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

For spraying or dispensing 1:1 mix ratio materials, including epoxies, polyurethane foam, and polyurea coatings. not for use in explosive atmospheres.
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Download this manual See also: Instruction Manual, Instructions-parts List Manual
Instructions - Parts List
For spraying or dispensing 1:1 mix ratio materials, including
epoxies, polyurethane foam, and polyurea coatings.
Not for use in explosive atmospheres.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 3 for a list of models and maximum working pressures.
Nonheated Package,
™
with 2K Ultra-Lite
Gun
and Cold Spray
disposable mixer
Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2005, Graco Inc. is registered to I.S. EN ISO 9001
Heated Package,
™
with Fusion
Gun
TI6989b
311075E
TI6987b

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Summary of Contents for Graco REACTOR E-10

  • Page 1 See page 3 for a list of models and maximum working pressures. Heated Package, ™ with Fusion Nonheated Package, ™ with 2K Ultra-Lite and Cold Spray disposable mixer TI6987b TI6989b Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441 Copyright 2005, Graco Inc. is registered to I.S. EN ISO 9001...

  • Page 2: Table Of Contents

    Pause (Heated Units) ..... . . 21 Graco Information ......58 Refilling Tanks .

  • Page 3: 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. Bare Maximum Package Proportioner Working Part No., Part No.,...

  • Page 4: Warnings

    Warnings Warnings The following general warnings are for the setup, use, grounding, maintenance, and repair of this equipment. Addi- tional, more specific warnings may be found throughout the body of this manual where applicable. Symbols appear- ing 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 5 Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer. • Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco replacement parts only. • Do not alter or modify equipment.

  • Page 6: Overview

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

  • Page 7: Isocyanate Hazard

    Never store ISO in an open container. • Keep the felt washers in the pump wet-cups satu- rated with Graco ISO pump oil, Part No. 217374. The lubricant creates a barrier between the ISO and the atmosphere. •...

  • Page 8: Component Identification

    Component Identification Component Identification Key for F Supply Tank A Desiccant Dryer (mounts on supply tank A) Supply Tank B Recirculation Tubes Pump A Air Line Inlet (quick-disconnect fitting) Pump B Outlet Hose Connections Heater A Return Hose Connections Heater B Fluid Temperature Sensors Fluid Pressure Gauges Hose Rack and Control Shield...
  • Page 9 Component Identification Key for F Supply Tank A Desiccant Dryer (mounts on supply tank A) Supply Tank B Recirculation Tubes Pump A Air Line Inlet (quick-disconnect fitting) Pump B Outlet Hose Connections Fluid Pressure Gauges Hose Rack and Control Shield Recirc/Spray and Overpressure Relief Valves Fluid Inlet Ball Valves (1 on each side) Control Panel;...

  • Page 10: Controls And Indicators

    Controls and Indicators Controls and Indicators TI7016a . 3. Controls and Indicators (heated unit shown) Motor/Pump Control Function Table 1: Status Codes Knob (see also the label on back of the control enclosure) Code Use knob (CF) to select desired function. Code Name Pressure imbalance between A and B sides Icon...

  • Page 11: Heater Power Switch/Circuit Breaker

    Controls and Indicators Heater Power Switch/Circuit Fluid Temperature Sensors and Breaker Displays See F . 3. Switch (HP) turns power on to heater ther- See F . 3. Fluid temperature sensors (T) monitor actual mostats. The switch includes a 20 A circuit breaker. temperature of component A and B fluid going to spray Present on heated units only.

  • Page 12: Setup

    National, State and Local safety and fire codes. Connect Reactor E-10 to the correct power source for Solvent pails used when flushing: follow your model. See T 2. Models with two power cords ABLE your local code.
  • Page 13 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 14 Flush before first use Connect gun air hose to the gun air input and to The Reactor E-10 is tested with a plasticizer oil the air filter outlet (Z). If you are using more than at the factory. Flush out the oil with a compatible one hose bundle, join the air hoses with the nip- solvent before spraying.
  • Page 15 Keep the felt washers in the pump wet-cups sat- tanks. Material left in the tanks overnight may need urated with Graco ISO pump oil, Part No. to be remixed in the tanks. 217374. The lubricant creates a barrier between the ISO and the atmosphere.
  • Page 16 Setup Purge air and flush fluid from Set Recirc/Spray valves to Recirc. lines Set function knob to Slow Recirc Remove both recirculation tubes (P) Fast Recirc from the tanks and secure each one in a dedicated waste container. When clean fluids exit both recirculation TI7022a tubes (P), set function knob to Stop/Park...

  • Page 17: Startup Of Heated Units

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

  • Page 18: Heatup Guidelines

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

  • Page 19: Heating Foam Resins With 245 Fa Blowing Agents

    Startup of Heated Units Heating Foam Resins with 245 fa At Cool Ambient Temperature (below 75°F/24°C) Blowing Agents New foam blowing agents will froth at temperatures • Use Fast Recirc to heat tanks to 75-90°F. above 90°F (33°C) when not under pressure, especially if agitated.

  • Page 20: Spraying/Dispensing

    Spraying/Dispensing Spraying/Dispensing Check fluid pressure gauges to ensure proper pressure balance. If imbalanced, reduce pres- sure of higher component by slightly turning Recirc/Spray valve for that component toward Air is supplied to spray gun with gun piston safety Recirc, until gauges show balanced pressures. lock or trigger safety lock engaged and gun fluid The pressure imbalance alarm (Status Code 1) manifold valves A and B closed (if present).

  • Page 21: Pause (Heated Units)

    Pause (Heated Units) Disengage piston safety lock or trigger safety Set Recirc/Spray valves to Recirc until tempera- lock. ture readouts come back up. Fusion Gun 2K Ultra-Lite Gun TI7070a If you stop spraying for more than 2 minutes when using an impingement mix gun, close gun fluid valves A and B.

  • Page 22: Pressure Relief Procedure

    Pressure Relief Procedure Pressure Relief Shutdown Procedure For longer breaks (more than 10 minutes), use the following procedure. If you will be shut down for more than 3 days, first see Flushing, page 24. Follow all steps of Pressure Relief Procedure, Engage piston safety lock or trigger safety lock.

  • Page 23: Maintenance

    Maintenance Maintenance • Check pump wet-cups fluid level daily, page 15. • If using an impingement mix gun, close gun fluid valves A and B when not spraying. Doing this will • Do not overtighten packing nut/wet-cup. Throat keep the internal parts of the gun cleaner and pre- u-cup is not adjustable.

  • Page 24: Flushing

    Flushing Flushing Shut off Heater Power (heated units only). Allow system to cool. Flush equipment only in a well-ventilated area. Do not spray flammable fluids. Do not turn on heaters while flushing with flammable solvents. • Generally, flush if you will be shut down for more than 3 days.
  • Page 25 Flushing To flush gun, refer to gun instruction manual. Wipe out any remaining material from the supply tanks. Fill each supply tank with 1-2 gal. (3.8-7.6 l) of solvent recommended by your material manufacturer. Purge Gun Hoses (Nonheated Units Only) Disconnect hoses from gun and secure back into the tanks for thorough cleaning with solvent.

  • Page 26: Troubleshooting

    Troubleshooting Troubleshooting Status Codes 3. Check fluid inlet strainers (51a, page 23) and fluid filters at gun. Determine the status code by counting the number of 4. Clean or change restrictor at mixer manifold if using times the status indicator (ST) blinks. disposable mixer gun kit.
  • Page 27 1. Motor temperature too high. Reduce pressure duty 2. Reverse A and B transducer electrical connections cycle, gun tip size, or move Reactor E-10 to a cooler at board, page 37. If error moves to transducer B location. Allow 1 hour for cooling.

  • Page 28: 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 to reset breaker. Motor does not operate. Power turned on with function knob Set function knob to Stop/Park set to a run position.
  • Page 29 Troubleshooting PROBLEM CAUSE SOLUTION Pressures are not balanced when Unequal viscosities. Change temperature setting to bal- running, but pressure is generated ance viscosities. and holds on both strokes. Change restrictor at mix point to bal- ance back pressure. Restriction on one side. Clean mix module or restrictor at mix manifold.
  • Page 30 Troubleshooting PROBLEM CAUSE SOLUTION No temperature display (heated units Loose display cables on control Check cable connections to each dis- only). board. play, page 36. Failed control board (displays get Remove access panel. Check if power from control board). board LED is lighted. If not, replace board, page 36.

  • Page 31: Repair

    2. Set function knob to Stop/Park 3. Shut off Motor Power. Disconnect power supply. TI7020a Use dropcloth or rags to protect Reactor E-10 and surrounding area from spills. 3. Open filter drain plug on Y-strainer (51). 4. Shut off Heater Power. Allow equipment to cool before repairing.

  • Page 32: Recirc/Spray Valves

    Repair Recirc/Spray Valves 2. See F . 8. Disassemble Recirc/Spray valves. Clean and inspect all parts for damage. Ensure that the seat (503a) and gasket (503b) are positioned inside each valve cartridge (503). 3. Apply PTFE pipe sealant to all tapered pipe threads 1.

  • Page 33: Displacement Pump

    6. Remove pump rod cover (222). Push clip up in back and push pin (217) out. Loosen locknut (218) by hit- Use dropcloth or rags to protect Reactor E-10 and ting firmly right-to-left with a non-sparking hammer. surrounding area from spills.

  • Page 34: Control Module

    Repair Control Module a. Loosen setscrew (22) on thermowell housing (21). See F . 10. Change Display Temperature Units (°F/°C) b. Pull sensor (424) out of thermowell housing. Unit is shipped with temperature displays set to °F. c. Work sensor and wire out of cable channel between tanks.
  • Page 35 Repair Replace Function Knob/Potentiometer 4. See F . 11. Remove two setscrews (416a) and pull function knob (416) off potentiometer (404) shaft. 5. Remove nut (N, part of 404) and detent plate (415). 6. Install new potentiometer (404) in reverse order. Position potentiometer so slot (S) is horizontal.
  • Page 36 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 board. Power must be on to check. See F . 12 for location. Main power from breaker Function is: Function knob Transducer A...
  • Page 37 Repair Heated Models Only LINE Heater Heater Power On/Off LINE (20 A Breaker) Single Cord Models Only Heater Black Twin Flat Cable Motor J11 (120 V Board) Black J4 (240 V Board) CONTROL BOARD Function Yellow 249434 (120 V) Knob Cycle 249432 (240 V) Yellow...

  • Page 38: 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 31. Relieve To replace a pressure transducer, see at right. pressure, page 22.

  • Page 39: Drive Housing

    Repair Drive Housing 3. Install bronze bearings (209, 211) and steel washer (208) on crankshaft (210). Install bronze bearing (213) and steel washer (212) on gear reducer (214). Removal 4. Install gear reducer (214) and crankshaft (210) into motor end bell (MB). Crankshaft (210) must be in line with crankshaft at other end of motor.

  • Page 40: Electric Motor

    Repair (steel) (bronze) (bronze) (steel) (bronze) (bronze) Crankshaft must be in line with crankshaft at other end of motor, TI7029a so pumps move up and down in unison. . 14. Drive Housing Electric Motor Test Motor Removal If motor is not locked up by pumps, it can be tested If replacing a component with electrical cabling, using a 9 V battery.

  • Page 41: Motor Brushes

    Repair 4. Disconnect motor cables as follows: Motor Brushes a. Find control board at back of control module, Replace brushes worn to less than 1/2 in. (13 see F . 12, page 37. mm). Brushes wear differently on each side of motor;...

  • Page 42: Parts

    Parts Parts Part No. 249800, 120 V, 15 A, Heated Package Part No. 249802, 240 V, 10 A, Heated Package Part No. 249804, 240 V, 20 A, Heated Package TI6988b Ref. Ref. Part No. Description Part No. Description 249499 HOSE BUNDLE, insulated; see 249570 PROPORTIONER, heated, 120 V, page 49 15 A;...
  • Page 43 Parts Part No. 249806, 120 V, 15 A, Nonheated Package Part No. 249808, 240 V, 10 A, Nonheated Package TI6990b Ref. Ref. Part No. Description Part No. Description 249633 HOSE BUNDLE, non-insulated; 249576 PROPORTIONER, nonheated, 120 see page 49 249834 GUN, 2K Ultra-Lite; see 309000 V, 15 A;...
  • Page 44 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) 424 (Ref) TI7068a TI6975b 311075E...
  • Page 45 Parts Heated Proportioners Ref. Ref. Part No. Description Part No. Description 249630 HOSE, component B (RES); 1/4 in. 249582 CART; see page 53 (6 mm) ID; thermoplastic hose; 1/4 249438 TANK, with lid and outlet fitting; npsm(f) x 48 in. (1219 mm) LDPE;...
  • Page 46 Parts Part No. 249576, 120 V, Nonheated Proportioner Part No. 249577, 240 V, Nonheated Proportioner 1 (Ref) 40▲ 1 (Ref) 30 (Ref) 1 (Ref) TI7068a TI6981b 311075E...
  • Page 47 Parts Nonheated Proportioners Ref. Ref. Part No. Description Part No. Description 15G218 CORD, 120 V; Model 249576 249582 CART; see page 53 15G220 CORD, 240 V; Model 249577 249438 TANK, with lid and outlet fitting; 15G458 CABLE, fan; see page 48 LDPE;...
  • Page 48 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 †214 222‡ ◆216 †213 220‡ 217◆ 207‡ TI6978a Ref. Ref. Part No. Description Part No.
  • Page 49 Parts Part No. 249499, Insulated Hose Bundle with recirculation lines 302 (Ref) 303 (Ref) TI6991a Ref. Ref. Part No. Description Part No. 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 50 Parts Part No. 249556, 120 V Heated Display Part No. 249557, 240 V Heated Display 416a 416a 404 (Ref) TI6979a Ref. Ref. Part No. Description Part No. Description 101765 GROMMET 15F984 PLATE 116773 CONNECTOR, plug 119927 SWITCH, motor or heater power, 15C866 WIRE, jumper with circuit breaker 15G279 LABEL, display...
  • Page 51 Parts Part No. 249537, 120 V Nonheated Display Part No. 249538, 240 V Nonheated Display 416a 416a 404 (Ref) TI6983a Ref. Ref. Part No. Description Part No. Description 15G279 LABEL, display 15F984 PLATE 15G053 PLATE, detent 119927 SWITCH, motor power, with circuit 249453 KNOB, function;...
  • Page 52 Parts Part No. 287712 Recirculation Manifold, Heated Models Ref. Part No. Description 15F870 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...
  • Page 53 Parts Part No. 249582, Cart TI6976a Ref. Part No. Description 154636 WASHER, flat 116411 SPRING 116477 WASHER, flat; nylon 116478 WHEEL, pneumatic 101242 RING, retaining GRIP, handle 311075E...

  • Page 54: 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 No. Description Part No. Description 119974 DRYER, desiccant; package of 2 119869 DISPLAY, temperature, with sensor 15F895 O-RING, lid, tank 119857 FUSE, heater over-temperature 119927 SWITCH, motor or heater power, with circuit...

  • Page 55: Dimensions

    Dimensions Dimensions All Models 44 in. (1118 mm) 26.5 in. 30 in. (673 mm) (762 mm) TI6974a 311075E...

  • Page 56: Technical Data

    Technical Data Technical Data Maximum fluid working pres- 2000 psi (14 MPa, 140 bar) sure Electrical requirements Model 249800: 120 Vac, 1 phase, 50/60 Hz, 3500 W; requires two separate, dedi- cated 15 A circuits Model 249802: 240 Vac, 1 phase, 50/60 Hz, 3800 W; requires two separate, dedi- cated 10 A circuits Model 249804: 240 Vac, 1 phase, 50/60 Hz, 3800 W;...
  • Page 57 Technical Data Tank Capacity 7 gal. (26.5 liters) each (nominal) Fluid Outlets Component A (ISO): #5 JIC (1/2-18) male Component B (RES): #6 JIC (9/16-18) male Fluid Circulation Returns Component A (ISO): #5 JIC (1/2-18) male Component B (RES): #6 JIC (9/16-18) male Air Inlet 1/4 in.

  • Page 58: 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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