Graco Reactor 2 Hydraulic Operation

Proportioning systems

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Operation

Reactor® 2 2 2 Hydraulic

Reactor®

Proportioning Systems

Proportioning

Hydraulic, Heated,

Heated, Plural

Plural Component

Hydraulic,

Heated,

Plural

coatings. Not

Not for

for outdoor

outdoor use.

coatings.

Not

for

outdoor

Not approved

approved for

for use

use in in in explosive

Not

approved

for

use

Important

Important Safety

Important

Safety Instructions

Safety

Read all warnings and instructions in this manual.

Save

Save these

these instructions.

these

instructions.

For model information, see page 9.

Hydraulic

Systems

Component Proportioner

Proportioner for

Component

Proportioner

use. For

For professional

professional use

use.

For

professional

explosive atmospheres

atmospheres or or or hazardous

explosive

atmospheres

Instructions

PROVEN QUALITY. LEADING TECHNOLOGY.

for spraying

spraying polyurethane

polyurethane foam

for

spraying

polyurethane

use only.

only.

use

only.

hazardous locations.

locations.

hazardous

locations.

334945C

foam and

and polyurea

polyurea

foam

and

polyurea

Table of Contents

Summary of Contents for Graco Reactor 2 Hydraulic

Page 1 Operation Reactor® 2 2 2 Hydraulic Hydraulic Reactor® Reactor® Hydraulic 334945C Proportioning Proportioning Systems Proportioning Systems Systems Hydraulic, Heated, Heated, Plural Plural Component Component Proportioner Proportioner for for spraying spraying polyurethane polyurethane foam foam and and polyurea polyurea Hydraulic, Hydraulic, Heated, Plural Component...
Page 2: Table Of Contents
Install Heated Hose to Proportioner....31 Technical Speciications........66 Advanced Display Module (ADM) Operation..........32 Dimensions ............68 Advanced Setup Screens ......35 Notes ............... 69 System 1 ............. 36 System 2 ............. 36 Graco Extended Warranty ........70 334945C...
Page 3: Warnings
Warnings Warnings Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-speciic risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings.
Page 4 Warnings WARNING WARNING WARNING SKIN SKIN SKIN INJECTION INJECTION INJECTION HAZARD HAZARD HAZARD High-pressure luid from dispensing device, 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 surgical treatment.
Page 5 Warnings WARNING WARNING WARNING THERMAL THERMAL THERMAL EXPANSION EXPANSION HAZARD EXPANSION HAZARD HAZARD Fluids subjected to heat in conined spaces, including hoses, can create a rapid rise in pressure due to the thermal expansion. Over-pressurization can result in equipment rupture and serious injury.
Page 6 Warnings WARNING WARNING WARNING EQUIPMENT EQUIPMENT EQUIPMENT MISUSE MISUSE HAZARD MISUSE HAZARD HAZARD Misuse can cause death or serious injury. • Do not operate the unit when fatigued or under the inluence of drugs or alcohol. • Do not exceed the maximum working pressure or temperature rating of the lowest rated Technical Data Data in all equipment manuals.
Page 7: Important Isocyanate Information
Important Isocyanate Information Important Isocyanate Isocyanate Information Information Important Important Isocyanate Information Isocyanates (ISO) are catalysts used in two component materials. Isocyanate Isocyanate Isocyanate Conditions Conditions Conditions Spraying or dispensing luids that contain isocyanates creates potentially harmful mists, vapors, and atomized particulates.
Page 8 Important Isocyanate Information Material Material Material Self Self - - - Ignition Self Ignition Ignition Moisture Moisture Sensitivity Moisture Sensitivity Sensitivity of of of Isocyanates Isocyanates Isocyanates Exposure to moisture (such as humidity) will cause ISO to partially cure, forming small, hard, abrasive crystals that become suspended in the luid.
Page 9: Models
Elite packages also include may be less. Graco InSite and luid inlet sensors. All Elite Total system watts used by system, based on hose and gun system packages include �...
Page 10 Elite packages also include may be less. Graco InSite and luid inlet sensors. All Elite Total system watts used by system, based on hose and gun system packages include �...
Page 11 Elite packages also include may be less. Graco InSite and luid inlet sensors. All Elite Total system watts used by system, based on hose and gun system packages include �...
Page 12 Elite packages also include may be less. Graco InSite and luid inlet sensors. All Elite Total system watts used by system, based on hose and gun system packages include �...
Page 13 Elite packages also include may be less. Graco InSite and luid inlet sensors. All Elite Total system watts used by system, based on hose and gun system packages include �...
Page 14: Approvals
Elite packages also include 9902471 9902471 9902471 Graco InSite and luid inlet sensors. All Elite hose and gun system packages include Conforms to ANSI/UL Std. 499 Xtreme-Wrap™ 50 ft (15 m) heated hose. Certiied to CAN/CSA Std. C22.2 No. 88...
Page 15: Accessories
Graco InSite Kit Manuals are available at www.graco.com. 17F837 Inlet Sensor Kit System System Manuals System Manuals Manuals 16X521 Graco InSite Extension cable 24.6 ft 334946 Reactor 2 Hydraulic Repair-Parts (7.5 m) Displacement Pump Pump Manual Manual Displacement Displacement Pump...
Page 16: Typical Installation, Without Circulation
Typical Installation, without circulation Typical Typical Typical Installation, Installation, Installation, without without circulation without circulation circulation (B-RES) (A-ISO) Figure 1 * Shown exposed for clarity. Wrap with tape during operation. Reactor Proportioner Fluid Supply Lines Heated Hose Feed Pumps Fluid Temperature Sensor (FTS) Agitator Heated Whip Hose Desiccant Dryer...
Page 17: Typical Installation, With System Luid Manifold To Drum Circulation
Typical Installation, with system luid manifold to drum circulation Typical Installation, Installation, with with system system luid luid manifold manifold to to to drum drum Typical Typical Installation, with system luid manifold drum circulation circulation circulation (B-RES) (A-ISO) Figure 2 * Shown exposed for clarity.
Page 18: Typical Installation, With Gun Luid Manifold To
Typical Installation, with gun luid manifold to drum circulation Typical Installation, Installation, with with gun gun luid luid manifold manifold to to to drum drum Typical Typical Installation, with luid manifold drum circulation circulation circulation (B-RES) (A-ISO) Figure 3 * Shown exposed for clarity. Wrap with tape during operation. Reactor Proportioner Fluid Supply Lines Heated Hose...
Page 19: Notes
Notes Notes Notes Notes 334945C...
Page 20: Component Identiication
Component Identiication Component Identiication Identiication Component Component Identiication Figure 4 334945C...
Page 21 Component Identiication ISO Side Pressure Relief Outlet Graco InSite Cellular Module (Elite models only) RES Side Pressure Relief Outlet Red Stop Button Advanced Display Module (ADM) ISO Side PRESSURE RELIEF/SPRAY Electrical Cord Strain Relief Valve RES Side PRESSURE RELIEF/SPRAY Electric Motor (behind shroud)
Page 22: Advanced Display Module (Adm)
Advanced Display Module (ADM) Advanced Display Display Module Module (ADM) (ADM) Advanced Advanced Display Module (ADM) Table 1 1 1 : : : ADM ADM Keys Keys and and Indicators Indicators The ADM display shows graphical and text Table Table Keys Indicators information related to setup and spray operations.
Page 23 Advanced Display Module (ADM) Figure 6 ADM Back View Flat Panel Mount (VESA 100) Model and Serial Number USB Port and Status LEDs CAN Communication Cable Connection Module Status LEDs Accessory Cable Connection Token Access Cover Backup Battery Access Cover Table Table 2 2 2 ADM Table...
Page 24: Adm Display Details
Advanced Display Module (ADM) ADM Display Display Details Display Details Details System Errors Errors System System Errors The current system error is displayed in the middle of Power Up Up Screen Screen Power Power Screen the menu bar. There are four possibilities: The following screen appears when the ADM is Icon Function...
Page 25 Advanced Display Module (ADM) Icons Icons Icons Icons Icons Icons Softkeys Softkeys Softkeys Icon Function Icon Function Icon Icon Function Function Icon Icon Function Function Component A Start Proportioner Stop Proportioner Component B Turn on or off the speciied heat zone. Estimated Supply Material Park pump Hose Temperature...
Page 26: Electrical Enclosure
Electrical Enclosure Electrical Electrical Electrical Enclosure Enclosure Enclosure H-40, H-50, H-50, H-XP3 H-XP3 H-30, H-XP2 H-XP2 H-40, H-40, H-50, H-XP3 H-30, H-30, H-XP2 AAA Temperature Control Module (TCM) AAB Hydraulic Control Module (HCM) AAC Enclosure Fan(s) AAD Wiring Terminal Blocks (H-30/H-XP2 only) AAE Power Supply AAF Sacriicial Surge Protector (SSP) AAG Hose Breaker...
Page 27: Hydraulic Control Module (Hcm)
Module Status LEDs see LED Status Table CAN Communication Connections Motor Over-Temperature A Pump Output Pressure B Pump Output Pressure A Fluid Inlet Sensor B Fluid Inlet Sensor Pump Position Switches Graco Insite ™ Motor Contactor and Solenoids Rotary Switch 334945C...
Page 28: Temperature Control Module (Tcm) Cable
Temperature Control Module (TCM) Cable Connections Temperature Control Control Module Module (TCM) (TCM) Cable Cable Connections Connections Temperature Temperature Control Module (TCM) Cable Connections Figure 8 Table Table 4 4 4 TCM Table TCM Module Module Module LED LED (7) (7) Status Status Descriptions Status...
Page 29: Setup
Setup Setup Setup Setup General General Equipment General Equipment Guidelines Equipment Guidelines Guidelines NOTICE NOTICE NOTICE Grounding Grounding Grounding Failure to properly size the equipment may result in damage. To avoid damage to the equipment, follow the guidelines listed below. •...
Page 30: Connect Power
Setup Connect Connect Connect Power Power Power Table 5 5 5 Power Power Cord Cord Requirements Requirements Table Table Power Cord Requirements Model Model Model Input Input Input Power Power Power Cord Cord Speciications* Cord Speciications* Speciications* NOTE: All electrical wiring must be done by a NOTE: NOTE: AWG (mm^2)
Page 31: Lubrication System Setup
Temperature Sensor Temperature Sensor Sensor (LR) with Graco Throat Seal Liquid (TSL), part 206995 (supplied). The Fluid Temperature Sensor (FTS) is supplied. 1. Lift the lubricant reservoir (LR) out of the bracket Install FTS between main hose and whip hose (see (RB) and remove the container from the cap.
Page 32: Advanced Display Module (Adm)
Advanced Display Module (ADM) Operation Advanced Display Display Module Module (ADM) (ADM) Operation Operation Advanced 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.
Page 33 Advanced Display Module (ADM) Operation Setup Setup Setup Mode Mode 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 .
Page 34 Advanced Display Module (ADM) Operation Setup Screens Screens Navigation Navigation Setup Setup Screens Navigation 334945C...
Page 35: Advanced Setup Screens
Advanced Display Module (ADM) Operation Advanced Advanced Advanced Setup Setup Screens Setup Screens Screens Advanced setup screens enable users to set units, adjust values, set formats, and view software information for each component. Press to scroll through the Advanced setup screens. Once in the desired Advanced setup screen, press to access the ields and make changes.
Page 36: System 1
Advanced Display Module (ADM) Operation System System System 1 1 1 System System 3 3 3 System Use this screen to set the activation pressure for the Use this screen to enable alternate pump cylinder Pressure Imbalance Alarm and Deviation, enable or sizes, to turn motor standby mode on and off, and disable diagnostic screens, set the maximum and to enable recirculation cycle count.
Page 37 Advanced Display Module (ADM) Operation Add Recipe Recipe Recipe 2. Use to highlight the next ield and use the number pad to enter a value. Press to save. 1. Press and then use to select a recipe ield. Press to enter a recipe name Enable or or or Disable Disable Recipes Recipes...
Page 38: Run Mode
Advanced Display Module (ADM) Operation Run Mode Mode 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 From the Run screens, press to access the Setup screens.
Page 39 Advanced Display Module (ADM) Operation Home System Off Home System With With Error Error Home Home System System Home Home System System With Error Active errors are shown in the status bar. The error This is the home screen when the system is off. code, alarm bell, and description of the error will This screen displays actual temperatures, actual scroll in the status bar.
Page 40 Advanced Display Module (ADM) Operation Maintenance Events Maintenance Maintenance Events Events Use this screen to view daily and lifetime cycles or This screen shows the date, time, event code, and gallons that have been pumped and gallons or liters description of all events that have occurred on remaining in the drums.
Page 41 61, for more information on error codes. To quickly view online help for a given error code, scan the displayed QR code with your smartphone. Alternately, visit http://help.graco.com and search for the error code to view online help for that code. 334945C...
Page 42 Advanced Display Module (ADM) Operation Diagnostic Job Data Data Diagnostic Diagnostic Data Use this screen to view information for all system Use this screen to enter a job name or number. components. NOTE: If not visible, this screen may be on the Setup Systems screen (see Setup Mode).
Page 43 Advanced Display Module (ADM) Operation System System System Events Events Events Use the table below to ind a description for all system non-error events. All events are logged in the USB log iles. Event Event Code Event Code Code Description Description Description Recipe Selected...
Page 44: Startup
Startup Startup Startup Startup Conirm main main power power switch switch is is is OFF OFF before before starting starting 5. Conirm Conirm main power switch before starting generator. generator. generator. To prevent serious injury, only operate Reactor with all covers and shrouds in place. NOTICE NOTICE NOTICE...
Page 45 Startup 9. Switch on the air compressor, air dryer, and e. Open luid inlet valves (FV). Check for leaks. breathing air, if included. 10. For For irst irst irst startup startup startup of of of new new system, system, system, load load luid load luid...
Page 46 Startup 11. Press to activate ADM. Thermal expansion can cause over-pressurization, resulting in 12. If necessary, setup the ADM in Setup Mode. See equipment rupture and serious injury, Advanced Display Module (ADM) Operation, including luid injection. Do not page pressurize system when preheating 13.
Page 47: Fluid Circulation
Fluid Circulation Fluid Circulation Circulation Fluid Fluid Circulation Circulation Circulation Circulation Through Through Reactor Through Reactor Reactor 4. Set temperature targets. See Targets, page 5. Before starting the motor, unlock the hydraulic NOTICE NOTICE NOTICE compensator knob, then rotate counter-clockwise until it ceases to move.
Page 48: Circulation Through Gun Manifold
Fluid Circulation Circulation Circulation Circulation Through Through Gun Through Gun Manifold Manifold Manifold 2. Route circulation lines back to respective component A or B supply drum. Use hoses NOTICE NOTICE NOTICE rated for the maximum working pressure of this Technical Speciications Speciications.
Page 49: Spraying
Spraying Spraying Spraying Spraying 6. Open luid inlet valve (FV) located at each pump inlet. The Fusion AP gun is shown. 1. Engage gun piston safety lock and close gun luid inlet valves A and B. 7. Press to start motor and pumps. Fusion Probler Fusion...
Page 50: Spray Adjustments
Spraying 9. Check luid pressure gauges (GA, GB) to 11. Disengage gun piston safety lock. ensure proper pressure balance. If imbalanced, reduce pressure of higher component by slightly turning PRESSURE RELIEF/SPRAY slightly slightly valve for that component toward PRESSURE RELIEF/CIRCULATION until gauges show balanced pressures.
Page 51: Manual Hose Heat Mode
Spraying Manual Manual Manual Hose Hose Hose Heat Heat Heat Mode Mode Mode 3. Select Enable Manual Hose Mode. NOTE: NOTE: NOTE: When manual hose mode is enabled, the If the system produces the T6DH Sensor Error Hose manual hose mode advisory EVCH-V will appear. 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.
Page 52 Spraying Disable Manual Manual Hose Hose Mode Mode Disable Disable Manual Hose Mode 5. Navigate back to the Run Mode Home screen. The hose now displays a current instead of a temperature. 1. Enter Setup Mode and navigate to System 2 Screen and deselect Enable Manual Hose Mode, or repair the hose RTD cable or FTS.
Page 53: Standby
Standby Standby Standby Standby If you stop spraying for a period of time, the unit will enter standby by shutting down the electric motor and hydraulic pump, to reduce equipment wear and minimize heat buildup. The pump icon on the ADM Home screen will lash when in standby.
Page 54: Pressure Relief Procedure
Pressure Relief Procedure 6. Turn off the air compressor, air dryer, and 8. Close all luid supply valves. breathing air. 9. Set PRESSURE RELIEF/SPRAY valves to 7. Turn main power switch OFF. SPRAY to seal out moisture from the drain line. 10.
Page 55 Pressure Relief Procedure 6. Route luid to waste containers or supply tanks. 7. Engage gun piston safety lock. Turn PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION . Ensure gauges drop to 0. 8. Disconnect gun air line and remove gun luid manifold.
Page 56: Flushing
Flushing Flushing Flushing Flushing To lush entire system, circulate through gun luid manifold (with manifold removed from gun). To prevent moisture from reacting with isocyanate, To avoid ire and explosion: always leave the system illed with a moisture-free plasticizer or oil. Do not use water. Never •...
Page 57: Maintenance
Maintenance Maintenance Maintenance Maintenance Table Table Table 6 6 6 Frequency Frequency Frequency of of of Oil Oil Changes Changes Changes Ambient Ambient Ambient Recommended Recommended Recommended Temperature Temperature Temperature Frequency Frequency Frequency 1000 hours or 12 months, 0° to 90° F Prior to performing any maintenance procedures, whichever comes irst (-17°...
Page 58: Flush Inlet Strainer Screen
Maintenance Gun Check Check Valve Valve Screens Screens Check Valve Screens 1. Close the luid inlet valve at the pump inlet and shut off the appropriate feed pump. This prevents Clean gun check valve screens regularly. See gun material from being pumped while cleaning the manual.
Page 59: Pump Lubrication System
Maintenance Pump Pump Pump Lubrication Lubrication System Lubrication System System 5. Thread the reservoir onto the cap assembly and place it in the bracket. Check the condition of the ISO pump lubricant daily. 6. Push the larger diameter supply (ST) tube Change the lubricant if it becomes a gel, its color approximately 1/3 of the way into the reservoir.
Page 60: Errors
Otherwise, manually navigate to enough to stop the system at this time. http://help.graco.com and search for the active error. Advisories are indicated by . This condition indicates a parameter that is not immediately critical to the process.
Page 61: Error Codes And Troubleshooting
Troubleshooting Error Error Codes Troubleshooting See system repair manual 334946 or visit http://help.graco.com for causes and solutions to each error code, or call your Graco contact listed on the back page of this manual. USB Data Data USB Logs Logs...
Page 62: System Coniguration Settings
• Pressure A The Blackbox log maintains a record of how the • Pressure B system runs and the features that are used. This log will help Graco troubleshoot system errors. • A side inlet pressure (Elite only) Diagnostics Log Log File...
Page 63: Custom Language File
The custom language ile is a tab-delimited text ile folder within the GRACO folder. Each folder is that contains two columns. The irst column consists labeled with the corresponding serial number of of a list of strings in the language selected at the the ADM.
Page 64: Performance Charts
Performance Charts Performance Charts Charts Performance Performance Charts Use this chart to help identify the proportioner that will work most eficiently with each mix chamber. Flow rates are based on a material viscosity of 60 cps. NOTICE NOTICE NOTICE To prevent system damage, do not pressurize the system above the line for the gun tip size being used.
Page 65 Performance Charts Coatings Coatings Coatings Performance Performance Chart Performance Chart Chart Table 8 8 8 Coatings Coatings Performance Performance Chart Chart Table Table Coatings Performance Chart ti26345a G = H-XP2 at 50 Hz H = H-XP2 at 60 Hz PRESSURE psi J = H-XP3 at 50 Hz (MPa, bar) K = H-XP3 at 60 Hz...
Page 66: Technical Speciications
Technical Speciications Technical Speciications Speciications Technical Technical Speciications Reactor Reactor 2 2 2 Hydraulic Reactor Hydraulic Hydraulic Proportioning Proportioning Proportioning System System System U.S. Metric U.S. U.S. Metric Metric Maximum Maximum Fluid Maximum Fluid Fluid Working Working Working Pressure Pressure Pressure for for Bare Bare Proportioners...
Page 67 Technical Speciications Supply Voltage Voltage Tolerance Tolerance Supply Supply Voltage Tolerance 200 240V nominal, 1 phase 195 264 VAC, 50/60 Hz (H-30, H-XP2 only) 200 240V nominal, 3 phase 195 264 VAC, 50/60 Hz 350 415V nominal, 3 phase 338 457 VAC, 50/60 Hz Amperage Amperage Requirement Amperage...
Page 68: Dimensions
Dimensions Dimensions Dimensions Dimensions 334945C...
Page 69: Notes
Notes Notes Notes Notes 334945C...
Page 70: Graco Extended Warranty
Graco will, for a period as deined in the table below from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.

Graco Reactor 2 Hydraulic Operation

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