Graco Reactor 2 E-30 Operation
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Operation
Reactor 2 E-30 and E-XP2
333023G
Proportioning Systems
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l e c t r i c , H e a t e d , P l u r a l C o m p o n e n t P r o p o r t i o n e r f o r s p r a y i n g p o l y u r e t h a n e f o a m a n d p o l y u r e a c o a t i n g s .
N o t f o r o u t d o o r u s e . F o r p r o f e s s i o n a l u s e o n l y . N o t a p p r o v e d f o r u s e i n e x p l o s i v e a t m o s p h e r e s o r
h a z a r d o u s l o c a t i o n s .
m p o r t a n t S a f e t y n s t r u c t i o n s
e a d a l l w a r n i n g s a n d i n s t r u c t i o n s i n t h i s m a n u a l .
S a v e t h e s e i n s t r u c t i o n s .
PROVEN QUALITY. LEADING TECHNOLOGY.
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Summary of Contents for Graco Reactor 2 E-30
- Page 1 Operation Reactor 2 E-30 and E-XP2 333023G Proportioning Systems l e c t r i c , H e a t e d , P l u r a l C o m p o n e n t P r o p o r t i o n e r f o r s p r a y i n g p o l y u r e t h a n e f o a m a n d p o l y u r e a c o a t i n g s .
- Page 2 Contents W a r n i n g s ............3 u n M o d e .
- Page 3 Warnings Warnings T h e f o l l o w i n g w a r n i n g s a r e f o r t h e s e t u p , u s e , g r o u n d i n g , m a i n t e n a n c e , a n d r e p a i r o f t h i s e q u i p m e n t . T h e e x c l a m a t i o n p o i n t s y m b o l a l e r t s y o u t o a g e n e r a l w a r n i n g a n d t h e h a z a r d s y m b o l s r e f e r t o p r o c e d u r e - s p e c i fi...
- Page 4 Warnings WARNING S K N N J E C T O N H A Z A R D H i g h - p r e s s u r e fl u i d f r o m g u n , h o s e l e a k s , o r r u p t u r e d c o m p o n e n t s w i l l p i e r c e s k i n . T h i s m a y l o o k l i k e j u s t a c u t , b u t i t i s a s e r i o u s i n j u r y t h a t c a n r e s u l t i n a m p u t a t i o n .
- Page 5 Warnings WARNING P R E S S U R Z E D A L U M N U M P A R T S H A Z A R D U s e o f fl u i d s t h a t a r e i n c o m p a t i b l e w i t h a l u m i n u m i n p r e s s u r i z e d e q u i p m e n t c a n c a u s e s e r i o u s c h e m i c a l r e a c t i o n a n d e q u i p m e n t r u p t u r e .
- Page 6 Warnings WARNING B U R N H A Z A R D E q u i p m e n t s u r f a c e s a n d fl u i d t h a t i s h e a t e d c a n b e c o m e v e r y h o t d u r i n g o p e r a t i o n . T o a v o i d s e v e r e b u r n s : •...
- Page 7 Important Isocyanate Information Important Isocyanate Information I s o c y a n a t e s ( I S O ) a r e c a t a l y s t s u s e d i n t w o c o m p o n e n t m a t e r i a l s . Isocyanate Conditions S p r a y i n g o r d i s p e n s i n g fl...
- Page 8 Important Isocyanate Information Material Self-Ignition Moisture Sensitivity of Isocyanates E x p o s u r e t o m o i s t u r e ( s u c h a s h u m i d i t y ) w i l l c a u s e I S O t o p a r t i a l l y c u r e , f o r m i n g s m a l l , h a r d , a b r a s i v e c r y s t a l s t h a t b e c o m e s u s p e n d e d i n t h e fl...
- Page 9 Models Reactor 2 E-30 and E-30 Elite A l l e l i t e s y s t e m s i n c l u d e fl u i d i n l e t s e n s o r s , G r a c o I n S i t e , a n d X t r e m e - W r a p 5 0 f t ( 1 5 m ) h e a t e d h o s e . F o r...
- Page 10 Models Reactor 2 E-XP2 and E-XP2 Elite A l l e l i t e s y s t e m s i n c l u d e fl u i d i n l e t s e n s o r s , G r a c o I n S i t e , a n d X t r e m e - W r a p 5 0 f t ( 1 5 m ) h e a t e d h o s e . F o r p a r t n u m b e r s , s e e A c c e s s o r i e s , p a g e 1 1 M o d e l...
- Page 11 Approvals Approvals Accessories I n t e r t e k a p p r o v a l s a p p l y t o p r o p o r t i o n e r s w i t h o u t K i t N u m b e r D e s c r i p t i o n h o s e s .
- Page 12 Supplied Manuals Supplied Manuals T h e f o l l o w i n g m a n u a l s a r e s h i p p e d w i t h t h e e a c t o r 2 .
- Page 13 Typical Installation, without circulation Typical Installation, without circulation (RES) (ISO) F i g u r e 1 * S h o w n e x p o s e d f o r c l a r i t y . W r a p w i t h t a p e d u r i n g o p e r a t i o n . e a c t o r P r o p o r t i o n e r F l u i d S u p p l y L i n e s H e a t e d H o s e...
- Page 14 Typical Installation, with system fluid manifold to drum circulation Typical Installation, with system fluid manifold to drum circulation (RES) (ISO) F i g u r e 2 * S h o w n e x p o s e d f o r c l a r i t y . W r a p w i t h t a p e d u r i n g o p e r a t i o n . e a c t o r P r o p o r t i o n e r F l u i d S u p p l y L i n e s H e a t e d H o s e...
- Page 15 Typical Installation, with gun fluid manifold to drum circulation Typical Installation, with gun fluid manifold to drum circulation F i g u r e 3 * S h o w n e x p o s e d f o r c l a r i t y . W r a p w i t h t a p e d u r i n g o p e r a t i o n . e a c t o r P r o p o r t i o n e r F l u i d S u p p l y L i n e s H e a t e d H o s e...
- Page 16 Component Identification Component Identification F i g u r e 4 3 3 3 0 3 G...
- Page 17 Component Identification K e y I S O S i d e P r e s s u r e e l i e f O u t l e t e d S t o p B u t t o n E S S i d e P r e s s u r e e l i e f O u t l e t I S O S i d e P E S S U E E L I E F / S P A Y V a l v e...
- Page 18 Advanced Display Module (ADM) Advanced Display Module (ADM) NOTICE T h e A D M d i s p l a y s h o w s g r a p h i c a l a n d t e x t i n f o r m a t i o n r e l a t e d t o s e t u p a n d s p r a y o p e r a t i o n s .
- Page 19 Advanced Display Module (ADM) T a b l e 1 : A D M K e y s a n d n d i c a t o r s K e y F u n c t i o n P r e s s t o s t a r t u p o r s h u t d o w n t h e s y s t e m .
- Page 20 Advanced Display Module (ADM) M o d u l e S t a t u s L E D s F i g u r e 6 B a c k V i e w A c c e s s o r y C a b l e C o n n e c t i o n F l a t P a n e l M o u n t ( V E S A 1 0 0 ) T o k e n A c c e s s C o v e r M o d e l a n d S e r i a l N u m b e r...
- Page 21 Advanced Display Module (ADM) ADM Display Details A l a r m / D e v i a t i o n Power Up Screen h e c u r r e n t s y s t e m e r r o r i s d i s p l a y e d i n t h e m i d d l e o f t h e m e n u b a r .
- Page 22 Advanced Display Module (ADM) Icons c o n s S o f t k e y s c o n F u n c t i o n c o n F u n c t i o n C o m p o n e n t A S t a r t P r o p o r t i o n e r S t a r t a n d S t o p P r o p o r t i o n e r i n J o g M o d e C o m p o n e n t B...
- Page 23 Electrical Enclosure Electrical Enclosure A A A T e m p e r a t u r e C o n t r o l M o d u l e ( T C M ) A A B M o t o r C o n t r o l M o d u l e ( M C M ) A A C E n c l o s u r e F a n A A D W i r i n g T e r m i n a l B l o c k s A A E P o w e r S u p p l y...
- Page 24 Motor Control Module (MCM) Motor Control Module (MCM) B a s e M o d e l E l i t e M o d e l A c c e s s o r y o u t p u t F i g u r e 7 N o t u s e d D e s c r i p t i o n...
- Page 25 Temperature Control Module (TCM) Cable Connections Temperature Control Module (TCM) Cable Connections F i g u r e 8 P o w e r I n p u t H e a t e r O v e r t e m p e r a t u r e C A N C o m m u n i c a t i o n s C o n n e c t i o n s P o w e r O u t ( I S O ) P o w e r O u t ( e s )
- Page 26 Installation Installation 1 . U s e t h e s u p p l i e d b o l t s t o i n s t a l l t h e s u p p l i e d S e t u p F r o m S h i p p i n g C o n fi...
- Page 27 Setup Setup General Equipment Guidelines • D e t e r m i n e t h e c o r r e c t s i z e g e n e r a t o r . U s i n g t h e Grounding c o r r e c t s i z e g e n e r a t o r a n d p r o p e r a i r c o m p r e s s o r w i l l e n a b l e t h e p r o p o r t i o n e r t o r u n a t a n e a r l y...
- Page 28 Setup Connect Power T e r m i n a l j u m p e r s a r e l o c a t e d i n s i d e t h e N O T E : e l e c t r i c a l e n c l o s u r e d o o r .
- Page 29 Setup Supply Wet Cups With Throat Seal • C h e c k f e l t w a s h e r s C o m p o n e n t B ( R e s i n ) P u m p : Liquid (TSL) i n p a c k i n g n u t / w e t - c u p ( S ) d a i l y .
- Page 30 3 . C o n n e c t F T S c a b l e c o n n e c t o r s ( ) . F u l l y t i g h t e n T D c o n n e c t o r s , i f p r o v i d e d . Register and Activate the Graco InSite Note E l i t e s y s t e m s o n l y .
- Page 31 Advanced Display Module (ADM) Operation Advanced Display Module (ADM) Operation W h e n m a i n p o w e r i s t u r n e d o n b y t u r n i n g t h e m a i n p o w e r s w i t c h ( M P ) t o t h e O N p o s i t i o n , t h e p o w e r u p s c r e e n w i l l b e d i s p l a y e d u n t i l c o m m u n i c a t i o n a n d i n i t i a l i z a t i o n i s c o m p l e t e .
- Page 32 Advanced Display Module (ADM) Operation Setup Mode T h e A D M w i l l s t a r t i n t h e u n s c r e e n s a t t h e H o m e s c r e e n . F r o m t h e u n s c r e e n s , p r e s s a c c e s s t h e S e t u p s c r e e n s .
- Page 33 Advanced Display Module (ADM) Operation S e t u p S c r e e n s N a v i g a t i o n D i a g r a m F i g u r e 1 3 3 3 3 0 3 G...
- Page 34 Advanced Setup Screens Advanced Setup Screens A d v a n c e d s e t u p s c r e e n s e n a b l e u s e r s t o s e t u n i t s , a d j u s t v a l u e s , s e t f o r m a t s , a n d v i e w s o f t w a r e i n f o r m a t i o n f o r e a c h c o m p o n e n t .
- Page 35 System 1 Recipes System 1 U s e t h i s s c r e e n t o s e t t h e a c t i v a t i o n p r e s s u r e f o r t h e U s e t h i s s c r e e n t o a d d r e c i p e s , v i e w s a v e d r e c i p e s , P r e s s u r e I m b a l a n c e A l a r m a n d D e v i a t i o n , e n a b l e o r a n d e n a b l e o r d i s a b l e s a v e d r e c i p e s .
- Page 36 Run Mode Run Mode T h e A D M w i l l s t a r t i n t h e u n s c r e e n s a t t h e “ H o m e ” s c r e e n . P r e s s t o n a v i g a t e t h r o u g h t h e u n M o d e s c r e e n s .
- Page 37 Run Mode Home — System Off Home — System With Error T h i s i s t h e h o m e s c r e e n w h e n t h e s y s t e m i s o f f . A c t i v e e r r o r s a r e s h o w n i n t h e s t a t u s b a r .
- Page 38 Run Mode Maintenance Events U s e t h i s s c r e e n t o v i e w d a i l y a n d l i f e t i m e c y c l e s o r T h i s s c r e e n s h o w s t h e d a t e , t i m e , e v e n t c o d e , a n d g a l l o n s t h a t h a v e b e e n p u m p e d a n d g a l l o n s o r l i t e r s d e s c r i p t i o n o f a l l e v e n t s t h a t h a v e o c c u r r e d o n...
- Page 39 Run Mode Troubleshooting T h i s s c r e e n d i s p l a y s t h e l a s t t e n e r r o r s t h a t o c c u r r e d o n t h e s y s t e m .
- Page 40 Run Mode Diagnostic Note ★ M a x i m u m v a l u e s b a s e d o n m a x i m u m i n p u t U s e t h i s s c r e e n t o v i e w i n f o r m a t i o n f o r a l l s y s t e m v o l t a g e .
- Page 41 Run Mode System Events U s e t h e t a b l e b e l o w t o fi n d a d e s c r i p t i o n f o r a l l s y s t e m n o n - e r r o r e v e n t s . A l l e v e n t s a r e l o g g e d i n t h e U S B l o g fi...
- Page 42 Startup Startup d e s i r e d , t h e l e v e l c a n b e e n t e r e d a n d t r a c k e d i n t h e A D M .
- Page 43 Startup 9 . S w i t c h o n t h e a i r c o m p r e s s o r , a i r d r y e r , a n d e .
- Page 44 Startup 1 1 . P r e s s t o a c t i v a t e A D M . T h e r m a l e x p a n s i o n c a n c a u s e o v e r p r e s s u r i z a t i o n , r e s u l t i n g i n e q u i p m e n t r u p t u r e a n d s e r i o u s i n j u r y , i n c l u d i n g fl...
- Page 45 Fluid Circulation Fluid Circulation Circulation Through Reactor 3 . S e t P E S S U E E L I E F / S P A Y v a l v e s ( S A , NOTICE S B ) t o P E S S U E E L I E F / C I C U L A T I O N T o p r e v e n t e q u i p m e n t d a m a g e , d o n o t c i r c u l a t e fl...
- Page 46 Jog Mode Circulation Through Gun Manifold h o s e s r a t e d a t t h e m a x i m u m w o r k i n g p r e s s u r e o f t h i s e q u i p m e n t . S e e NOTICE T e c h n i c a l S p e c i fi...
- Page 47 Spraying Spraying 6 . O p e n fl u i d i n l e t v a l v e l o c a t e d a t e a c h p u m p i n l e t . T h e F u s i o n A P g u n i s s h o w n .
- Page 48 Spraying 9 . O p e n g u n fl u i d i n l e t v a l v e s A a n d B . 1 1 . P u l l g u n t r i g g e r t o t e s t s p r a y o n t o c a r d b o a r d . I f n e c e s s a r y , a d j u s t p r e s s u r e a n d t e m p e r a t u r e t o g e t d e s i r e d r e s u l t s .
- Page 49 Manual Hose Heat Mode Manual Hose Heat Mode 3 . S e l e c t E n a b l e M a n u a l H o s e M o d e . Note I f t h e s y s t e m p r o d u c e s t h e T 6 D H s e n s o r e r r o r h o s e W h e n m a n u a l h o s e m o d e i s e n a b l e d , t h e a l a r m o r t h e T 6 D T s e n s o r e r r o r T C M a l a r m , u s e m a n u a l h o s e m o d e a d v i s o r y E V C H - V...
- Page 50 Manual Hose Heat Mode Disable Manual Hose Mode 5 . N a v i g a t e b a c k t o t h e u n M o d e H o m e s c r e e n . T h e h o s e n o w d i s p l a y s a c u r r e n t i n s t e a d o f a t e m p e r a t u r e .
- Page 51 Shutdown Shutdown NOTICE 6 . T u r n o f f t h e a i r c o m p r e s s o r , a i r d r y e r , a n d b r e a t h i n g a i r .
- Page 52 Shutdown 9 . S e t P E S S U E E L I E F / S P A Y v a l v e s ( S A , 1 0 . E n g a g e g u n p i s t o n s a f e t y l o c k t h e n c l o s e fl u i d i n l e t v a l v e s A a n d B .
- Page 53 Pressure Relief Procedure Pressure Relief Procedure 3 . C l o s e g u n fl u i d i n l e t v a l v e s A a n d B . F o l l o w t h e P r e s s u r e e l i e f P r o c e d u r e w h e n e v e r y o u s e e t h i s s y m b o l .
- Page 54 Flushing Flushing T o fl u s h f e e d h o s e s , p u m p s , a n d h e a t e r s s e p a r a t e l y f r o m h e a t e d h o s e s , s e t P E S S U E E L I E F / S P A Y v a l v e s ( S A , S B ) t o P E S S U E T o h e l p p r e v e n t fi...
- Page 55 Maintenance Maintenance G r e a s e C i r c u l a t i o n V a l v e s G r e a s e c i r c u l a t i o n v a l v e s ( S A a n d S B ) w i t h F u s i o n g r e a s e ( 1 1 7 7 7 3 ) w e e k l y .
- Page 56 Maintenance Flush Inlet Strainer Screen c o m p a t i b l e s o l v e n t a n d s h a k e i t d r y . I n s p e c t t h e s c r e e n .
- Page 57 Maintenance Pump Lubrication System 4 . W h e n t h e r e s e r v o i r i s fl u s h e d c l e a n , fi l l w i t h f r e s h l u b r i c a n t .
- Page 58 Errors Errors Troubleshoot Errors T o t r o u b l e s h o o t t h e e r r o r : View Errors 1 . P r e s s t h e s o f t k e y n e x t t o “ H e l p W i t h T h i s E r r o r ” f o r h e l p w i t h t h e a c t i v e e r r o r .
- Page 59 Troubleshooting Troubleshooting S e e T r o u b l e s h o o t i n g , p a g e 3 9 f o r t h e t e n m o s t r e c e n t e r r o r s t h a t h a v e o c c u r r e d o n t h e s y s t e m .
- Page 60 USB Data USB Data Download Procedure USB Logs Note Note S y s t e m c o n fi g u r a t i o n s e t t i n g fi l e s a n d c u s t o m T h e A D M c a n r e a d / w r i t e t o F A T ( F i l e l a n g u a g e fi...
- Page 61 USB Data J o b L o g S y s t e m S o f t w a r e L o g T h e j o b l o g fi l e n a m e i s 2 – J O B . C S V a n d i s s t o r e d T h e s y s t e m s o f t w a r e fi...
- Page 62 USB Data Custom Language File • T h e fi l e f o r m a t m u s t b e a t a b - d e l i m i t e d t e x t fi l e u s i n g U n i c o d e ( U T F - 1 6 ) c h a r a c t e r r e p r e s e n t a t i o n .
- Page 63 Performance Charts Performance Charts U s e t h e s e c h a r t s t o h e l p i d e n t i f y t h e p r o p o r t i o n e r t h a t w i l l w o r k m o s t e f fi c i e n t l y w i t h e a c h m i x c h a m b e r . F l o w r a t e s a r e b a s e d o n a m a t e r i a l v i s c o s i t y o f 6 0 c p s .
- Page 64 Performance Charts Proportioners For Coatings T a b l e 6 F u s i o n A i r P u r g e , R o u n d P a t t e r n 3500 (241) 3000 (207) 2500...
- Page 65 Performance Charts T a b l e 8 F u s i o n M e c h a n i c a l P u r g e , R o u n d P a t t e r n 3500 (241, 24.1) E-XP2...
- Page 66 Technical Specifications Technical Specifications R e a c t o r 2 E - 3 0 a n d E - X P 2 P r o p o r t i o n i n g S y s t e m M e t r i c U .
- Page 67 Technical Specifications S o u n d P r e s s u r e S o u n d P r e s s u r e m e a s u r e d p e r I S O - 9 6 1 4 – . E - 3 0 8 7 .
- Page 68 Notes Notes 3 3 3 0 3 G...
- Page 69 Graco Extended Warranty for Reactor ® Components G r a c o w a r r a n t s a l l e q u i p m e n t r e f e r e n c e d i n t h i s d o c u m e n t w h i c h i s m a n u f a c t u r e d b y G r a c o a n d b e a r i n g i t s n a m e t o b e f r e e f r o m d e f e c t s i n m a t e r i a l a n d w o r k m a n s h i p o n t h e d a t e o f s a l e t o t h e o r i g i n a l p u r c h a s e r f o r u s e .
- Page 70 Graco Information F o r t h e l a t e s t i n f o r m a t i o n a b o u t G r a c o p r o d u c t s , v i s i t w w w . g r a c o . c o m .