings le name is SETTINGS.TXT and is stored in the DOWNLOAD folder.
A system conguration settings le automatically downloads each time a USB flash drive is inserted into the ADM. Use this le to back up system settings for future recovery or to easily replicate settings across multiple systems. Refer to the
Upload Procedure, page 62 for instructions on how
to use this le.
333023G 61
USB Data

Custom Language File

The custom language le name is DISPTEXT.TXT andisstoredintheDOWNLOADfolder.
A custom language le automatically downloads each time a USB flash drive is inserted into the ADM. If desired, use this le to create a user-dened set of custom language strings to be displayed within the ADM.
The system is able to display the following Unicode 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 (B asic 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)
Create Custom Language Strings
The custom language le is a tab-delimited text le 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 le as needed and the follow Upload Procedure, page 62 , to install the file.
The format of the custom language le 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
The fil e format must be a tab-delimited text le using Unicode (UTF-16) character representation.
The le must contain only two columns, with columns separated by a single tab character.
Do not add or remove rows to the le.
Do not change the order of the rows.

Upload Procedure

Use this procedure to install a system conguration file and/or a custom language file.
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 ash drive window automatically opens.
If it does not, open USB ash 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 le into the UPLOAD folder.
7. If installing the custom language le, place
DISPTEXT.TXT le into the UPLOAD folder.
8. Remove USB ash drive from the computer.
9. Install USB ash drive into the ADM USB port.
10. The menu bar and USB indicator lights indicate
that the USB is downloading les. Wait for USB activity to complete.
11. Remove USB flash drive from USB port.
Note
Download Procedure
to
If the custom language le is used, you must define a custom string for each entry in the DISPTEXT.TXT le. Blank second-column elds will be displayed blank on the ADM.
The file name must be DISPTEXT.TXT.
62 333023G
If the custom language le was installed, users can now select the new language from the Language drop-down menu in
Advanced Screen 1 General, page 34.

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)
(9.1)
20
FLOW lbs/min (kg/min)
AR6060
(03)
AR7070
(04)
25
(11.3)
E-30
30
(13.6)
35
(15.9)
40
(18.1)
333023G 63
Performance Charts

Proportioners For Coatings

Table 6 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 7 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-XP2
1.5
(5.7)
E-XP2
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)
64 333023G

Table 8 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-XP2
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 9 Fusion Mechanical Purge, Flat Pattern

3500
(241, 24.1)
(1.5)
XF2323
(FTM424)
MF2929
(FTM424)
XF2929
(FTM424)
(FTM638)
0.6
(2.3)
XF3535
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-XP2
1.8
(6.8)
2.0
(7.6)
333023G 65
Technical Specications
Technical Specifications
Reactor 2 E-30 and E-XP2 Proportioning System
U.S.
Maximum Fluid Working Pressure
E-30 2000 psi 14 MPa, 140 bar E-XP2 3500 psi 24.1 MPa, 241 bar
Maximum Fluid Temperature
E-30 E-XP2
Maximum Flow Rate
E-30 30 lb/min 13.5 kg/min E-XP2 2 gpm 7.6 lpm
Maximum Inlet Temperature
E-30 E-XP2
Maximum Inlet Fluid Pressure
E-30 300 psi 2.1 MP a, 21 bar E-XP2 300 psi 2.1 MPa, 21 bar
Maximum Heated Hose Length
Length
Output per Cycle
ISO and RES E-30 0.0272 gal. 0.1034 liter
E-XP2 0.0203 gal. 0.0771 liter
Operating Ambient Temperature Range
Temperature
Line Voltage Requirement
Nominal 200–240 VAC, 1 Phase, 50/60 Hz
Nominal 200–240 VAC, 3 phase, DELTA, 50/60 Hz
Nominal 350–415 VAC, 3 phase, WYE, 50/60 Hz
Heater Power
(at 2 30 VAC rated voltage) E-30 10 kW 10,200 Watts
E-30, 15 kW 15,300 Watts E-XP2 15 kW 15,300 Watts
190°F 88°C 190°F 88°C
150°F 66°C 150°F 66°C
310 ft
2 to 12F -7° to 49°C
195–265 VAC
195–265 VAC
340–455 VAC
Metric
94 m
66 333023G
Technical Specications
Sound Pressure
Sound Pressure measured per ISO-9614–2.
E-30
Measured from 3.1 ft (1 m), at 1000 psi (7 MPa, 70 bar), 3 gpm (11.4 lpm)
E-XP2 Measured from 3.1 ft (1 m), at 3000 psi (21 MPa, 207 bar), 1 gpm (3.8 lpm)
Sound Power
E-30 Measured from 3.1 ft (1 m), at 1000 psi (7 MPa, 70 bar), 3 gpm (11.4 lpm)
E-XP2 Measured from 3.1 ft (1 m), at 3000 psi (21 MPa, 207 bar), 1 gpm (3.8 lpm)
Fluid Inlets
Component A ISO) and 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) Maximum Pressure 250 psi 1.75 MPa, 17.5 bar
Dimensions
Width 26.3 in. 668 mm Height 63 in. 1600 mm Depth 15 in. 381 mm
Weight
E-30, 10 kW 315 lb 143 kg E-30, 15 kW 350 lb 159 kg E-30, 10 kW Elite 320 lb 145 kg E-30, 15 kW Elite 355 lb 161 kg E-XP2 345 lb 156 kg E-XP Elite 350 lb 159 kg
Wetted Parts
Material Aluminum, stainless steel, zinc plated carbon steel, brass,
carbide, chrome, chemically resistant o-rings, PTFE, ultra-high
3/4 NPT(f) with 3/4 NPSM(f) union
molecular weight polyethylene
87.3 dBA
79.6 dBA
93.7 dBA
86.6 dBA
333023G 67

Notes

Notes
68 333023G

Graco Extended Warranty for 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 accordance with Gracos 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 verication of the claimed defect. If the claimed defect is veried, 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 reects 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 c hanges at any time without notice.
Original Instructions. This manual contains English. MM 333023
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 G, June 2015
Fax:
612-378-3505
Minneapolis
Belgium, China, Japan, Korea
www.graco.com
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