Graco Reactor 2 E-XP2, Reactor 2 E-30 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.

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

333023D

PROVEN QUALITY. LEADING TECHNOLOGY.

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 ﬂuid manifold

to drum circulation................................. 14

Typical Installation, with gun ﬂuid manifold to

drum circulation..................................... 15

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

Advanced Display Module (ADM).................. 18

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

Advanced Display Module (ADM)

Operation.............................................. 30

Advanced Setup Screens ............................. 33

System 1 ..................................................... 34

System 2 ..................................................... 34

Recipes....................................................... 34

Run Mode ................................................... 35

Startup............................................................... 41

Fluid Circulation.................................................. 44

Circulation Through Reactor ......................... 44

Circulation Through Gun Manifold ................. 45

Jog Mode........................................................... 45

Spraying ............................................................ 46

Spray Adjustments....................................... 47

Manual Hose Heat Mode.............................. 48

Shutdown........................................................... 50

Pressure Relief Procedure .................................. 52

Flushing............................................................. 53

Maintenance ...................................................... 54

Preventative Maintenance Schedule ............. 54

Proportioner Maintenance ............................ 54

Flush Inlet Strainer Screen ........................... 55

Pump Lubrication System............................. 56

Errors ................................................................ 57

View Errors.................................................. 57

Troubleshoot Errors ..................................... 57

Troubleshooting.................................................. 58

Error Codes and Troubleshooting.................. 58

USB Data........................................................... 59

Download Procedure.................................... 59

USB Logs.................................................... 59

System Conﬁguration Settings...................... 60

Custom Language File ................................. 61

Upload Procedure........................................ 61

Performance Charts............................................ 62

Technical Speciﬁcations...................................... 65

Graco Extended Warranty for Reactor® 2

Components ......................................... 67

333023D

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 ﬂuids or fumes can cause serious injury or death if splashed in the eyesoronskin, inhaled, or swallowed.

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

• 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.

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.

333023D 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. Get immediate surgical 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 Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing equipment.

• Tighten all ﬂuid connections before operating the equipment.

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

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help 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 Grounding instructions.

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

333023D

Warnings

WARNING

PRESSURIZED ALUMINUM PARTS HAZARD

Use of ﬂuids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or ﬂuids containing such solvents.

• Many other ﬂuids may contain chemicals that can react with aluminum. 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.

•SeeTechnical Data in this and all other equipment instruction manuals. Read ﬂuid and solvent manufacturer’s MSDSs and recommendations.

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 Technical Data in all equipment manuals.

• 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 equipment and follow the Pressure Relief Procedure when equipment is not in use.

• 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 youareusingit.

• 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

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 and disconnect all power sources.

333023D 5

Warnings

WARNING

BURN HAZARD

Equipment surfaces and ﬂuid that is heated can become very hot during operation. To avoid severe burns:

• Do not touch hot ﬂuid or equipment.

6 333023D

Important Isocyanate Information

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

Important Isocyanate Information

Isocyanate Conditions

Spraying or dispensing materials containing isocyanates creates potentially harmful mists, 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 dryer in the vent, or a nitrogen atmosphere. 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.

333023D

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 multiple times to ensure it is thoroughly clean.

• 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 often have amines on the B (resin) side.

8 333023D

Models

Reactor 2 E-30 and E-30 Elite

All elite systems include ﬂuid inlet sensors, Graco InSite™, and Xtreme-Wrap 50 ft (15 m) heated hose. For part numbers, see Accessories, page 11

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* 78 50 34 100 62 35 78 50 34 100 62 35

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)

Graco Insite

Fluid Inlet Sensors (2)

™

E-30, 10 kW E-30, 15 kW Elite, 10 kW Elite, 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

2301Ø230

3Ø∆

AP2010

(246102)

CS2010

(CS02RD)

P22010

(GCP2R2)

24K240 (scuff guard)

246050 246050 246050 246050

Base Model Elite Model

380 3ØY

2301Ø230

3Ø∆

AP2011

(246102)

CS2011

(CS02RD)

P22011

(GCP2R2)

24K240 (scuff guard)

380 3ØY

2301Ø230

3Ø∆

AP2110

(246102)

CS2110

(CS02RD)

P22110

(GCP2R2)

24Y240 (XtremeWrap)

✓✓

380 3ØY

2301Ø230

AP2111

(246102)

CS2111

(CS02RD)

P22111

(GCP2R2)

24Y240 (XtremeWrap)

3Ø∆

380 3ØY

Full load amps with all devices operating at

maximum capabilities. Fuse requirements at various ﬂow rates and mix chamber sizes may be less.



Total system watts used by system, based on maximum heated hose length for each unit.

• E–30 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 ﬂuid inlet sensors.

333023D 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

E–XP2, 15 kW E–XP2, 15 kW Proportioner ★ 272012 272112

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)

Conﬁgurable 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)

™

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

240 1Ø 240 3Ø 380 3Ø 240 1Ø 240 3Ø 380 3Ø

100 62 35 100 62 35

AP2012

(246101)

P22012

(GCP2R1)

24K241

(scuff guard)

246050 246050

Base Model Elite Model

AP2112

(246101)

P22112

(GCP2R1)

24Y241 (Xtreme-Wrap)

✓

Full load amps with all devices operating at

maximum capabilities. Fuse requirements at various ﬂow rates and mix chamber sizes may be less.



Total system watts used by system, based on maximum heated hose length for each unit.

• E–30 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 ﬂuid inlet sensors.

10 333023D

Approvals

Intertek approvals apply to proportioners without hoses.

Proportioner Approvals:

9902471

Conforms to ANSI/UL Std. 499

Certiﬁed to CAN/CSA Std. C22.2 No. 88

Note

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

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

24N365

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)

RTD Test Cables (to aide resistance measurements)

333023D

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 Air Manifold Kit, Instructions-Parts

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

Instructions-Parts Graco InSite ™ Kit, Instructions-Parts

P2 Gun

333023D

Typical Installation, without circulation

(RES)

(ISO)

Figure 1

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

A Reactor Proportioner

BHeatedHose

C Fluid Temperature Sensor (FTS) D HeatedWhipHose

G Feed Pump Air Supply Lines H

Fusion Spray Gun

Gun Air Supply Hose

Agitator Air Supply Line

K Feed Pumps

L Agitator

MDesiccantDryer

N Bleed Lines

S Remote Display Module Kit (optional)

Fluid Supply Lines

Gun Fluid Manifold (part of gun)

333023D 13

Typical Installation, with system ﬂuid manifold to drum circulation

(RES)

(ISO)

Figure 2

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

A Reactor Proportioner

BHeatedHose

C Fluid Temperature Sensor (FTS) D Heated Whip Hose

G Feed Pump Air Supply Lines H

Fusion Spray Gun

Gun Air Supply Hose

Agitator Air Supply Line

K Feed Pumps

L Agitator

M Desiccant Dryer

R Recirculation Lines

S Remote Display Module (optional)

Fluid Supply Lines

Gun Fluid Manifold (part of gun)

333023D

Typical Installation, with gun ﬂuidmanifoldtodrumcirculation

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

G Feed Pump Air Supply Lines H

333023D 15

Gun Air Supply Hose

Agitator Air Supply Line

K Feed Pumps

L Agitator

MDesiccantDryer

R Recirculation Lines

S Remote Display Module (optional)

Fluid Supply Lines

Gun Fluid Manifold (part of gun)

Component Identiﬁcation

16 333023D

Figure 4

Key

CD Advanced Disp

DG Drive Gear Hou

EC Electrical C EM Electric Motor

GA ISO Side Pre

GB RES Side Pr HA

HC Heated Ho MP

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

rs (behind shroud)

id Manifold

Valve(RESsideshown)

se Electrical Connectors

rSwitch

ump

lay Module (ADM)

sing

d Manifold Inlet

ssure Gauge

essure Gauge

se Connection

ose Connection

ump

Component Identiﬁcation

RS Red Stop Button

SA ISO Side PRESSURE RELIEF/SPRAY

SB RES Side PRESSURE RELIEF/SPRAY

XA Fluid Inlet Sensor (ISO side, Elite models

Graco InSite Cellular Module (Elite models only)

Valve

Valve ISO Side Pressure Transducer (behind

gauge GA) RES Side Pressure Transducer (behind

gauge GB)

only) Fluid Inlet Sensor (RES side, Elite models

only)

333023D

Component Identiﬁcation

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 ﬁngernails.

Figure 5 Front View

18 333023D

Table 1 : ADM Keys and Indicators

Key Function

Press to startup or shutdown the system.

Component Identiﬁcation

Stop

tdown

ator

Press to stop all proportioner processes. This Is not a safety or 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.

Usetocanceladataentryﬁeld.

Startup/Shu

Key and Indic

Soft Keys

Navigation Keys

Numeric Keypad Use to input values.

Usetomovefromscreentoscreen.

Usetomoveamongﬁeldsonascreen,itemsonadropdown

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

333023D 19

Component Identiﬁcation

Figure 6 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

information when in this mode

Power applied to module

Red Steady Flashing Software upload from token in

progress

Red Random Flashing or Solid

Module error exists

20 333023D

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 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 i of the menu bar.

No information or no error has occurred

Advisory

Deviation

Alarm

s displayed at the lower right

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 ﬁngernails.

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.

System Mode

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

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.

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.

333023D

Component Identiﬁcation

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 37 for more information.

Deviation. See Errors, page 37 for more information

Alarm. See Errors, page 37 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 45

Reset Cycle Counter (press and hold)

Select Recipe

Move Cursor Left One Character

Move Cursor Right One Character

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

Backspace

Cancel

Clear

Troubleshoot Selected Error

Increase value

Decrease value

Next screen

Previous screen

Return to ﬁrst screen

333023D

Electrical Enclosure

Component Identiﬁcation

AAA Temperature Control Module (TCM)

AAB Motor Control Module (MCM)

AAC Enclosure Fan

AAD Wiring Terminal Blocks

AAE Power Supply

AAF Surge Protector

AAG Hose Breaker

AAH Motor Breaker

AAJ A Side Heat Breaker

AAK B Side Heat Breaker

AAL Transformer Breaker

MP Main Power Switch

333023D 23

Component Identiﬁcation

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

6 7

Table 3 MCM Module LED (MB) Status Descriptions

LED

MCM Status

CAN Communication Connections

Not used

A Pump Output Pressure

B Pump Output Pressure

A Fluid Inlet Sensor (Elite only)

B Fluid Inlet Sensor (Elite only)

Conditions

Green Solid

Yellow Solid Active Communication

Red Steady Flashing Software upload from token in

10 Accessory output

11 Not used

12 Pump Cycle Counter

14 Graco Insite

15 Motor Power Output

16 Main Power Input

RS Rotary Switch

MCM Rotary Switch Positions

2=E-30

3=E-XP2

™

Description

Power applied to module

progress

Red Random Flashing or Solid

Module error exists

333023D

Temperature Control Module (TCM) Cable Connections

Component Identiﬁcation

Figure 8

1 Power Input

2 Heater Overtemperature

3 CAN Communications Connections

4 Power Out (ISO) 5

6PowerOut(Hose) 7

8 Heater A Temperature (ISO)

9 Heater B Temperature (RES)

10 Hose Temperature

Power Out (Res)

Module Status LEDs

333023D 25

Installation

Setup From Shipping Conﬁguration

1. Remove bolts (A) and nuts.

2. Swing up the electrical enclosure and reinstall 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 supplied 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 do not line up with the wall stud spacing, bolt a 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 333023D

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 spray 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 ﬂushing or relieving pressure,

ﬁrmly 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

hold a metal part of spray gun

metal

pail, then

General Equipment Guidelines

• Determine the correct size generator. Using the

correct size generator and proper air compressor will enable the proportioner to run at a nearly constantRPM.Failuretodosowillcausevoltage ﬂuctuations 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-amperes)

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 ﬂuctuations 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 ﬂuctuations 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

333023D

• Use a wall power supply with enough current

to meet system requirements. Failure to do so will cause voltage ﬂuctuations that can damage electrical equipment.

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 4 Incoming Power Requirements

Model Input Power

Cord Speciﬁcations AWG (mm

E-30, 10 kw

230 1Ø

4(21.2),2wire + ground

230 3Ø∆

6(13.3),3wire +ground

380 3ØY

8 (8.4), 4 wire +ground

E-30, 15 kw

230 1Ø 4 (21.2), 2 wire

+ ground

230 3Ø∆

6(13.3),3wire +ground

380 3ØY

8 (8.4), 4 wire +ground

Model Input Power

Cord Speciﬁcations AWG (mm

)

E-XP2, 15 kw

230 1Ø

4(21.2),2wire

)

+ ground

230 3Ø∆

6(13.3),3wire +ground

380 3ØY

8(8.4),4wire +ground

28 333023D

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

• Component B (Resin) Pump: Check felt washers 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.

Figure 10 Component B Pump

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.

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 digit serial number from

the cellular module below.

333023D 29

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) ﬁrst 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 recipes. 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 34.

Recipes Screen, page 34.

Advanced Screen 1 — General, page 33.

Advanced Screen 2 — Units, page 33.

Advanced Screen 3— USB, page 33.

Targets, page 36.

levels. See Maintenance, page 37.

30 333023D

Advanced Display Module (ADM) 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

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 33. 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.

333023D 31

Advanced Display Module (ADM) Operation

Setup Screens Navigation Diagram Figure 11

32 333023D

Advanced Display Module (ADM) Operation

Advanced Setup Screens

Advanced setup screens enable users to set units, adjust values, set formats, and view software information

for each component. Press

Advanced setup screen, press

to exit edit mode.

Note

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

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 enable USB downloads/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 .

Advanced Screen 2 — Units

Usethisscreentosetthetemperatureunits,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.

333023D 33

Advanced Display Module (ADM) Operation

System 1

Usethisscreentosettheactivationpressureforthe 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 recipes can displayed on the three recipe screens.

Add Recipe

1. Press andthenuse to select a

recipe ﬁeld. Press

(maximum 16 characters). Press old recipe name.

to enter a recipe name

to clear the

2. Use to highlight the next ﬁeld and use the

number pad to enter a value. Press

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

34 333023D

to highlight the enabled check box.

to enable

or disable the recipe.

Advanced Display Module (ADM) Operation

Run Mode

The ADM will start in the Run screens at the “Home” screen. Press to navigate through the Run Mode screens. See Run Screens Navigation Diagram, page 44.

From the Run screens, press

to access the Setup screens.

333023D 35

Run Screens Navigation Diagram Fi

ure 12

Advanced Display Module (ADM) Operation

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 — Sy

When the actual t at the ﬂu the num contro

emperature for heat zones, actual pressures

l soft keys.

stem Active

system is active, the home screen displays

id manifold, coolant temperature, jog speed,

ber of cycles, along with all associated

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 for corrective action.

to acknowledge the error.

Targets

Use this screen to deﬁne the setpoints for the A Component Temperature, B Component Temperature, heated hose temperature, and pressure.

Maximum A and B temperature: 190°F (88°C)

Maximum heated hose temperature: 10°F (5°C) 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.

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: Screen shown displays inlet sensor temperatures and pressures. These will not be shown on models without inlet sensors.

36 333023D

Advanced Display Module (ADM) Operation

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 ﬁrst 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 58 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 59.

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.

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.

333023D 37

Advanced Display Module (ADM) Operation

Troubleshooting

This screen displays the last ten errors that occurred on the system. Use the up and down

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 58,formore

information on error codes.

to view

QR Codes

To quickly view online help for a given error code, scanthedisplayedQRcodewithyoursmartphone. Alternately, visit http://help.graco.com and search for the error code to view online help for that code.

38 333023D

Advanced Display Module (ADM) Operation

Diagnostic

Usethisscreentoviewinformationforallsystem components.

The following information is displayed:

Temperature

•AChemical

•BChemical

• Hose Chemical

• TCM PCB — temperature control module temperature

Amps

•ACurrent

•BCurrent

Job Data

Use this screen to enter a job name or number.

Recipes

Use this s up and do

by a green box.

creen to select an enabled recipe. Use the

wn 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 34.

• Hose Current

Volts

• MCM Bus — displays the voltage supplied to the motor controller, which is the DC voltage that has been converted from the AC voltage supplied to the system

• Hose Voltage (90V)

Pressure

•PressureA—chemical

•PressureB—chemical

Cycles

•CPM—cyclesperminute

• Total Cycles — lifetime cycles

333023D 39

Advanced Display Module (ADM) Operation

System Events

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

Event Code Description

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

40 333023D

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 ﬂuid inlet ﬁlter screens.

Startup

3. Check generator fuel level.

NOTICE

Running out of fuel will cause voltage ﬂuctuations that can damage electrical equipment and void the warranty. Do not run out of fuel.

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

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

Flush Inlet Strainer Screen, page 55

2. Check ISO lubrication reservoir.

Check level and condition of ISO lube daily. See

Pump Lubrication System, page 56.

5. Ensure the main breaker on the generator is in the off position.

6. Start the generator. Allow it to reach full operating temperature.

7. Turn main power switch ON.

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

333023D

Startup

8. Switch on the air compressor, air dryer, and breathing air, if included.

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

a. Check that all Setup steps are complete.

See Setup, page 27.

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

inlet valve.

c. Ifyouneedtocirculateﬂuidthroughthe

system to preheat the drum supply, see

Circulation Through Reactor, page 44.

If you need to circulate material through the heat hose to the gun manifold, see

Circulation Through Gun Manifold, page 45.

d. Turn both PRESSURE RELIEF/SPRAY

valves (SA, SB) to SPRAY

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

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.

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

f. 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.

333023D

Startup

10. Press

11. If necessary, setup the ADM in Setup Mode. See

Advanced Display Module (ADM) Operation, page 30.

12. Preheat the system:

a. Press

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.

to activate ADM.

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 44.

If you need to circulate material through the heat hose to the gun manifold, see

Circulation Through Gun Manifold, page 45.

c. Wait for the hose to reach set point

temperature.

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

• 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).

333023D 43

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 45.

1. Follow Startup, page 41.

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.

. Lines must be

3. Set PRESSURE RELIEF/SPRAY valves (SA,

SB) to PRESSURE RELIEF/CIRCULATION

4. Set temperature targets. See Targets, page 36.

5. Press A and B temperatures reach targets. See

Jog Mode, page 45 for more information about

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.

8. Exit jog mode.

9. Set PRESSURE RELIEF/SPRAY valves (SA,

SB) to SPRAY

to circulate ﬂuid 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 65.

333023D

Jog Mode

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: 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. 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.

pressure of this equipment. See

Technical Speciﬁcations, page 65.

3. Follow procedures from Startup, page 41.

4. Turn main power switch on

5. Set temperature targets. See Targets, page 36.

6. Press A and B temperatures reach targets. See

Jog Mode, page 45 for more information about

jog mode.

to circulate ﬂuid in jog mode until

Jog Mode

Jog mode

• It can speed ﬂuid heating during circulation.

• It can ease system ﬂushing and priming.

has two purposes:

The Fusion AP gun manifold is shown.

CK Gun

246362 Fusion AP 309818

256566

2. Route circulation lines back to respective component A or B supply drum. Use hoses rated at the maximum working

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. Pre

5. To stop the motor and exit jog mode press

or .

to start motor.

to enter jog mode.

to change jog speed

333023D 45

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 ﬂuid manifold. Connect gun air line. Open air line valve.

6. Open ﬂuid inlet valve located at each pump inlet.

7. 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. Verify heat zones are on and temperatures are on target, see Home screen, page 36.

8. Check ﬂuid pressure gauges (GA, GB) to ensure proper pressure balance. If imbalanced, reduce pressure of higher component by slightly turning PRESSURE RELIEF/SPRAY valve for that component toward PRESSURE

RELIEF/CIRCULATION balanced pressures.

until gauges show

46 333023D

Spraying

9. Open gun ﬂuid inlet valves A and B.

Fusion Probler

NOTICE

To prevent material crossover on impingement guns, never open ﬂuid manifold valves or trigger gun if pressures are imbalanced.

10. Disengage gun piston safety lock.

Fusion Probler

Spray Adjustments

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

• Fluid pressure setting. Toolittlepressureresults

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. Similareffectstoﬂuidpressure

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

• Mix chamber size. Choice of mix chamber is based

on desired ﬂow rate and ﬂuid viscosity.

• Clean-off air adjustment. Too little clean-off air

results in droplets building up on the front of the nozzle, and no pattern containment to control overspray. Too much clean-off air results in air-assisted atomization and excessive overspray.

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

333023D

Spraying

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 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.

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 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.

Hose Current Settings Hose Current

Default

Maximum 37A

20A

48 333023D

Spraying

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.

333023D 49

Shutdown

NOTICE

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 pressure. See

Pressure Relief Procedure, page 52.

4. Press to park the Component A Pump. The park operation is complete when green dot goes out. Verify the park operation is complete before 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 ﬂuid supply valves.

50 333023D

9. Engage gun piston safety lock then close ﬂuid

inlet valves A and B.

Fusion Probler

Shutdown

333023D 51

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.

6. Disconnect gun air line and remove gun ﬂuid manifold.

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

52 333023D

Flushing

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

To help prevent ﬁre and explosion:

• 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.

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 Two-

Component Material Information, page 7 .

.Flushthroughbleed

333023D 53

Maintenance

Prior to performing any maintenance procedures, follow Pressure Relief Procedure, page 52.

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

Grease Circulation Valves

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

ti10955a

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 ﬂuid inlet strainer screens daily, see

Flush Inlet Strainer Screen, page 55.

ISO Lubricant Level

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

Pump Lubrication System, page 56.

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 regularly. See gun manual.

Dust Protection

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

Vent Holes

Keep vent holes on bottom of electrical cabinet open.

54 333023D

Maintenance

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

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.

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

4. Ensurethepipeplug(D)isscrewedintothe strainer plug (C). Install the strainer plug with the screen (A) and o-ring (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.

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

3. Remove the screen (A) from the strainer manifold. Thoroughly ﬂush the screen with

Figure 13

333023D 55

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 52.

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 ﬂush it with clean lubricant.

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 14

56 333023D

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 58. Error codes are stored in the error log and displayed on the Error 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.

three types of errors that can occur. Errors

ated on the display as well as by the light

tional).

. This condition indicates

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 previously displayed screen.

or to return to the

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.

Advisories are indicated by indicates a parameter that is not immediately critical to the process. The advisory needs attention to prevent more serious issues in the future.

To diagnose the active error, see

Troubleshoot Errors, page 57.

. This condition

2. TheQRcodescreenwillbedisplayed. Scan

the QR code with your smartphone 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.

3. If no internet connection is available, see

Error Codes and Troubleshooting, page 58 for

causes and solutions for each error code.

333023D 57

Troubleshooting

See Errors, page 57 for information about errors that can occur on the system.

Error Codes and Troubleshooting

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

See Troubleshooting, page 38 for the ten most recent errors that have occurred on the system. See

Troubleshoot Errors, page 57 to diagnose errors on

the ADM that have occurred on the system.

58 333023D

USB Data

Download Procedure

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.

1. Insert USB ﬂash drive into USB port.

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

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. 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 ﬁles open in Microsoft® Excel by default as long as the program is installed. However, they can also be opened in any text 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.

USB Logs

Note

TheADMcanread/writetoFAT(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 ﬁles. The ADM maintains six log ﬁles:

• Event Log

• Job Log

• Daily Log

• System Software Log

• Blackbox Log

• Diagnostics Log

Follow Download Procedure, page 59,toretrieve log ﬁles.

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 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

•Eventcode

•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.

333023D 59

USB Data

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 33,for

information on setting the Download Depth and USB 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

System Software Log

The system software ﬁle name is 4–SYSTEM.CSV and is stored in the DATAxxxx folder.

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

•Asideinletpressure

•Bsideinletpressure

• Inlet pressure setpoint

• System lifetime pump cycle counts

• Pressure, volume, and temperature units

• Job name/number

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

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 61 for instructions on how

to use this ﬁle.

• Total volume sprayed for day

60 333023D

USB Data

Custom Language File

The custom language ﬁle name is DISPTEXT.TXT and is stored in the DOWNLOAD folder.

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.

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 (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)

• 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 remove 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.

1. If necessary, follow the Download Procedure to

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.

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 61 , to install the ﬁle.

The format of the custom language ﬁle is critical. Thefollowingrulesmustbefollowedinorderforthe 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.

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 the ADM. (The serial number is on the back of 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 the 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.

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 33.

• TheﬁlenamemustbeDISPTEXT.TXT.

333023D 61

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)

(2.3)

AR5252

(02)

(4.5)

(6.8)

(9.1)

FLOW lbs/min (kg/min)

AR6060

(03)

AR7070

(04)

(11.3)

E-30

(13.6)

(15.9)

(18.1)

62 333023D

Proportioners For Coatings

Table 5 Fusion Air Purge, Round Pattern

3500

(241)

3000

(207)

Performance Charts

2500

(172)

PRESSURE

psi (bar)

2000

(138)

150 0

(103)

100 0

(69)

500

(34)

0 0.5

Table 6 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)

333023D 63

Performance Charts

Table 7 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

(3.8)

MR3535

(RTM040)

XR4747

(RTM055)

MR4747

(RTM055)

1.5

(5.7)

2.0

(7.6)

FLOW gal./min (l/min)

Table 8 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)

XF1818

(FTM424)

0.2

(0.7)

MF1818

FLOW gal./min (l/min)

MF3535

(FTM638)

0.8

(3.0)

(3.8)

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)

64 333023D

Technical Speciﬁcations

Reactor 2 E-30 and E-XP2 Proportioning System

Technical Speciﬁcations

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 Heated Hose Length

Length

Output per Cycle

150°F 66°C

190°F 88°C

310 ft

Metric

94 m

ISO and RES

E-30 0.0272 gal. 0.1034 liter

E-XP2 0.0203 gal. 0.0771 liter

Operating Ambient Temperature Range

Temperature 20° to 120°F -7° to 49°C

Heater Power

E-30 10 kw 10,200 Watts

E-30, 15 kw 15,300 Watts

E-XP215kw 15,300 Watts

Sound Pressure

Sound Pressure measured per ISO-9614–2.

E-30

87.3 dBA

Measured from 3.1 ft (1 m), at 1000 psi (7 MPa, 70 bar), 3 gpm (11.4 lpm)

E-XP2

79.6 dBA

Measured from 3.1 ft (1 m), at 3000 psi (21 MPa, 207 bar), 1 gpm (3.8 lpm)

333023D 65

Technical Speciﬁcations

Sound Power

E-30

93.7 dBA

Measured from 3.1 ft (1 m), at 1000 psi (7 MPa, 70 bar), 3 gpm (11.4 lpm)

E-XP2

86.6 dBA

Measured from 3.1 ft (1 m), at 3000 psi (21 MPa, 207 bar), 1 gpm (3.8 lpm)

Fluid Inlets

Component A ISO) and 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

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

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

molecular weight polyethylene

66 333023D

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 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 FOR A PARTICULAR PURPOSE.

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. These items sold, but not 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

Motor Control Module 36 Months or 3 Million Cycles

Heater Control Module 36 Months or 3 Million Cycles

36 Months or 3 Million Cycles

Graco Information

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

To place an order, contact your Graco Distributor or call to identify the nearest distributor.

Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505

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

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

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

Original Instructions. This manual contains English. MM 333023

Graco Headquarters: Minneapolis

International Ofﬁces: Belgium, China, Japan, Korea

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

www.graco.com

Revision D, March 2014

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

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Warnings

Important Isocyanate Information

Isocyanate Conditions

Keep Components A and B Separate

Moisture Sensitivity of Isocyanates

Material Self-Ignition

Foam Resins with 245 fa Blowing Agents

Changing Materials

Models

Reactor 2 E-30 and E-30 Elite

Reactor 2 E-XP2 and E-XP2 Elite

Approvals

Accessories

Supplied Manuals

Related Manuals

Component Manuals in English:

Typical Installation, without circulation

Advanced Display Module (ADM)

Table 1 : ADM Keys and Indicators

Table 2 ADM LED Status Descriptions

ADM Display Details

Navigating the Screens

Icons

Electrical Enclosure

Motor Control Module (MCM)

Table 3 MCM Module LED (MB) Status Descriptions

Temperature Control Module (TCM) Cable Connections

Installation

Setup

Grounding

General Equipment Guidelines

Connect Power

Table 4 Incoming Power Requirements

Supply Wet Cups With Throat Seal Liquid (TSL)

Install Fluid Temperature Sensor

Register and Activate the Graco InSite

Advanced Display Module (ADM) Operation

Setup Mode

Set Password

Advanced Setup Screens

Advanced Screen 1 — General

Advanced Screen 3 — USB

Advanced Screen 2 — Units

Advanced Screen 4— Software

System 1

System 2

Recipes

Add Recipe

Enable or Disable Recipes

Run Mode

Home — System Off

Home — System With Error

Targets

Maintenance

Events

Cycles

Errors

Troubleshooting

Diagnostic

Job Data

Recipes

System Events

Startup

Fluid Circulation

Circulation Through Reactor

Jog Mode

Circulation Through Gun Manifold

Spraying

Spray Adjustments

Manual Hose Heat Mode

Enable Manual Hose Mode

Disable Manual Hose Mode

Shutdown

Pressure Relief Procedure

Flushing