Graco Reactor E-10 Instructions-Parts List Manual
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Graco Reactor E-10 Instructions-Parts List Manual

Graco Reactor E-10 Instructions-Parts List Manual

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Instructions - Parts List
For spraying or dispensing 1:1 mix ratio materials, including epoxies,
polyurethane foam, polyurea coatings, and joint fill materials.
For professional use only.
Not approved for use in European explosive atmosphere locations.
Important Safety Instructions
Read all warnings and instructions in
this manual. Save these instructions.
See page 4 for a list of models and maximum working pressures.
Heated
Package, with
™
Fusion
Gun
Nonheated Package, MD2 Cold Spray Gun
311075V
EN

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Summary of Contents for Graco Reactor E-10

  • Page 1 Instructions - Parts List 311075V For spraying or dispensing 1:1 mix ratio materials, including epoxies, polyurethane foam, polyurea coatings, and joint fill materials. For professional use only. Not approved for use in European explosive atmosphere locations. Important Safety Instructions Read all warnings and instructions in this manual.

  • Page 2: Table Of Contents

    Graco Standard Warranty ....74 Graco Information ......74 Models .

  • Page 3: Related Manuals

    Related Manuals Related Manuals The following manuals are for Reactor E-10 components and accessories. Some are supplied with your package, depending on its configuration. Manuals are also available at www.graco.com. Fusion Mechanical Purge Spray Gun Displacement Pump Part No. Description Part No.

  • Page 4: Models

    Models Models The model no., series letter, and serial no. are located on the back of the Reactor E-10. For faster assistance, please have that information ready before calling Customer Service. Maximum Working Bare Pressure, Proportioner * Electrical Part, Series...

  • Page 5: Warnings

    Warnings Warnings The following general warnings are for the setup, use, grounding, maintenance, and repair of this equipment. Additional, more specific warnings may be found throughout the body of this manual where applicable. Symbols appearing in the body of the manual refer to these general warnings. When these symbols appear throughout the manual, refer back to these pages for a description of the specific hazard.
  • Page 6 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 7 Graco replacement parts only. • Do not alter or modify equipment. • Use equipment only for its intended purpose. Call your Graco distributor for infor- mation. • Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

  • Page 8: Overview

    • Slow circulation results in a higher tem- perature transfer in the heater, so hoses Reactor E-10 is gravity-fed from 7 gal. (26.5 and gun heat up quicker. liter) supply tanks mounted on the unit. The •...

  • Page 9: 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 Sheet (SDS) to know specific haz- ards and precautions related to isocyanates.
  • Page 10 Important Isocyanate (ISO) Information Keep Components A and B For all applications except spray foam Separate Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and atom- Cross-contamination can result in cured material in ized particulates. fluid lines which could cause serious injury or damage equipment.

  • Page 11: Changing Materials

    Important Isocyanate (ISO) 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...

  • Page 12: Component Identification

    Component Identification Component Identification Key for F A Supply Tank A M Fusion Air Purge Spray Gun B Supply Tank B N Desiccant Dryer (mounts on supply tank A) C Pump A P Recirculation Tubes D Pump B Q Air Line Inlet (quick-disconnect fitting) E Heater A R Outlet Hose Connections F Heater B...
  • Page 13 Component Identification Key for F A Supply Tank A N Desiccant Dryer (mounts on supply tank A) B Supply Tank B P Recirculation Tubes C Pump A Q Air Line Inlet (quick-disconnect fitting) D Pump B R Outlet Hose Connections G Fluid Pressure Gauges U Hose Rack and Control Shield H Recirc/Spray and Overpressure Relief Valves...

  • Page 14: Controls And Indicators

    Controls and Indicators Controls and Indicators TI7016a . 3. Controls and Indicators (heated unit shown) Motor/Pump Control • Indicator (ST) blinking: If error occurs, STA- TUS indicator will blink 1 to 7 times to indi- Function Knob cate status code, pause, then repeat. See 1 for a brief description of status ABLE Use knob (CF) to select desired function.

  • Page 15: Motor Power Switch/Circuit Breaker

    Controls and Indicators Motor Power Switch/Circuit Heater Temperature Breaker Controls Switch (MP) turns power on to control board See F . 4. Control knobs (HC) set tempera- and function knob. The switch includes a 20 A ture of component A and B heaters. Indicator circuit breaker.

  • Page 16: Setup

    Be sure your installation complies with all National, State and Local Object being sprayed: follow your safety and fire codes. local code. Connect Reactor E-10 to the correct power source for your model. See T 2. Models Solvent pails used when flushing: ABLE with two power cords must be connected to follow your local code.
  • Page 17 Setup Table 2: Electrical Requirements Model Required Power Source Power Cord Connector 120 V, 1 phase, 50/60 Hz, two Two separate, dedicated cir- Two NEMA 5-15T 15 ft (4.5 m) power cords, cuits rated at minimum of 15 Heated A each 240 V, 1 phase, 50/60 Hz, two Two separate, dedicated cir- Two IEC 320, with...
  • Page 18 To avoid electric shock, always unplug both cords before servicing Reactor E-10. Ensure no other high amp loads are connected while running Reactor E-10. To verify separate circuits, plug in Reactor E-10 or a worklight and cycle breakers on and off. Heater Power Motor Power TI7061a .
  • Page 19 Setup 311075V...
  • Page 20 Setup Heated Units A (ISO) B (RES) Nonheated Units A (ISO) B (RES) . 6. Hose Connections 311075V...
  • Page 21 Setup Fill wet-cups Fill fluid tanks Keep the felt washers in the pump wet-cups saturated with Graco ISO pump oil, Part No. 217374. The lubri- cant creates a barrier between the ISO and the atmosphere. NOTICE To prevent cross-contamination of fluids and...
  • Page 22 Setup Purge air and flush fluid from Lift hose rack. Remove tank A lines cover and pour ISO into tank A (red side, with desiccant filter in cover). Replace cover Remove both recirculation tubes TI7017a (P) from the tanks and secure each one in a dedicated waste Desiccant filter is blue when fresh, and container.
  • Page 23 Setup Turn on Motor Power. When clean fluids exit both recir- culation tubes (P), set function knob to Stop/Park Set Recirc/Spray valves to Recirc. Replace recirculation tubes in supply tanks. On nonheated units, purge the Set function knob to Slow Recirc hoses through the gun without a or Fast Recirc static mixer installed.

  • Page 24: Startup Of Heated Units

    Some models heat the fluid, which can cause equipment surfaces to become very hot. To avoid severe burns: • Do not operate Reactor E-10 without all Temporarily set heater control knobs to covers and shrouds in place. maximum setting. •...

  • Page 25: Heatup Guidelines

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

  • Page 26: Heating Foam Resins With 245 Fa Blowing Agents

    Startup of Heated Units Heating Foam Resins with c. Fill tanks, page 21. 245 fa Blowing Agents d. Set Recirc/Spray valves to Recirc. New foam blowing agents will froth at tempera- tures above 90°F (33°C) when not under pres- sure, especially if agitated. Never fill the 7 gal.

  • Page 27: Spraying/Dispensing

    Spraying/Dispensing Spraying/Dispensing Use lower pressures for joint filling applications. For air operated guns only: Air is sup- Check fluid pressure gauges to ensure plied to spray gun with gun piston safety proper pressure balance. If imbalanced, lock or trigger safety lock engaged and reduce pressure of higher component gun fluid manifold valves A and B by slightly turning Recirc/Spray valve...

  • Page 28: Pause (Heated Units)

    Pause (Heated Units) Disengage piston safety lock or trigger Set Recirc/Spray valves to Recirc until safety lock. temperature readouts come back up. ti10441a Fusion If you stop spraying for more than 2 min- utes when using an impingement mix gun, close gun fluid valves A and B. Test spray onto cardboard or plastic Doing this will keep the internal parts of sheet.

  • Page 29: Pressure Relief Procedure

    Pressure Relief Procedure Pressure Relief Shutdown Procedure For longer breaks (more than 10 min- utes), use the following procedure. If you will be shut down for more than 3 days, first see Flushing, page 31. Follow all steps of Pressure Relief Pro- Engage piston safety lock or trigger cedure, at left.

  • Page 30: Maintenance

    Maintenance Maintenance • Check pump wet-cups fluid level daily, • Generally, flush if you will shutdown for page 21. more than three days. Flush more often if material is moisture sensitive and humidity • Do not overtighten packing nut/wet-cup. is high in the storage area, or if material Throat u-cup is not adjustable.

  • Page 31: Flushing

    Flushing Flushing Set function knob to Stop/Park Flush equipment only in a well-ventilated area. Do not spray flammable fluids. Do not turn on heaters while flushing with flammable solvents. Shut off Heater Power (heated units only). Allow system to cool. •...
  • Page 32 Flushing To flush gun, refer to gun instruction Set function knob to Stop/Park manual. Purge Gun Hoses (Nonheated Units Only) Wipe out any remaining material from Disconnect hoses from gun and secure the supply tanks. Fill each supply tank back into the tanks for thorough clean- with 1-2 gal.

  • Page 33: Troubleshooting

    Troubleshooting Troubleshooting Status Codes In this example, B side pressure is higher, so Determine the status code by counting the use the B side valve to number of times the status indicator (ST) balance pressures. blinks. Turn Recirc/Spray valve only enough to balance pressure.
  • Page 34 Troubleshooting Status Code 1 and 2 Settings (Default) 1. Locate switch SW2 on the control board, page 49. TI7023a TI7024a . 7. DIP Switch (SW2) Settings 2. Set the four DIP switches to the desired positions. See F . 7 and T 5 on page ABLE Table 5: Status Code 1 and 2 Settings...
  • Page 35 1. Motor temperature too high. Reduce pres- 1. Locked rotor; motor unable to turn. Replace sure duty cycle, gun tip size, or move motor, page 53. Reactor E-10 to a cooler location. Allow 1 hour for cooling. 2. Short on control board. Replace board, page 48.

  • Page 36: Troubleshooting Chart

    Troubleshooting Troubleshooting Chart PROBLEM CAUSE SOLUTION Reactor E-10 does not operate. No power. Plug in power cord. Cycle Motor Power off then on to reset breaker. Motor does not operate. Power turned on with function Set function knob to Stop/Park knob set to a run position.
  • Page 37 Troubleshooting PROBLEM CAUSE SOLUTION Pressure is higher on one side Pump intake valve partially Clean pump intake valve. See when setting pressure with func- plugged. page 43. tion knob. Air in hose. Fluid is compressible. Purge air from hose. Unequal size hoses or unequal Use matching hoses, or balance hose construction.
  • Page 38 Troubleshooting PROBLEM CAUSE SOLUTION A side rich; lack of B side. A side gauge is low. B side restriction downstream of gauge. Check gun check valve screen, mix module, or mix mani- fold restrictor. B side gauge is low. B side material supply problem. Check B side inlet strainer and pump intake valve.
  • Page 39 Troubleshooting PROBLEM CAUSE SOLUTION No heat, and heater indicator light Heater Power shut off, or circuit is off. breaker tripped. Cycle Heater Power off then on to reset circuit breaker. Bad thermostat. With power on, check for continu- ity at clicks of heater control knob. To replace thermostat, see 311210.
  • Page 40 Troubleshooting 311075V...

  • Page 41: Repair

    Repair Repair Before Beginning Repair Removing Supply Tanks Displacement pump repair and parts information is included in manual 311076, which is supplied with your unit. Repairing this equipment requires access to 1. See Before Beginning Repair, page 41. parts which may cause electric shock or other serious injury if work is not performed Relieve pressure, page 29.

  • Page 42: Recirc/Spray Valves

    Repair Recirc/Spray Valves 2. See F . 8. Disassemble Recirc/Spray valves. Clean and inspect all parts for dam- age. Ensure that the seat (503a) and gas- ket (503b) are positioned inside each valve cartridge (503). 1. See Before Beginning Repair, page 41. 3.

  • Page 43: Displacement Pump

    If the pump is not generating pressure on the downstroke, intake ball check may be Use dropcloth or rags to protect stuck open. Reactor E-10 and surrounding area from spills. Either of these conditions can be serviced with the pump in place.
  • Page 44 Repair To Remove Entire Pump Assembly 5. Disconnect fluid inlet (C) and outlet (D) lines. Also disconnect steel outlet tube (16) from heater inlet. 6. Remove pump rod cover (222). Push clip up in back and push pin (217) out. Loosen locknut (218) by hitting firmly right-to-left with a non-sparking hammer.

  • Page 45: Control Module

    Repair Control Module Replace Temperature Display and Sensor (Heated Units Only) Change Display Temperature Units (°F/°C) Unit is shipped with temperature displays set to °F. 1. See Before Beginning Repair, page 41. Relieve pressure, page 29. 2. Remove temperature sensor (424): a.
  • Page 46 Repair 8. Reassemble in reverse order. Mount tem- (P) faces up. Install knob on shaft so slot perature display so Heater Power switch off (S) engages alignment pin in knob. Push (0) position is at left when facing control knob onto shaft against detent spring panel.
  • Page 47 Repair Detail of Function Knob/Potentiometer 416a 416a 416a TI7076a 416a *402 *403 *424 410* 424* * These items are not included on the nonheated display. TI6979a . 11. Control Module (Heated Model Shown) 311075V...
  • Page 48 Repair Control Board Table 6: Control Board Connectors (see F . 12) Power Bootup Check Board Jack Description There is one red LED (D11) on the Main power from breaker board. Power must be on to check. See Function knob .
  • Page 49 Repair Heated Models LINE Heater Heater Power On/Off LINE (20 A Breaker) Single Cord Models Only Heater Black Twin Flat Cable Motor J11 (120 V Black Board) CONTROL Function Yellow BOARD Knob Cycle Yellow Counter Black Status SW2 (see page Indicator 34 to adjust Black Sheath...

  • Page 50: Fluid Heaters (If Supplied)

    Repair Fluid Heaters (if supplied) Pressure Transducers Fluid heater repair and parts information is included in manual 311210, which is supplied with heated units. 1. See Before Beginning Repair, page 41. Relieve pressure, page 29. To replace a pressure transducer, see at right.

  • Page 51: Drive Housing

    Repair Drive Housing B side crankshaft (210) includes the cycle counter magnet (224). When reassembling, be sure to install crank- Removal shaft with magnet on B side. If replacing crankshaft, remove magnet (224). Reinstall magnet in center of off- set shaft on new crankshaft. Position shaft in Park position.

  • Page 52: Cycle Counter Switch Replacement

    Repair Cycle Counter Switch Replacement B side drive housing cover (227) includes the cycle counter switch (223), mounted in the cover. When reassembling, be sure to install cover with switch on B side. 0.6 in. (15.2 mm) from inside edge 1.0 in.

  • Page 53: Electric Motor

    Repair Electric Motor Test Motor e. Thread motor power switch harness out bottom of control module and cable If motor is not locked up by pumps, it can be channel, to free motor. tested using a 9 V battery. Open recirculating valves, disconnect J4 or J11 from control NOTICE board, see F...

  • Page 54: Motor Brushes

    Repair Motor Brushes Replace brushes worn to less than 1/2 in. (13 mm). Brushes wear differently on each side of motor; check both sides. Brush Repair Kit 287735 is available; kit includes instruction sheet 406582. Motor commutator should be smooth. If not, resurface commutator or TI7030a replace motor.
  • Page 55 Repair 311075V...

  • Page 56: Parts

    Parts Parts Part No. AP9570 or CS9570, 120 V, 15 A, Heated Package Part No. AP9571 or CS9571, 240 V, 10 A, Heated Package Part No. AP9572 or CS9572, 240 V, 20 A, Heated Package Proportioner Description AP9570 120 V, 15 A, Heated 249570 249499 249810...
  • Page 57 Parts Part No. 249806, 120 V, 15 A, Nonheated Package, MD2 Part No. 249808, 240 V, 10 A, Nonheated Package, MD2 Part No. 24R984, 120 V, 15 A, Nonheated Package, 2K Dispense Part No. 24R985, 240 V, 10 A, Nonheated Package, 2K Dispense 255325 24R021 249633...
  • Page 58 Parts Part No. 249570, 120 V, 15 A, Heated Proportioner Part No. 249571, 240 V, 10 A, Heated Proportioner Part No. 249572, 240 V, 20 A, Heated Proportioner 40▲ 1 (Ref) 1 (Ref) 1 (Ref) 63 64 311075V...
  • Page 59 Parts Heated Proportioners Ref. Part Description Ref. Part Description 24K995 CORD, 120 V; Model 249570 24R382 CART; see page 69 24K997 CORD, 240 V; Model 249571 24L000 TANK, with lid and outlet fitting; 24K996 CORD, 240 V; Model 249572 LDPE; includes item 2a 15G458 CABLE, fan;...
  • Page 60 Parts Ref. Part Description 24E555 KIT, temperature sensor 121063 O-RING, fluroroelastomer 66b‡ 123787 FITTING, elbow, 45°; 3/8 jic x 1/4-18 npt 66c‡ 123788 FITTING, elbow, 45°; 5/16 jic x 1/4-18 npt 555561 RING, retaining, 3/8 16C785 HOUSING, thermowell 16C786 MANIFOLD, fluid 16C787 SPACER, sensor 113641 GAUGE, pressure, fluid;...
  • Page 61 Parts 311075V...
  • Page 62 Parts Part No. 249576, 120 V, Nonheated Proportioner Part No. 249577, 240 V, Nonheated Proportioner 40▲ 1 (Ref) 47 38 30 (Ref) 1 (Ref) 64 65 311075V...
  • Page 63 Parts Nonheated Proportioners Ref. Part Description Ref. Part Description 108296 SCREW, machine, hex washer 24R382 CART; see page 69 hd; 1/4-20 x 5/8 in. (16 mm) 24L000 TANK, with lid and outlet fitting; 217374 LUBRICANT, ISO pump; not LDPE; includes item 2a shown 15F895 .
  • Page 64 Parts Part No. 287655, 120 V Bare Proportioner Part No. 287656, 240 V Bare Proportioner 201 (Ref) ‡221 208* 209* 210* 215‡ 211* 220‡ 207‡ †212 †213 222‡ †214 ◆216 †213 220‡ 217◆ 207‡ TI6978a Ref. Part Description Ref. Part Description 24L006 PUMP, displacement;...
  • Page 65 Parts Part No. 249499, Insulated Hose Bundle with recirculation lines 302 (Ref) 303 (Ref) TI6991a Ref. Part Description Ref. Part Description 15G342 HOSE, air; 1/4 in. (6 mm) ID; 1/4 249508 HOSE, fluid (component A), mois- npsm (fbe); 35 ft (10.7 m) TUBE, foam, insulated;...
  • Page 66 Parts Part No. 24L004, 120 V Heated Display Part No. 24L005, 240 V Heated Display 416a 416a 404 (Ref) TI6979a Ref. Part Description Ref. Part Description 101765 GROMMET 15F984 PLATE 116773 CONNECTOR, plug 24K983 SWITCH, motor or heater 15C866 WIRE, jumper power, with circuit breaker 15G279 LABEL, display 15G386 MODULE, display, tempera-...
  • Page 67 Parts Part No. 249537, 120 V Nonheated Display Part No. 249538, 240 V Nonheated Display 416a 416a 404 (Ref) TI6983a Ref. Part Description Ref. Part Description 15G279 LABEL, display 15F984 PLATE 15G053 PLATE, detent 24K983 SWITCH, motor power, with cir- 24L001 KNOB, function;...
  • Page 68 Parts Part No. 24L009 Recirculation Manifold, Heated Models Ref. Part Description 24K993 MANIFOLD, recirculation 111763 ELBOW; 1/4 npt (mbe) 239914 VALVE, recirc/spray; includes items 503a, 503b 503a 15E022 . SEAT 503b 111699 . GASKET 503a 224807 BASE, valve ▲512 503b 187625 HANDLE, valve, drain 111600 PIN, grooved 100721 PLUG, pipe;...
  • Page 69 Parts Part No. 249582, Cart Ref. Part Description 154636 WASHER, flat 116411 SPRING 116477 WASHER, flat; nylon 116478 WHEEL, pneumatic 101242 RING, retaining GRIP, handle 24U760 BRACKET, tank mount 24U761 BRACKET, crossbar 24U762 BRACKET, motor mount 24T150 GUSSET 110996 NUT, hex, flange head 311075V...

  • Page 70: Suggested Spare Replacement Parts

    Suggested Spare Replacement Parts Suggested Spare Replacement Parts Keep the following spare parts on hand to reduce downtime. All Units Heated Units Only Part Description Part Description 24K984 DRYER, desiccant 24K981 DISPLAY, temperature, with sensor 15F895 O-RING, lid, tank 24K980 FUSE, heater over-temperature 24K983 SWITCH, motor or heater power, with cir- 24K978 THERMOSTAT, heater 24K989 HEATER ELEMENT;...

  • Page 71: Dimensions

    Dimensions Dimensions All Models ti6974b 311075V...

  • Page 72: Technical Data

    Technical Data Technical Data Maximum fluid working 2000 psi (14 MPa, 140 bar) pressure Model AP9570, CS9570: 120 Vac, 1 phase, 50/60 Hz, 3500 W; Electrical requirements requires two separate, dedicated 15 A circuits Model AP9571, CS9571: 240 Vac, 1 phase, 50/60 Hz, 3800 W; requires two separate, dedicated 10 A circuits Model AP9572, CS9572: 240 Vac, 1 phase, 50/60 Hz, 3800 W;...
  • Page 73 Technical Data Tank Capacity 7 gal. (26.5 liters) each (nominal) Component A (ISO): -5 JIC male Fluid Outlets Component B (RES): -6 JIC male Fluid Circulation Returns Component A (ISO): -5 JIC male Component B (RES): -6 JIC male Air Inlet 1/4 in.

  • Page 74: 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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