Graco Reactor 2 E-30 Repair And Parts Manual
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Graco Reactor 2 E-30 Repair And Parts Manual

Graco Reactor 2 E-30 Repair And Parts Manual

Proportioning system
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Repair, Parts
Reactor
2 E-30 and E-XP2
®
Proportioning System
Electric, heated, plural component proportioning system. For spraying polyurethane foam
and polyurea coatings. For professional use only. Not approved for use in explosive
atmospheres or hazardous (classified) locations.
Important Safety Instructions
Read all warnings and instructions in this
manual before using the equipment.
Save these instructions.
333024V
EN

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Table of Contents

Troubleshooting

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Summary of Contents for Graco Reactor 2 E-30

  • Page 1 Repair, Parts Reactor 2 E-30 and E-XP2 ® 333024V Proportioning System Electric, heated, plural component proportioning system. For spraying polyurethane foam and polyurea coatings. For professional use only. Not approved for use in explosive atmospheres or hazardous (classified) locations. Important Safety Instructions Read all warnings and instructions in this manual before using the equipment.

  • Page 2: Table Of Contents

    System DIN Rail and Harness Module Kit ..94 Reactor 2 E-30 and E-30 Elite ....8 Heater and Transformer Terminal Block Module 95 Reactor 2 E-XP2 and E-XP2 Elite .

  • 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 dispensing devise, 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. •...
  • Page 5 Warnings WARNING PRESSURIZED ALUMINUM PARTS HAZARD Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage. • Do not use 1, 1, 1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents.

  • Page 6: Important Isocyanate Information

    Important Isocyanate Information Important Isocyanate 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 hazards and precautions related to isocyanates.

  • Page 7: Material Self-Ignition

    Important Isocyanate Information Material Self-Ignition Moisture Sensitivity of Isocyanates Exposure to moisture (such as humidity) will cause ISO to partially cure, forming small, hard, abrasive crystals that become suspended in the fluid. Eventually a film Some materials may become self-igniting if applied will form on the surface and the ISO will begin to gel, too thick.

  • Page 8: Models

    Models Models Reactor 2 E-30 and E-30 Elite All elite systems include fluid inlet sensors, ratio monitoring, and Xtreme-Wrap 50 ft (15 m) heated hose. For part numbers, see Accessories, page 10. E-30 Model E-30 Elite Model Model 10 kW...

  • Page 9: Reactor 2 E-Xp2 And E-Xp2 Elite

    Models Reactor 2 E-XP2 and E-XP2 Elite All elite systems include fluid inlet sensors and Xtreme-Wrap 50 ft (15 m) heated hose. For part numbers, see Accessories, page 10. E-XP2 Model E-XP2 Elite Model Model 15 kW 15 kW Proportioner ★ 272012 272112 Maximum Fluid Working...

  • Page 10: Approvals

    24U315 Air Manifold Kit (4 outlets) 24U314 Wheel and Handle Kit Proportioner Approvals: 16X521 Graco InSite Extension cable, 24.6 ft (7.5 m) 24N449 50 ft (15 m) CAN cable (for remote display module) 24K207 Fluid Temperature Sensor (FTS) with RTD...

  • Page 11: Supplied Manuals

    Related Manuals The following manuals are shipped with the Reactor 2. The following manuals are for accessories used with Refer to these manuals for detailed equipment the Reactor. Manuals are available at www.graco.com information. Component Manuals in English Manual Description...

  • Page 12: Troubleshooting

    To avoid injury due to unexpected machine operation online troubleshooting for the active error code. Or, initiated by a remote controller, disconnect the manually navigate to help.graco.com and search cellular module from the system prior to for the active error.

  • Page 13: Error Codes

    Error Codes Online Troubleshooting See help.graco.com for more detail on troubleshooting errors. NOTE: When an error code occurs, be sure to determine the code before resetting it. If you forget which error code occurred, see the Errors screen to view the last 200 errors, including date, time, and description.
  • Page 14 Troubleshooting Error Location Description Cause Solution Type A4DA Heater A High Current A Short circuit in heater Check wiring for touching wires. wiring. Bad Heater. Confirm resistance of heater. Heater resistance should be 18–21 Ω for each heater element, 9–12 Ω combined for 10 kW systems, and 6-8 Ω...
  • Page 15 Troubleshooting Error Location Description Cause Solution Type A8DA Heater A No Current A Tripped circuit Visually check circuit breaker for a breaker. tripped condition. Loose/broken Check heater wiring for loose wires. connection. A8DB Heater B No Current B Tripped circuit Visually check circuit breaker for a breaker.
  • Page 16 Troubleshooting Error Location Description Cause Solution Type CACM Cross threaded CAN CAN cables carry 24 VDC power and Communication cable. communication between modules. A Error cross threaded CAN cable connector may cause problems with communication and/or power to modules. Carefully check for cross threaded CAN connections on the TCM and on other modules.
  • Page 17 Troubleshooting Error Location Description Cause Solution Type CACT Cross threaded CAN CAN cables carry 24 VDC power and Communication cable. communication between modules. A Error cross threaded CAN cable connector may cause problems with communication and/or power to modules. Carefully check for cross threaded CAN connections on the TCM and on other modules.
  • Page 18 Troubleshooting Error Location Description Cause Solution Type DADX Pump Runaway Flow rate is too large. Mix chamber too large for system selected. Use mix chamber rated for system. Ensure the system has chemical and the feed pumps are operating correctly. No material in pumps.
  • Page 19 Troubleshooting Error Location Description Cause Solution Type F9FB Flow Cutback Low B-side (RES) inlet Increase the B-side (RES) feed pump Inlet Pressure pressure is too low. pressure. (B-side) B-side (RES) inlet flow Install a larger B-side (RES) feed is too low. pump.
  • Page 20 Troubleshooting Error Location Description Cause Solution Type P0AX Pressure Imbalance Pressure difference Ensure material flow is equally A High between A and B restricted on both material lines. material is greater than the defined value. Pressure imbalance is Ensure that the pressure imbalance defined too low.
  • Page 21 Troubleshooting Error Location Description Cause Solution Type P2FB Low Inlet Pressure B Inlet pressure lower Ensure that inlet pressure to the pump than defined value. is sufficient. Value defined too high. Ensure that the low pressure alarm level defined on the System Setup screen is acceptable.
  • Page 22 Troubleshooting Error Location Description Cause Solution Type P6BX Pressure Sensor Loose/bad Check to ensure the pressure Error B connection. transducer is properly installed and all wires are properly connected. Bad sensor. Check if the error follows the transducer. Disconnect transducer cables from the MCM (connectors 6 and 7).
  • Page 23 Troubleshooting Error Location Description Cause Solution Type P7AX Pressure Imbalance Pressure difference Ensure material flow is equally A High between A and B restricted on both material lines. material is greater than the defined value. Pressure imbalance is Ensure that the pressure imbalance defined too low.
  • Page 24 Troubleshooting Error Location Description Cause Solution Type R4D0 High Ratio/Low Flow Damaged B-side (RES) Inspect the B-side (RES) pump for (B-side) pump. damage. If necessary, replace the pump. Fluid leak between the Inspect the fluid lines for leaking B-side pump and the B-side chemical (RES).
  • Page 25 Troubleshooting Error Location Description Cause Solution Type T2DB Heater B Low Temperature B Flow is too high at Use a smaller mix chamber that is current setpoint. rated for the unit in use. If recirculating, decrease flow or decrease temperature setpoint. Loose or missing Reconnect or install jumper.
  • Page 26 Troubleshooting Error Location Description Cause Solution Type T3CT TCM Cutback High ambient Ensure ambient temperature is below temperature. 120° F (48° C) before using the system. Enclosure fan not Ensure fan in electrical enclosure is operating. spinning. If it is not, check fan wiring or replace fan.
  • Page 27 Troubleshooting Error Location Description Cause Solution Type T4CT High Temperature High ambient Ensure ambient temperature is below temperature. 120° F (48° C) before using the system. Enclosure fan not Ensure fan in electrical enclosure is operating. spinning. If it is not, check fan wiring or replace fan.
  • Page 28 (Wrapping replacement insulation over the whole hose bundle is not sufficient for proper hose temperature control.) Replacement insulation is available from Graco or a hardware store. T4DH Hose High Temperature Setting the A or B...
  • Page 29 Troubleshooting Error Location Description Cause Solution Type T4EA Heater A High Temperature Overtemperature Heater was delivered too much power, Switch A switch sensed a fluid causing the overtemperature switch to temperature above open. RTD is not reading properly. 230° F (110° C). After the heater cools down, replace RTD.
  • Page 30 Troubleshooting Error Location Description Cause Solution Type T4NM High Temperature High ambient Ensure ambient temperature is below Motor temperature. 120° F (49° C) before using the system. • Cooling fan is not Check to see that the motor fan is moving.
  • Page 31 Troubleshooting Error Location Description Cause Solution Type T6DH Hose Sensor Error Hose Disconnected or Expose each hose RTD connection to shorted RTD cable in check and re-tighten any loose hose or bad FTS. connector. Measure hose RTD cable and FTS continuity. See Repair Heated Hose, page 65.
  • Page 32 Troubleshooting Error Location Description Cause Solution Type T8DA Heater A No Temperature Rise Bad RTD or bad RTD Swap A and B heater output cables placement against and RTD cables and see if issue heater. follows. If so, replace RTD. Loose heater wires or Check for loose heater element wires connector.
  • Page 33 If the generator is wired in a high-leg high-leg delta delta configuration and is consistently configuration. causing this error, change generator configuration to 208 VAC wye (star). Contact Graco Technical Assistance. V3MB High Voltage B Incoming line voltage Ensure incoming system power is is too high.
  • Page 34 Troubleshooting Error Location Description Cause Solution Type V4CM High Voltage MCM Incoming line voltage Ensure incoming system power is is too high. wired properly. Verify voltage at each circuit breaker is between 195 and 264 VAC. V4IT High Voltage CAN Bad 24 VDC power Check voltage of power supply.
  • Page 35 Troubleshooting Error Location Description Cause Solution Type Z4DH Hose High Resistance Hose section added or Re-calibrate the hose. Follow the Hose Wire replaced without Calibration Procedure, page 69. re-calibration. Hose wire temperature Ensure hose wire temperature is below is too high. 221°F (105°...

  • Page 36: System

    Troubleshooting System Before performing any troubleshooting procedures: 1. Relieve pressure. See Pressure Relief Procedure, page 42. 2. Turn main power switch OFF. 3. Allow equipment to cool. Problem Cause Solution Reactor ADM does not turn on. No power. Turn main power switch ON. Failed 24 V power supply.

  • Page 37: Hose Heat System

    Troubleshooting Hose Heat System Before performing any troubleshooting procedures: 1. Relieve pressure. See Pressure Relief Procedure, page 42. 2. Turn main power switch OFF. 3. Allow equipment to cool. Problem Cause Solution Hose heats but heats slower than Ambient temperature is too cold. Relocate hoses to a warmer area or usual or it does not reach recirculate heated fluid through the...
  • Page 38 Troubleshooting Problem Cause Solution Hose temperature exceeds setpoint. A and/or B heaters are overheating Check primary heaters for either a material. RTD problem or a failed element attached to RTD, see Electrical Schematics, page 99. Faulty FTS connections. Verify that all FTS connections are snug and that pins of connectors are clean.
  • Page 39 Troubleshooting Problem Cause Solution Hoses near Reactor are warm, but Shorted connection or failed hose With power off, check the hose hoses downstream are cold. heating element. resistance with and without the whip hose attached. With the whip hose attached, the reading should be less than 3 ohm.

  • Page 40: Primary Heater

    Troubleshooting Primary Heater Before performing any troubleshooting procedures: 1. Relieve pressure. See Pressure Relief Procedure, page 42. 2. Turn main power switch OFF. 3. Allow equipment to cool. Problems Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Also, determine that all circuit breakers, switches, and controls are properly set and wiring is correct before assuming there is a problem.

  • Page 41: Flow Meter

    Troubleshooting Flow Meter Before performing any troubleshooting procedures: 1. Relieve pressure. See Pressure Relief Procedure, page 42. 2. Turn main power switch OFF. 3. Allow equipment to cool. Problems Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Problem Cause Solution...

  • Page 42: Pressure Relief Procedure

    Pressure Relief Procedure Pressure Relief Procedure 5. Shut off feed pumps and agitator, if used. Follow the Pressure Relief Procedure whenever you see this symbol. 6. Route fluid to waste containers or supply tanks. Turn PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION .

  • Page 43: Shutdown

    Pressure Relief Procedure Shutdown 5. Press to deactivate the system. NOTICE Proper system setup, startup, and shutdown proce- dures are critical to electrical equipment reliability. The following procedures ensure steady voltage. Failure to follow these procedures will cause voltage fluctuations that can damage electrical equipment and void the warranty.
  • Page 44 Pressure Relief Procedure 8. Close all fluid supply valves. 10. Engage gun piston safety lock then close fluid inlet valves A and B. Fusion Probler 9. Set PRESSURE RELIEF/SPRAY valves to SPRAY to seal out moisture from the drain line. 333024V...

  • Page 45: Flushing

    Flushing Flushing To flush feed hoses, pumps and heaters separately from heated hoses, set PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION . Flush through bleed lines (N). To avoid fire and explosion. • Flush equipment only in a well-ventilated area. •...

  • Page 46: Repair

    Repair Repair NOTE: Clean the A-side screen only during daily startup. This minimizes moisture contamination by immediately flushing out any isocyanate residue at the start of dispensing operations. 1. Close the fluid inlet valve on the y-strainer inlet and shut off the appropriate feed pump. This prevents Repairing this equipment requires access to parts material from being pumped while cleaning the that may cause electric shock or other serious injury...

  • Page 47: Change Pump Lubricant

    Repair Change Pump Lubricant 5. Thread the reservoir onto the cap assembly and place it in the bracket. Check the condition of the ISO pump lubricant daily. 6. Manually prime the ISO pump. Plug the small vent Change the lubricant if it becomes a gel, its color hole (H) between the tube grommets while darkens, or it becomes diluted with isocyanate.

  • Page 48: Clean Flow Meter

    Repair Clean Flow Meter 9. Reinstall the gears. a. Place the gear with the magnets (MG) on the 1. Perform Shutdown, page 43. left pin of the housing. 2. Perform Pressure Relief Procedure, page 42. 3. Disconnect the flow meter cable. 4.

  • Page 49: Clean E-Xp2 Flow Meter

    Repair Clean E-XP2 Flow Meter 9. Reinstall the gears. a. Place the gear with the magnets (G) on the left 1. Perform Shutdown, page 43. pin of the housing. 2. Perform Pressure Relief Procedure, page 42. 3. Disconnect the flow meter cable. 4.

  • Page 50: Remove Pump

    Repair Remove Pump 8. Route fluid to waste containers or supply tanks. Turn PRESSURE RELIEF/SPRAY valves (SA, SB) to PRESSURE RELIEF/CIRCULATION . Ensure gauges drop to 0. Pump rod and connecting rod move during operation. Moving parts can cause serious injury such as pinching or amputation.
  • Page 51 Repair 11. Loosen locknut (G) by hitting firmly with a 12. Disconnect fluid inlet (C) and outlet (D). Also non-sparking hammer. Unscrew pump far enough disconnect steel outlet tube from heater inlet. to expose rod retaining pin. Push retaining wire clip 13.

  • Page 52: Install Pump

    Repair Install Pump 7. Start threading pump into bearing housing (M). When pin holes align, insert pin. Pull retaining wire clip down. NOTE: Steps 1-5 apply to pump B. To reconnect pump A, proceed to step 6. 8. Continue threading pump into bearing housing (M) until top threads are +/- 1/16 in.
  • Page 53 Repair 7. Perform Pressure Relief Procedure, page 42. 13. Disconnect pump inlet and outlet lines. Remove screws (113), washers (115), and bearing housing 8. Remove the system frame from the floor and (103). L-brackets. NOTICE Do not drop gear cluster (104) when removing drive housing (102).

  • Page 54: Installation

    Repair Installation 4. Push drive housing (102) onto motor (101). Install screws (112) and washers (114). 1. Apply heavy duty extreme pressure grease liberally to washers (107, 108, 118), all gears, and inside NOTE: If bearing housing (103), connecting rod (105), drive housing (102).

  • Page 55: Repair Electric Motor

    Repair Repair Electric Motor 6. Remove four screws (25) holding motor (101) to bracket. Lift motor off unit. Removal NOTICE Be careful not to drop or damage the motor. The motor is heavy and may require two people to lift. 1.

  • Page 56: Repair Circuit Breaker Module

    Repair Repair Circuit Breaker Module 1. See Before Beginning Repair, page 46. 2. Using an ohmmeter, check for continuity across circuit breaker (top to bottom). If no continuity, trip breaker, reset, and retest. If still no continuity, replace breaker as follows: a.

  • Page 57: Replace Fluid Inlet Sensor

    Repair Replace Fluid Inlet Sensor Replace Flow Meter NOTE: For elite models only. NOTE: For E-30 Elite models only. 1. Perform Shutdown, page 43. 1. Perform Shutdown, page 43. 2. Disconnect inlet sensor cable from the fluid inlet 2. Perform Pressure Relief Procedure, page 42. assembly.

  • Page 58: Repair Pressure Transducer

    Repair Repair Pressure Transducer 7. Route new cable into cabinet and thread into bundle as before. Attach cable ties to bundle as before. 8. Connect A side pressure transducer cable to MCM port #6. Connect B side pressure transducer cable to MCM port #7.

  • Page 59: Replace Fans

    Repair Replace Fans Replace Electrical Enclosure Fan 1. Perform Shutdown, page 43. 2. Open electrical enclosure door (401). Loosen four nuts (421) and remove fan (404). Shutdown system to avoid electric shock. To avoid 3. Install new fan (404) in reverse order of disassembly burns, do not perform maintenance on the fan until so that the fan blows out of the electrical enclosure.
  • Page 60 Repair Replace Transformer Fan 4. Disconnect fan and transformer connections from terminal blocks. Connections are on left side labeled: V+, V-, 1, 2, 3, and 4. 5. Remove four nuts (27) holding metal transformer cover (8) to frame. Carefully remove cover while 1.

  • Page 61: Repair Primary Heater

    Repair Repair Primary Heater 6. Turn main power switch OFF. Replace Heater Element 7. Relieve pressure. See Pressure Relief Procedure, page 42. 1. Press to stop the pumps. 2. Turn off heat zones. 8. Wait for heater to cool. 9. Remove four bolts (23) and shroud (10). 3.
  • Page 62 Repair 12. Test heater wires with ohmmeter. 18. Place heater block (201) in a vise. Use a wrench to remove heater element (208). System Total Heater Element Ohms Wattage 19. Inspect element. It should be relatively smooth and E-30 (10 kw) 10,200 2,550 18-21 per...

  • Page 63: Repair Overtemperature Switch

    Repair Repair Overtemperature Switch 5. If switch fails test, remove screws. Discard failed switch. Apply a thin layer of thermal compound 110009, install new switch in same location on housing (201), and secure with screws (213). Reconnect cables. 1. Perform Shutdown, page 43. 2.
  • Page 64 Repair Replace RTD 8. Replace RTD (212). a. Apply PTFE tape and thread sealant to male pipe threads and tighten RTD housing (H) into adapter (206). 1. Perform Shutdown, page 43. b. Push in RTD (212) so tip contacts heater element (208).

  • Page 65: Repair Heated Hose

    Repair Repair Heated Hose 4. Disconnect system wires from terminal block. 5. Use an ohmmeter to check between the hose Refer to heated hose manual for replacement hose wires. There should be continuity. parts. 6. If the hose fails the test, retest at each length of Check Hose Wires hose from the system out of the gun, including whip hose, until the failure is isolated.

  • Page 66: Check Rtd Cable And Fts

    Repair Check RTD Cable and FTS 6. If the FTS reads properly at the manifold but not at the end of the hose, check cable (C) connections. Verify they are tight. 1. Perform Shutdown, page 43. 2. Disconnect RTD cable (C) at Reactor. 3.
  • Page 67 Repair RTD Resistance vs. Temperature RTD or FTS Resistance Ohms RTD or FTS Temperature °C (°F) -40 (-40) -30 (-22) -20 (-4) -10 (14) 1000 0 (32) 1039 10 (50) 1078 20 (68) 1117 30 (86) 1155 40 (104) 1194 50 (122) 1232 60 (140)

  • Page 68: Repair Fluid Temperature Sensor (Fts)

    Repair Repair Fluid Temperature Sensor (FTS) Installation The Fluid Temperature Sensor (FTS) is supplied with the system. Install FTS between main hose and whip hose. See heated hose manual for instructions. . 15 4. If FTS fails, replace FTS. a. Disconnect air hoses (C, L) and electrical Test/Removal connectors (D).

  • Page 69: Calibration Procedure

    Repair Calibration Procedure 3. Wait while the system measures the hose resistance. NOTICE To prevent damage to the heated hose, a hose cali- bration is required if any of the following conditions are true: • The hose has never been calibrated before. •...

  • Page 70: Transformer Primary Check

    Repair Transformer Primary Check 4. Accept or cancel the hose calibration. NOTE: A temperature estimate will be displayed if the See Electrical Schematics, page 99. system was able to measure the hose wire resistance. 1. Check wires and transformer. a. See Shutdown, page 43. b.

  • Page 71: Transformer Secondary Check

    Repair Transformer Secondary Check d. Apply incoming power to system. e. To verify voltage on the secondary leads of the See Electrical Schematics, page 99. transformer, measure between the terminals 3 and 4 on TB17 and TB18. Verify voltage is 1.

  • Page 72: Replace Transformer

    Repair Replace Transformer 4. Install new power supply (535) in reverse order. 1. Perform Shutdown, page 43. 2. Remove four bolts (23) and shroud (10). 3. Remove lower din rail cover (48). 4. Disconnect fan and transformer connections from terminal blocks. Connections are on left side labeled: V+, V-, 1, 2, 3, and 4.

  • Page 73: Replace Motor Control Module (Mcm)

    Repair Replace Motor Control Module Replace Temperature Control (MCM) Module (TCM) 1. Perform Shutdown, page 43. 1. Perform Shutdown, page 43. 2. Disconnect connectors from MCM (63). Disconnect 2. Open electrical enclosure door (61). two power cables. See Electrical Schematics, 3.

  • Page 74: Replace Advanced Display Module (Adm)

    Repair Replace Advanced Display Software Update Procedure Module (ADM) NOTICE 1. Loosen four screws (70) on inside of electrical Repair kit GCA modules are shipped prepro- enclosure door (61). Lift up and pull out to remove grammed and with upgrade token (part number ADM (88).

  • Page 75: Update Adm Software

    Repair Update ADM Software NOTE: When the ADM display turns on, you may see the following screens: First: Software is checking which modules will take the available updates. 1. Turn main power switch OFF. Second: Status of the update with approximate time until completion.

  • Page 76: Parts

    Parts Parts Proportioners 333024V...
  • Page 77 Parts Apply anaerobic polyacrylate pipe sealant to all non-swiveling pipe threads. Apply grease to tube fitting threads. Torque to 43 ft-lb (58 N·m). Safety labels are from label sheet (68). 333024V...
  • Page 78 Parts Quantity Part Description 272010 272011 272012 272110 272111 272112 FRAME ENCLOSURE, electrical; see Electrical Enclosure, page 92 246995 BOTTLE, assembly 16X531 BRACKET, tsl, bottle 24U843 HEATER, 10kw, 2 zone, RTD; Fluid Heater, page 24U842 HEATER, 7.5kw, 1 zone, RTD; see Fluid Heater, page 84 24U704 MANIFOLD, fluid;...
  • Page 79 Parts Quantity Part Description 272010 272011 272012 272110 272111 272112 111800 SCREW, cap, hex hd; 7/32 in. x 5/16-18 111218 CAP, tube, square 110996 NUT, hex, flange head 104859 SCREW, tapping pnhd; 5/16 in. x #10-16 103181 WASHER, lock ext 100020 WASHER, lock 115836 GUARD, finger 24U847 FAN, cooling, 120mm,...
  • Page 80 Parts Quantity Part Description 272010 272011 272012 272110 272111 272112 24U321 KIT, asm, pair, elite, Reactor; see Fluid Inlet Kits, page 97 24U320 KIT, asm, pair, std, Reactor; see Fluid Inlet Kits, page 97 53‡ 24T050 CABLE, m8 4p f to m12 8p m 1.5m 54‡...
  • Page 81 Parts Quantity Part Description 272010 272011 272012 272110 272111 272112 24K411 BAR, 55 gal chem. ◊ measure; B side 127278 BOLT, carriage, 1/2-13 x 2.5 L 24U854 MODULE, ADM 16W967 FITTING, swivel, 3/4 npt x 1 npsm 118459 FITTING, union, swivel, 3/4 in.

  • Page 82: Proportioner Module

    Parts Proportioner Module 24V150, Module for E-30 24V151, Module for E-XP2 Torque to 190-210 in-lbs (21-24 N·m). Lubricate threads with ISO oil or grease. Assemble pump cylinders flush to one full thread under-flush of housing surface. Apply grease to all gear teeth proportionally, motor pinion and drive housing.
  • Page 83 Parts 24V150 24V151 Part Description E-30 E-XP2 24U050 MOTOR, brushless, double ended, 2hp 102* 17W869 KIT, drive housing 103✖❖ 257355 HOUSING, bearing 245927 HOUSING, bearing 104‡ 287290 KIT, repair, gear 105†✖❖ 241279 KIT, rod, connecting 245971 PUMP, displacement, B-side ◊ ❖...

  • Page 84: Fluid Heater

    Parts Fluid Heater 24U843 - 10kw, 2-zone 24U842 - 7.5kw, 1-zone Torque to 120 ft-lbs (163 N·m). Torque to 23 ft-lbs (31 N·m). Torque to 40 ft-lbs (54 N·m). Apply thermal paste. Apply pipe sealant and PTFE to all non-swiveling threads and threads without o-rings. Apply lithium grease lubricant to o-rings before assembling in block (1).
  • Page 85 Parts Part Description 24U843 24U842 15J090 HEATER, machined, 1 zone 15K825 HEATER, machined, dual zone 124132 O-RING 15H305 FITTING, plug, hollow, hex, 1-3/16 sae 121309 FITTING, adapter, sae-orb x jic 15H304 FITTING, plug 9/16 sae 15H306 ADAPTER, 9/16 x 1/8 120336 O-RING, packing 16A110...

  • Page 86: Flow Meter

    Parts Flow Meter 25N930 Torque to 90-100 in-lbs (10-11 N·m). Torque to 15-25 in-lbs (2-3 N·m). 333024V...
  • Page 87 Parts Part Description Qty. ---- HOUSING, 3/4” orb, w/ pins, sub-assembly 25C298 GEAR, magnets, sd/matrix 15V690PKG GEAR, oval, metering element 17Y063PKG GASKET, meter 131971PKG O-RING, 031, fx75 17Y062PKG CAP, meter 108787 SCREW, cap, sch 110163PKG SCREW, thd forming, pnh 24E134PKG BOARD, assembly, ratio monitor ---- COVER, meter 131172...

  • Page 88: E-Xp2 Flow Meter

    Parts E-XP2 Flow Meter 25P388 Torque to 396-720 in-lbs (44-47 N·m). Torque to 15-25 in-lbs (2-3 N·m). 333024V...
  • Page 89 Parts Part Description Qty. 18A877 HOUSING, high pressure meter 25C298 GEAR, magnets, sd/matrix 15V690 GEAR, oval, metering element 166623 PACKING, o-ring 192387 PIN, dowel 109114 SCREW, cap, sch 18A878 CAP, high pressure meter 25E134 BOARD, assy Reactor ratio monitor 110163 SCREW, thd forming, pnh 18A879 COVER, high pressure meter...

  • Page 90: Fluid Manifold

    Parts Fluid Manifold 24U844 Torque to 355-395 in-lbs (40-45 N·m). Apply sealant (113500) to threads. Valve must be closed with handle position as shown on drawing. Apply PTFE tape and thread sealant to gauge threads. Apply grease on valve. Apply PTFE tape or thread sealant to tapered threads. 333024V...
  • Page 91 Parts Part Description Qty. 401† 2008292 MANIFOLD, fluid 247824 KIT, valve, cartridge, drain ◊ 402a 158674 O-RING, BUNA-N ◊ 402b 247779 SEAL, seat, valve ◊ 102814 GAUGE, press, fluid 162453 FITTING, 1/4 npsm x 1/4 npt 15M669 SENSOR, pressure, fluid outlet 247788 HANDLE, red 247789...

  • Page 92: Electrical Enclosure

    Parts Electrical Enclosure 333024V...
  • Page 93 Parts Part Description Qty. 24U087 ENCLOSURE 24U855 MODULE, TCM 24U848 FAN, cooling, 80 mm, 24VDC 24R736 SWITCH, disconnect, door mounted 117666 TERMINAL, ground 255048 NUT, strain relief, M40 thread 255047 BUSHING, strain relief, M40 thread 123967 KNOB, operator disconnect 115942 NUT, hex, flange head 103181 WASHER, lock external...

  • Page 94: System Din Rail And Harness Module Kit

    Parts System DIN Rail and Harness Module Kit 24U850 See Electrical Schematics, page 99. Torque to 6-8 in-lbs (0.7-1 N·m). Torque to 28-33 in-lbs (3-3.8 N·m). Torque to 23-26 in-lbs (2.6-3 N·m). Part Description Qty. 16U529 HARNESS, breaker module 16V515 HARNESS, hose out 16U522 MODULE, din rail, term blk, power sup;...

  • Page 95: Heater And Transformer Terminal Block Module

    Parts Heater and Transformer Terminal Block Module 24U849 Part Description Qty. 24T315 RAIL, DIN; 35 mm x 7.5 mm x 7 in. 126811 BLOCK, clamp, end 126383 COVER, end 126382 BLOCK, terminal 120570 BLOCK, terminal 24R758 BLOCK, terminal, UT-2.5, red 24R759 BLOCK, terminal, UT-2.5, black 518*...

  • Page 96: System Circuit Breaker Module

    Parts System Circuit Breaker Module 16U526 Part Description Qty. 514014 RAIL, DIN; 35 mm x 7.5 mm x 8.625 in. 120838 TERMINAL, end stop 17A319 CIRCUIT, breaker, 1 pole, 50A, C Curve 17A314 CIRCUIT, breaker, 2P, 20A, UL489 17A317 CIRCUIT, breaker, 2P, 40A, UL489 Power Supply and Terminal Block Module 16U522 Part...

  • Page 97: Fluid Inlet Kits

    Parts Fluid Inlet Kits 24U320, Standard 25N920, Elite Apply sealant to all tapered pipe threads. Apply sealant to female threads. Apply to at least the first four threads and approximately 1/4 turn wide. Apply thermal paste to the stem of dial before assembling into housing. 333024V...
  • Page 98 Parts Quantity Part Description 24U320 25N920 160327 FITTING, union adapter, 90 degree 118459 FITTING, union swivel, 3/4 in. 603‡ 247503 MANIFOLD, strainer, inlet 24U852 THERMOMETER, dial 24U853 GAUGE, press, fluid 606† ---- FILTER, replacement 607†‡ 128061 PACKING, o-ring 608‡ 16V879 CAP, filter 609‡...

  • Page 99: Electrical Schematics

    Electrical Schematics Electrical Schematics Reactor 2 E-30 Reactor 2 E-XP2 To TCM 24U831 24U832 ti40831a 333024V...
  • Page 100 Electrical Schematics PS-L PS-N CB-B CB-A ti22680b 333024V...
  • Page 101 Electrical Schematics 16U526 24U855 16V515 ELEC ENCL GND STUD TO HTD HOSE Locate near TCM. ti35626a ti35627a 333024V...

  • Page 102: Reactor 2 Repair Spare Parts Reference

    Reactor 2 Repair Spare Parts Reference Reactor 2 Repair Spare Parts Reference Recommended Common Spare Parts Part Description Part of Assembly 106, Pump 15C852 E-30 Pump Repair Kit 106, Pump 15C851 E-XP2 Pump Repair Kit 106, Pump 246963 E-XP2 Wet Cup Repair Kit 106, Pump 246964...

  • Page 103: Performance Charts

    Performance Charts Performance Charts Use these charts to help identify the proportioner that will work most efficiently with each mix chamber. Flow rates are based on a material viscosity of 60 cps. NOTICE To prevent system damage, do not pressurize the system above the line for the gun tip size being used.

  • Page 104: Proportioners For Coatings

    Performance Charts Proportioners For Coatings Table 1 Fusion Air Purge, Round Pattern 3500 (241) 3000 (207) 2500 AR2020 E-XP2 (172) (000) PRESSURE AR2929 2000 (00) (138) psi (bar) 1500 (103) AR4242 (01) 1000 (69) (34) (1.9) (3.8) (5.7) (7.6) FLOW gal./min (l/min) Table 2 Fusion Air Purge, Flat Pattern 3500 (241, 24.1)
  • Page 105 Performance Charts Table 3 Fusion Mechanical Purge, Round Pattern 3500 (241, 24.1) E-XP2 3000 (207, 20.7) XR2323 (RTM040) 2500 (174, 17.4) XR2929 (RTM040) 2000 PRESSURE (138, 13.8) MR3535 psi (bar) (RTM040) 1500 MR4747 (103, 10.3) (RTM055) XR3535 (RTM055) XR4747 1000 (RTM055) (69, 6.9) (35, 3.5)

  • Page 106: Technical Specifications

    Technical Specifications Technical Specifications Reactor 2 E-30 and E-XP2 Proportioning System Metric Maximum Fluid Working Pressure E-30 2000 psi 14 MPa, 140 bar E-XP2 3500 psi 24.1 MPa, 241 bar Maximum Fluid temperature E-30 190°F 88°C E-XP2 190°F 88°C Maximum Flow Rate...
  • Page 107 Technical Specifications Reactor 2 E-30 and E-XP2 Proportioning System Metric Height 63 in. 1600 mm Depth 15 in. 381 mm Weight E-30, 10 kW 315 lb 143 kg E-30, 15 kW 350 lb 159 kg E-30, 10 kW Elite 320 lb...

  • Page 108: Graco Extended Warranty For Reactor

    PURPOSE. Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available.

  • Page 109: Graco Information

    Graco Extended Warranty for Reactor® 2 Components Graco Information For the latest information about Graco products, visit www.graco.com. For patent information, see www.graco.com/patents. TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Toll Free Phone Number: 1-800-328-0211 333024V...
  • Page 110 Original instructions. This manual contains English. MM 333024 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA Copyright 2021, Graco Inc. All Graco manufacturing locations are registered to ISO 9001. www.graco.com...

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