Graco Reactor E-10hp Instructions Manual
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Graco Reactor E-10hp Instructions Manual

Graco Reactor E-10hp Instructions Manual

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Instructions
Reactor
For spraying or dispensing polyurea coatings and polyurethane foam. For professional
use only.
Not approved for use in explosive atmospheres or hazardous locations.
3000 psi (21 MPa, 207 bar) Maximum Working Pressure
For model information, see page 9.
Important Safety Instructions
Read all warnings and instructions in this
manual before using the equipment.
Save these instructions.
®
E-10hp
332144H
EN
ti21488a

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Summary of Contents for Graco Reactor E-10hp

  • Page 1 Instructions ® Reactor E-10hp 332144H For spraying or dispensing polyurea coatings and polyurethane foam. For professional use only. Not approved for use in explosive atmospheres or hazardous locations. 3000 psi (21 MPa, 207 bar) Maximum Working Pressure For model information, see page 9. Important Safety Instructions Read all warnings and instructions in this manual before using the equipment.

  • Page 2: Table Of Contents

    Flushing........26 Graco Standard Warranty ....76 Purge Hoses .

  • Page 3: Warnings

    Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
  • Page 4 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. • Engage trigger lock when not spraying.
  • Page 5 Warnings WARNING 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. •...
  • Page 6 Warnings WARNING 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. • Equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.

  • Page 7: Important Isocyanate (Iso) Information

    Important Isocyanate (ISO) Information Important Isocyanate (ISO) Information Isocyanates (ISO) are catalysts used in two component materials. Isocyanate Conditions Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and atomized particulates. • Read and understand the fluid manufacturer’s warnings and Safety Data Sheets (SDSs) to know specific hazards and precautions related to isocyanates.

  • Page 8: Material Self-Ignition

    Important Isocyanate (ISO) Information Material Self-Ignition NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature. Foam Resins with 245 fa Some materials may become self-igniting if applied Blowing Agents too thick.

  • Page 9: Systems

    Systems Systems Maximum Working Pressure, Unheated Proportione Hose Cord Volts Part (MPa, bar) r Model 35 ft (10.6 m) Adapter Model Part 3000 ® APT100 100-120 VAC 24T100 25R000 249810 Fusion Air Purge (21, 207) 3000 100-120 ® P2T100 24T100 25R000 GCP2RA Probler...

  • Page 10: Related Manuals

    Related Manuals Related Manuals The following manuals are for Reactor E-10hp components and accessories. Some are supplied with your package, depending on its configuration. Manuals are also available at www.graco.com. Manual in English Description Displacement Pump 311076 Instruction-Parts Manual Fusion Air Purge Spray Gun...

  • Page 11: Overview

    • Good for touchup or low flow spraying, up to moderate temperature. The Reactor E-10hp is gravity-fed from 6 gal. (22.7 liter) • Not used to circulate full tanks up to temperature. supply tanks mounted on the unit. •...

  • Page 12: Component Identification

    Component Identification Component Identification ti21488a ti21488a ti6987b . 1 Component Identification Desiccant Dryer Supply Tank (ISO) Recirculation Tubes Supply Tank (RES) Air Line Inlet (quick-disconnect fitting) Pump (ISO) Outlet Hose Connections Pump (RES) Return Hose Connections Heater (under shroud) Fluid Temperature Sensors (located on heater Fluid Pressure Gauges assembly, under shroud) Spray and Overpressure Relief Valves...

  • Page 13: Controls And Indicators

    Controls and Indicators Controls and Indicators NOTICE To prevent damage to the soft key buttons, do not See Controls and Indicators identification table, page press the buttons with sharp objects such as pens, plastic cards, or fingernails. Heater Controls ° °...

  • Page 14: Controls And Indicators

    Controls and Indicators Controls and Indicators Name Description Heater Controls ISO Setpoint Increase Increases the temperature setpoint by one degree in the units selected within the setpoint limits. Press target key prior to adjusting. ISO Setpoint Decrease Decreases the temperature setpoint by one degree in the units selected within the setpoint limits.
  • Page 15 Controls and Indicators Motor/Pump Control Function Knob Heater Control Diagnostic Codes Heater control diagnostic codes appear on the Use the knob (AV) to select desired function temperature display. These alarms turn off heat. Icon Setting Function Table 2: Heater Control Diagnostic Codes Stops motor and Park Code...

  • Page 16: Setup

    Setup Setup Locate Reactor Locate the Reactor on a level surface. To avoid electric shock, always unplug both cords NOTE: Do not expose the Reactor to rain. before servicing the Reactor and wait one minute. Electrical Requirements Heater Power Improper wiring may cause electric shock or other serious injury if work is not performed properly.

  • Page 17: Grounding

    Setup Grounding 2. Connect the recirculation hoses from the gun recirculation ports to the connections (S). The equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode. Improper grounding can cause electric shock.

  • Page 18: Fill Wet-Cups

    Setup Fill Wet-Cups Fill Fluid Tanks Keep the felt washers in the pump wet-cups saturated with ISO pump oil. The lubricant creates a barrier between the ISO and the atmosphere. NOTICE To prevent cross-contamination of fluids and equipment parts, never interchange (isocyanate) and The pump rod and connecting rod move during (resin) parts or containers.

  • Page 19: Purge Air And Flush Fluid From Lines

    Setup Purge Air and Flush Fluid From 5. Turn on Motor Power. System status indicator (AY) should turn on. Lines 6. Set Recirc/Spray valves to Recirc. To avoid fire and explosion: • Flush equipment only in a well-ventilated area. • Ensure main power is off and heater is cool before flushing.

  • Page 20: Startup

    Startup Startup b. Press to display target temperatures. Heated fluid can cause equipment surfaces to become very hot. To avoid severe burns: c. To set heat zone target temperature, • Do not operate Reactor without all covers and shrouds in place. press until the display shows •...

  • Page 21: Heatup Guidelines

    Startup Heatup Guidelines Heat Management Tips The fluids must be circulated from the pumps through • Heaters perform better with lower flow rates or the heater, hoses, and back to the tanks to ensure warm smaller mix modules. fluids are supplied to the gun. •...

  • Page 22: Operation

    Operation Operation Spraying 4. Check fluid pressure gauges to ensure proper pressure balance. If imbalanced, reduce pressure of higher component by slightly turning Recirc/Spray valve for that component toward Recirc, until gauges show balanced pressures. The pressure imbalance alarm (Status Code 1) is inactive for 10 seconds after entering spray pressure mode, to NOTE: Air is supplied to the spray gun with the gun allow time to balance pressures.

  • Page 23: Pause

    Operation Pause Refill Tanks To bring the hose and gun back to spray temperature Material can be added to the tanks at any time. See Fill after a brief break, use the following procedure. Fluid Tanks, page 18. 1. Engage the piston safety lock or trigger safety lock. If you are operating at high temperatures or flow rates, follow Pause instructions, page 23, to bring the tanks up to temperature.

  • Page 24: Pressure Relief Procedure

    Operation Shutdown Pressure Relief Procedure Follow the Pressure Relief Procedure whenever For longer breaks (more than 10 minutes) use the you see this symbol. following procedure. If you will be shutdown for more than 3 days, first see Flushing, page 26. 1.

  • Page 25: Maintenance

    Maintenance Maintenance • Check pump wet-cups fluid level daily, page 18. • Generally, flush if you will shutdown for more than three days. Flush more often if material is moisture • Throat u-cup is not adjustable. Do not overtighten sensitive and humidity is high in the storage area, or packing nut/wet-cup.

  • Page 26: Flushing

    Flushing Flushing 4. Remove recirculation tubes (P) from supply tanks and place in original containers or waste containers. To avoid fire and explosion, always ground equipment and waste container. To avoid static sparking and injury from splashing, always flush at the lowest possible pressure.

  • Page 27: Purge Hoses

    Flushing Purge Hoses 10. When nearly clear solvent comes from recirculation tubes, set function knob to Stop/Park . Return Disconnect hoses from gun and secure back into the tanks for thorough cleaning with solvent. recirculation tubes to supply tanks. STATUS •...

  • Page 28: Troubleshooting

    Troubleshooting Troubleshooting Pump Control Status Codes To turn off automatic shutdown and/or change pressure tolerances for status code 2, see DIP Switch Settings, page 30. Determine the status code by counting the number of times the system status indicator blinks. The status Deviation can occur if power is turned on if the function indicator will blink 1-19 times to indicate a status code.
  • Page 29 Troubleshooting a. If status code 5 is still present, replace the 2. Check that the tank level sensor is in contact with the surface of the tank. Replace if necessary. See board. Tank Fluid Level Sensors, page 55. b. If status code 5 is not active, test the motor. See 3.

  • Page 30: Dip Switch Settings

    Troubleshooting DIP Switch Settings 3. Locate the DIP switch on the control board. To avoid electric shock, always unplug both power cords before servicing Reactor and wait one minute. 1. Turn power off and unplug the power cords from the wall outlets.
  • Page 31 Troubleshooting DIP Switch Settings and Functions DIP Switch Settings and Functions DIP Switch and Function DIP Switch 1 DEVIATION DEVIATION AND If selected, displays a status code or displays a status code SHUTDOWN and causes shutdown if the pressure imbalance exceeds selection made in DIP Switch 2.

  • Page 32: Heat Control Diagnostic Codes

    Troubleshooting Heat Control Diagnostic Codes E01: High Fluid Temperature • The thermocouple ISO or RES (310) senses a fluid Heat control diagnostic codes appear on the temperature above 260°F (71°C). temperature display. • The overtemperature switch ISO or RES (308) senses a fluid temperature above 230°F (110°C) These alarms turn off heat.
  • Page 33 Troubleshooting 5. Verify fluid temperature, using an external temperature sensing device. Table 7: Connector B Resistance Measurements 120V 230V Reading Connector Connector Description 1, 2 1, 2 Overtemperature Switch nearly 0 ohms Thermocouple ISO, R (red) 4-6 ohms Thermocouple ISO, Y (yellow) Thermocouple RES, R (red) 4-6 ohms Thermocouple RES, Y (yellow)

  • Page 34: Reactor Electronics

    Troubleshooting Reactor Electronics 2. Shut off Motor Power. 3. Relieve the pressure. Follow Pressure Relief Procedure, page 24. 4. Allow the equipment to cool. Before performing any troubleshooting procedures: 5. Try the recommended solutions in the order given for each problem to avoid unnecessary repairs. 1.

  • Page 35: Heaters

    Troubleshooting Heaters 2. Shut off Motor Power. 3. Relieve the pressure. Follow the Pressure Relief Procedure, page 24. 4. Allow the equipment to cool. Before performing any troubleshooting procedures: Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Also, 1.

  • Page 36: Proportioner

    Troubleshooting Proportioner 2. Shut off Motor Power. 3. Relieve the pressure. Follow the Pressure Relief Procedure, page 24. 4. Allow the equipment to cool. Before performing any troubleshooting procedures: Try the recommended solutions in the order given for 1. Shut off Heater Power. each problem, to avoid unnecessary repairs.
  • Page 37 Troubleshooting PROBLEM CAUSE SOLUTION One side doesn’t come up to Low fluid in the tank. Refill. pressure in spray mode. Dirty or damaged Spray valve. Clean or repair. See Replace Spray Valves, page 40. Plugged fluid inlet strainer. Clear. See Maintenance, page 25. Pump intake valve plugged or stuck Clean the pump intake valve.
  • Page 38 Troubleshooting PROBLEM CAUSE SOLUTION RES side rich; lack of ISO side. ISO side gauge is low. ISO side material supply problem. Check ISO side inlet strainer and pump intake valve. RES side gauge is low. ISO side restriction downstream of gauge.

  • Page 39: Repair

    Repair Repair Before Beginning Repair Remove Supply Tank 1. See Before Beginning Repair, page 39. 2. Relieve the pressure, Pressure Relief Procedure, Repairing this equipment requires access to parts page 24. which may cause electric shock or other serious injury 3.

  • Page 40: Replace Spray Valves

    Repair Replace Spray Valves 1. See Before Beginning Repair, page 39. 2. Relieve the pressure. Follow Pressure Relief Procedure, page 24. 3. See F . 7, page 40. Disassemble the Spray valves. ti21837a Clean and inspect all parts for damage. 10.

  • Page 41: Displacement Pump

    Repair Displacement Pump Remove Entire Pump Assembly 7. Disconnect the fluid inlet (C) and outlet (D) lines. Also disconnect the steel outlet tube (46) from the heater inlet. 8. Remove the pump rod cover (222). Push the clip up NOTE: Use a dropcloth or rags to protect the Reactor in back and push pin (217) out.

  • Page 42: Control Panel

    Repair Control Panel 9. Reassemble in reverse order, see F . 10, page 43. Apply medium strength thread sealant where shown. Replace Temperature Display Replace Function Knob/Potentiometer NOTICE 1. See Before Beginning Repair, page 39. Before handling the board, put on a static conductive wrist strap to protect against static discharge which 2.
  • Page 43 Repair ti21841a . 10 Control Panel 332144H...

  • Page 44: Motor Control

    Repair Motor Control Replace Control Board Power Bootup Check Power must be on to check. See F . 11 or location. Function is: Check the motor before replacing the board. See Test Motor, page 53. • Motor ready: LED on. •...
  • Page 45 Repair Table 8: Control Board Connectors (see F . 12) Top Board Connectors Bottom Board Connectors Board Jack Description Connector Description Not Used Female Quick Power Connect Terminals Not Used Plug Housing with Motor Power Male Blades Error LED Tank Level LED Function Knob Brown - ISO Sensor V+ Blue - ISO Sensor V-...
  • Page 46 Repair Replace Temperature Control Modules 3. Put on a static conductive wrist strap. 4. Disconnect all cables and connectors from the NOTICE temperature control module (59). Before handling the assembly put on a static conductive wrist strap to protect against discharge which can damage the assembly.
  • Page 47 Repair Temperature Control Modules Connections Table 9: Heater Control Module Connections Table 9: Heater Control Module Connections Description Connector 100-120VAC 200-240VAC Description POWER/RELAY (G) Circuit board power input and Connector 100-120VAC 200-240VAC contactor control output DATA (A) Not used Table 10: Temperature Power Module Connections Sensor (B) See Table 11 DISPLAY (C)

  • Page 48: Heater

    Repair Heater Nominal Heater Heater Wattage Per Element Voltage Zone Wattage Ohms Test Heater Element 1500 24-32 1000 12-16 2000 73-94 1380 32-43 Remove Heater Element 1. See Before Beginning Repair, page 39. 1. To remove the heater element (307), first remove the thermocouple (310) to avoid damage, see step 2.
  • Page 49 Repair Thermocouple 8. Replace the thermocouple, F . 16. a. Remove the protective tape from the thermocouple tip (T). b. Apply PTFE tape and thread sealant to male 1. See Before Beginning Repair, page 39. threads and tighten the thermocouple housing (H) into the adapter (305).

  • Page 50: Pressure Transducers

    Repair Overtemperature Switch 3. Disconnect the transducer cables from J11 and J12 connectors. Reverse ISO and RES transducer connections and check if status codes follows the bad transducer. 4. Replace the transducer if the transducer fails the 1. See Before Beginning Repair, page 39. test.

  • Page 51: Drive Housing

    Repair Drive Housing Installation 1. Apply grease liberally to the washers (208, 212), bearings (209, 211, 213), gear reducer (214), crankshaft (210), and inside the drive housing (215). Grease is supplied with the replacement parts kits. Removal NOTE: The RES side crankshaft (210) includes the cycle counter magnet (224).

  • Page 52: Replace Cycle Counter Switch

    Repair Replace Cycle Counter Switch The RES side drive housing cover (229) includes the cycle counter switch (223), mounted in the cover. When reassembling, be sure to install the cover with the switch on RES side. 0.6 in. (15.2 mm) from inside edge 1.0 in.

  • Page 53: Electric Motor

    Repair Electric Motor 7. Remove the RES supply tank. See Remove Supply Tank, page 39. Test Motor 8. Cut the zip ties. If the motor is not locked up by the pumps, it can be 9. Thread the motor power switch harness and over tested using a 9 V battery.

  • Page 54: Motor Brushes

    Repair Motor Brushes b. Remove the old brushes and install the new ones supplied in kit. 9. See the instruction sheet included with your brush repair kit. Replace brushes worn to less than 1/2 in. (13 mm). Brushes wear differently on each side of motor; check both sides.

  • Page 55: Tank Fluid Level Sensors

    Repair Tank Fluid Level Sensors 6. Route the new tank level sensor cable through the grommet on the bottom of the cart and through the grommet on the bottom of the control panel. Adjust Connect the new level sensor (57) to J6. Adjust the position of the tank fluid level sensor (57) so 7.
  • Page 56 Repair Reset Sensitivity 5. Use a small flathead screwdriver and slowly turn the adjustment screw (S) clockwise until the yellow LED The tank fluid level sensor sensitivity may need to be turns on. adjusted when: 6. Slowly turn the adjustment screw (S) •...

  • Page 57: Parts

    Parts Parts System Packages 16W239 15G958 15G962 ti21924a ti6987b ti21488a Proportioner Hose Power Cord Adapter System Package Part see page 58 see page 70 Number Region APT100 24T100 25R000 249810   P2T100 24T100 25R000 GCP2RA*   APT900 24R900 25R000 249810 16W239...

  • Page 58: E-10Hp Proportioners

    Parts E-10hp Proportioners 24T100, 100-120VAC, Proportioner 24R900, 200-240VAC, Proportioner 30, 30a ti21853b 332144H...
  • Page 59 Parts ti21855b 332144H...
  • Page 60 Parts 45 46 ti21854a 332144H...

  • Page 61: Proportioner

    Parts Apply sealant to all non-swiveling pipe threads. Orient SSR with terminals 1 and 2 towards the top. Apply sealant to threads of nut cap. Orient fan to flow down and connector plug towards the back. Apply lubricant to thread and axle of cart. Orient heater module with fins outwards.
  • Page 62 Parts Quantity Ref. Part Description 24T100, 100-120 VAC 24R900, 200-240 VAC 24T973 TANK 111800 SCREW, cap, hex hd 127148 SCREW, set, 7/16-14, 1/2, black 24T975 LID; includes o-ring (30a) 24T974 O-RING 24K976 MUFFLER,1/4 NPT 101044 WASHER, plain 119973 CABLE, sst lanyard; 14 in. 24K984 DRYER, desiccant, mini in-line 162453...
  • Page 63 Parts Quantity Ref. Part Description 24T100, 100-120 VAC 24R900, 200-240 VAC 24U007 CONNECTOR, contactor; 120 V 24T992 CONNECTOR, contactor; 230 V 126817 COVER, end 126818 BLOCK, terminal 3-wire 126810 RELAY, cradle 24T993 RELAY, 12V 255043 HOLDER, fuse terminal block; 5 x 20mm 255023 FUSE, 5A, 5 x 20 mm 74†...
  • Page 64 Parts 24T954, 100-120VAC and 200-40VAC Bare Proportioner 207 233 (steel) (bronze) (ref) (bronze) (ref) (steel) (bronze) (bronze) ti21847a 0.6 in. (15.2 mm) from inside edge 1.0 in. (25.4 mm) from inside bottom edge TI7028a Apply lubricant to all gear teeth, motor pinion, and motor Torque fasteners to 30-35 in-lb.
  • Page 65 Parts Ref. Part Description 24T758 MOTOR, electric 207‡ 115492 SCREW, mach, slot hex wash 208* 116074 WASHER, thrust 209* 107434 BEARING, thrust 210* 300001 KIT, crankshaft 211* 180131 BEARING, thrust 212† 116073 WASHER, thrust 213† 116079 BEARING, thrust 214† 244242 GEAR, reducer (first stage) 215‡...

  • Page 66: 24U009, 100-120Vac Heater 24T955, 200-240Vac Heater

    Parts 24U009, 100-120VAC Heater 24T955, 200-240VAC Heater ti21850a Torque to 120 ft-lb (163 N•m). Apply lubricant to o-rings before assembling in heater housing. Torque to 23 ft-lb (31 N•m). Tighten NPT fitting from sensor to heater housing as shown. Remove tape from probe tip prior to inserting. Insert probe Apply 110009 thermal heat sink compound.

  • Page 67: 24T962, Display

    Parts 24T962, Display ti21841a Ref. Part Description Qty. Ref. Part Description Qty. 117523 NUT, cap (#10) 24T963 PLATE, display, front 127157 SCREW, mach, captive, #8 24T964 ENCLOSURE, control 127158 NUT, captive, #8 24T966 DISPLAY, heat two zone 24T968 DIODE, light-emitting, red 24T967 CONTROL, board, assy 24T971 DIODE, light-emitting, yellow 24K983 SWITCH, rocker, w/breaker, 240v,...

  • Page 68: Fluid Inlets

    Parts Fluid Inlets 24T986, ISO Inlet 24T982, RES Inlet Align Y-strainer as shown Apply sealant to all npt threads. Do not apply to JIC threads. Apply thermal lubricant to thermometer probe. Torque fitting of bent tube to 45-50 ft-lb (61-67 N•m). Align bent tube to fitting within 2°.

  • Page 69: 24T960, Fluid Manifold

    Parts 24T960, Fluid Manifold Apply sealant to assembled non-swiveling pipe threads. 455b (Blue) Apply sealant and PTFE tape to threads. 455a (Red) Apply sealant to valve threads. Torque to 240-260 in-lb (27-29 N•m). Apply lubricant to mating surfaces of valve base and handle.

  • Page 70: 25R000, Insulated Hose Bundle With Recirculation Lines

    Parts 25R000, Insulated Hose Bundle with Recirculation Lines 502 (Ref) 503 (Ref) TI6991a Ref. Part Description Qty. Ref. Part Description Qty. 15G342 HOSE, air; 1/4 in. (6 mm) ID; 1/4 24R996 HOSE, fluid (component ISO), npsm (fbe); 35 ft (10.7 m) moisture guard;...
  • Page 71 Parts . 23 Power Harness (78) Wire Identification 332144H...
  • Page 72 Parts . 24 332144H...

  • Page 73: Suggested Replacement Parts

    Suggested Replacement Parts Suggested Replacement Accessories Parts Part Description 24E727 Probler Recirc Kit Part Description 24U342 Lift Ring Kit 24K984 DRYER, desiccant 24K983 SWITCH, motor or heater power, with circuit breaker 101078 Y-STRAINER 26A349 KIT, filter, replacement (2 pack) 26A350 KIT, filter replacement (10 pack) 15D909 ELEMENT, air filter, 5 micron;...

  • Page 74: Technical Specifications

    Technical Specifications Technical Specifications Reactor E-10hp Metric Maximum fluid working pressure 3000 psi 20.6 MPa, 206 bar Maximum spray pressure: 120 V 2200 psi 15.2 MPa, 152 bar Maximum spray pressure: 230 V 2500 psi 17.2 MPa, 172 bar Maximum fluid temperature 170°F...
  • Page 75 Technical Specifications Reactor E-10hp Metric Sound Power* In fast recirculation mode 79.9 dB(A) Measure at 2500 psi (17 MPa, 172 93.3 dB(A) bar), 1 gpm (3.8 lpm) Fluid Outlets ISO Side -5 JIC male RES Side -6 JIC male Fluid Circulation Returns...

  • Page 76: Graco Standard Warranty

    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.

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