Page 1
Rev. C Hydraulic, heated, plural component proportioner for spraying polyurethane foam and polyurea coatings. Only use with Reactor 3 heated hoses. For indoor use only. For professional use only. Not approved for use in explosive atmospheres or hazardous (classified) locations.
The following manuals and quick guides are shipped www.graco.com. with the Reactor. Refer to these manuals and quick guides for detailed equipment information. English Manual Description Manuals are also available at www.graco.com. Number X021208EN Reactor 3 Proportioner, Repair-Parts English Feed System Manuals Manual...
Models Reactor H-50 H-50 Pro 20 kW, 230 V H-50 Elite 20 kW, 230 V Model (27R375) (27R377) 2000 psi 2000 psi Maximum Working Pressure (14 MPa, 140 bar) (14 MPa, 140 bar) Approximate Output / Cycle A + B 0.074 gal (0.28 L) 0.074 gal (0.28 L) 53 lb/min...
Models Reactor H-50 H-50 Pro 20 kW, 400 V H-50 Elite 20 kW, 400 V Model (27R376) (27R378) 2000 psi 2000 psi Maximum Working Pressure (14 MPa, 140 bar) (14 MPa, 140 bar) Approximate Output / Cycle A + B 0.074 gal (0.28 L) 0.074 gal (0.28 L) 53 lb/min...
Models Reactor H-XP3 H-XP3 Pro 20 kW, 230 V H-XP3 Elite 20 kW, 230 V Model (27R385) (27R387) 3500 psi 3500 psi Maximum Working Pressure (24.1 MPa, 241 bar) (24.1 MPa, 241 bar) Approximate Output / Cycle A + B 0.042 gal (0.16 L) 0.042 gal (0.16 L) 3.0 gpm...
Models Reactor H-XP3 H-XP3 Pro 20 kW, 400 V H-XP3 Elite 20 kW, 400 V Model (27R386) (27R388) 3500 psi 3500 psi Maximum Working Pressure (24.1 MPa, 241 bar) (24.1 MPa, 241 bar) Approximate Output / Cycle A + B 0.042 gal (0.16 L) 0.042 gal (0.16 L) 3.0 gpm...
Safety Symbols Safety Symbols The following safety symbols appear throughout this manual and on warning labels. Read the table below to understand what each symbol means. Symbol Meaning Symbol Meaning Toxic Fluid or Fumes Hazard Burn Hazard Ground Equipment Crush Hazard Read Manual Electric Shock Hazard Follow Pressure Relief Procedure...
General Warnings General Warnings The following warnings apply throughout this manual. Read, understand, and follow the warnings before using this equipment. Failure to follow these warnings can result in serious injury. DANGER SEVERE ELECTRIC SHOCK HAZARD This equipment can be powered by more than 240 V. Contact with this voltage will cause death or serious injury.
Page 16
General 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. •...
Page 17
General 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. •...
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 Sheets (SDSs) to know specific hazards and precautions related to isocyanates.
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.
Component Identification Component Identification Proportioner ISO Side Pump ISO Side Pressure Relief Outlet RES Side Pump RES Side Pressure Relief Outlet Red Stop Button ISO Side Inlet Pressure Gauge ISO Side Pressure Relief/Spray Valve RES Side Inlet Pressure Gauge RES Side Pressure Relief/Spray Valve Advanced Display Module (ADM) System LED Status Light Electrical Cord Strain Relief...
Component Identification Electrical Enclosure Reactor H-30/H-XP2 Incoming Power Cord Strain Relief Temperature Control Module (TCM) Incoming Power Ground Terminal Hydraulic Control Module (HCM) Motor Contactor Wiring Terminal Blocks Main Power Disconnect Knob 24V Power Supply Main Power Disconnect Switch Surge Protector Transformer Breaker Motor Breaker A-Side Heat Breaker...
Component Identification Temperature Control Module (TCM) Main Power Input Heater Over-Temperature Inputs CAN Communications Connections A/B Inlet Temperatures and 24 VDC Power Supply Input A Heater Temperature Input B Heater Temperature Input A/B Hose Temperature Inputs A/B Heater Power Outputs A/B Hose Power Outputs TCM LED Status Lights X021141EN...
Component Identification Hydraulic Control Module (HCM) Engine J1939 CAN Connection CAN Communication Connections Motor Temperature and Hydraulic Oil Temperature A-Side Pump Outlet Pressure Motor Contactor and Solenoids B-Side Pump Outlet Pressure Electronic Pressure Control Output A-Side Pump Inlet Pressure HCM LED Status Lights B-Side Pump Inlet Pressure Flow Meter Inputs Pump Position Switches...
Assemble the Proportioner 2. Use the four holes in the base of the system frame Reactor 3 proportioners arrive in a shipping (BH) to secure the base to the floor. The bolts are configuration. Before mounting the system, assemble not supplied.
To determine the correct size generator: • Hose: use only Reactor 3 hoses to ensure static 1. List peak wattage requirements of all system ground continuity. Check electrical resistance of components. hoses from the gun to the Reactor system ground.
Setup Connect Heated Hose to Proportioner NOTICE To avoid damage to the hose, only connect Reactor 3 heated hose to your Reactor proportioner. Connect the hose-side power connectors (HB) to the machine-side power connectors (HA). Refer to your heated hose manual for detailed instructions.
Setup Connect Power H-30 / H-XP2 (50/60 Hz) All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations. 1. Turn the main power switch (MP) OFF. 2. Open the electrical enclosure door. NOTE: The terminal jumpers are located inside the electrical enclosure door.
Setup Connect Power H-30 / H-XP2 (50 Hz) H-50 / H-XP3 (50/60 Hz) All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations. 1. Turn the main power switch (MP) OFF. 2. Open the electrical enclosure door. 3.
If the reservoir is low or empty, add new TSL to the fill line. When ordering pre-filled bottles from Graco, use a marker to draw a line at the top of the fluid line as it was shipped. Replace TSL if the fluid develops a gel-like consistency.
Startup Startup 6. Confirm the system main power switch (MP) is OFF before starting generator. To prevent serious injury, only operate Reactor with all covers and shrouds in place. NOTICE Proper system setup, startup, and shutdown procedures are critical to electrical equipment reliability.
Page 35
Startup 11. Turn ON the air compressor, air dryer, and e. Open the fluid inlet valves (XA, XB). Check for breathing air (if applicable). leaks. 12. For the first startup of new system, use the transfer pumps to supply fluid to the system. Cross-contamination can result in cured material in a.
Page 36
Startup h. Turn off the transfer pumps. If you are using the electric transfer pump, tap to turn OFF the A-side transfer pump. Tap to turn Thermal expansion can cause overpressurization, OFF the B-side transfer pump. resulting in equipment rupture and serious injury, including fluid injection.
Operation Operation Pressure Relief Procedure 5. Close the gun fluid inlet valves A and B. Follow the Pressure Relief Procedure whenever you see this symbol. This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing NOTE: The Fusion AP gun is shown.
Operation Jog Mode Jog the Transfer Pumps Separately Jog mode has two purposes: Pneumatic Transfer Pumps: Manually turn on/off air • To speed fluid heating during circulation. to the pumps one a time. See your pump manual. • To ease system flushing and priming. Electric Transfer Pumps: NOTE: Jog Mode is only available if the Electronic Pressure Controller is installed, see Accessories, page...
Operation Purge Air Procedure 7. If using pneumatic transfer pumps, turn off air to the transfer pumps. See your pump manual, refer to Related Manuals, page 3. 8. Tap to turn the motor OFF. NOTE: Perform this procedure any time air is 9.
Operation Flush the Equipment 5. Set the pressure relief/spray valves (SA, SB) to spray To prevent fire and explosion: • Flush equipment only in a well-ventilated area. • Do not spray flammable fluids. • Do not turn on heaters while flushing with flammable solvents.
Operation Fluid Circulation 4. Tap +/- to set the temperature targets for ISO and RES on the ADM screen. Circulation Through Reactor 5. Use Jog Mode to circulate fluid until the desired drum temperature for ISO and RES temperatures NOTICE reach their respective targets.
Page 42
Operation Circulation Through Gun Manifold 3. Follow Startup, page 34. NOTICE 4. Set temperature targets for ISO and RES To prevent equipment damage, do not circulate fluid on the ADM screen. containing a blowing agent without consulting with your material supplier regarding fluid temperature 5.
Operation Calibration Calibrate the Transfer Pumps After installing a new electric transfer pump, you must Calibrate the Heated Hose calibrate the transfer pump motor. NOTICE 1. Tap . Go to Setup > Supply System. To prevent damage to the heated hose, a hose 2.
Operation Spray 4. Set the pressure relief/spray valves (SA, SB) to spray 1. Engage the gun piston safety lock and close gun fluid inlet valves A and B. 5. Verify the heat zones are on and temperatures are 2. Attach the gun fluid manifold. Connect the gun air on target.
Page 45
Operation 8. Select Spray Mode from the drop down menu. 12. Open the A and B gun fluid valves. 9. If using pneumatic transfer pumps, turn on air to the transfer pumps. See your pump manual, refer to Related Manuals, page 3. NOTICE To prevent material crossover on impingement guns, never open fluid manifold valves or trigger gun if...
Operation Spray Adjustments • Pressure compensator knob adjustment on Elite models: Use only in the event of an issue with the electronic control. Turn knob clockwise to increae Flow rate, atomization, and amount of overspray are pressure and counterclockwise to decrease affected by four variables: pressure.
Page 47
Operation 6. Select the Park Mode icon from the drop down 9. Close all fluid supply valves (XA, XB). menu. The Park Mode icon will flash red while the park operation is in progress. The park operation is complete when the motor and transfer pumps are off, and a green check appears next to the Park Mode icon .
Advanced Display Module (ADM) Advanced Display Module (ADM) Menu Bar The menu bar is located at the top of each screen of the ADM. The menu bar contains the Navigation menu (1), current screen (2), system notifications (3), and time (4). System Notification Icons Navigate the Screens Icon...
Advanced Display Module (ADM) Home Screen Icon Name Description B (RES) Tap +/- to adjust the Use the Home screen to control the Reactor system Temperature setpoint by one degree. Setpoint Press and hold +/- to rapidly operation functions. adjust the setpoint. Tap the number to open a pop-up Temperature Control Panel and type in the setpoint...
Page 50
Advanced Display Module (ADM) A and B side Supply Control Panels Cycle Count Panel The A and B Supply Control panels display the The Cycle Count panel contains information regarding remaining material supply for A and B side materials, pump cycles and the equivalent amount of material. and contains controls for electric transfer pumps (if applicable).
Page 51
Advanced Display Module (ADM) Jog Cycle Limit Panel Icon Name Description Proportioner Pump Tap +/- to adjust the The Jog Cycle Limit panel contains a feature Pressure Setpoint setpoint by ten psi. Press enable/disable check box to enable the feature. When and hold +/- to slew.
Description detailed information related to heat. Help Tap to display a QR code Pressure / Flow Data Tap to display more with a link to help.graco.com for error and troubleshooting detailed information information. related to pressure/ flow. Electric Transfer Tap to display more...
Page 53
Advanced Display Module (ADM) USB Data Download 1. Turn the main power switch (MP) OFF. 2. Open the electrical enclosure door. 3. Insert the USB drive to the port in the back of the ADM. NOTE: USB A type drives are supported. NOTE: The ADM can read/write to FAT (File Allocation Table) formatted storage devices.
Advanced Display Module (ADM) Setup Screens Setting Description Flow Meter A Tap the number value to enter the Use the Setup screens to edit settings for the Reactor K-Factor K-Factor for the A side flow meter. system. NOTE: The K-Factor is noted on the meter label.
Page 55
Advanced Display Module (ADM) Heat Setting Description Use the Heat screen to calibrate hose heat and set the Enable Power Tap the checkbox to enable/disable Management power management. Tap the number to hose control mode. To calibrate the system, see adjust the primary heater power limit.
Page 56
Pump Runaway Transfer Pump A or B Runaway alarms Electric Transfer Pump). Alarm (DAFA or DAFB). The Transfer Pump Electric: select when using the Graco Runaway alarms can be disabled if Electric Transfer Pumps. occurring frequently and disrupting Transfer Pump B Tap to select the type of transfer pump operation.
Page 57
An example of using this would zones. be in conjunction with the Graco Light Tower as shown Power On, Motor Off, All Heat Off: When in the image below.
Pressure Units Display and USB download pressure After resetting the Reactor key, all operators using the units. Graco Reactor Connect App must reconnect to the Volume Units Display and USB download volume Reactor. units. For security of wireless control, change the Reactor key...
Maintenance Maintenance • Change break-in oil in a new unit after the first 250 hours of operation or within 3 months, whichever comes first. See the table below for recommended frequency of oil changes. Prior to performing any maintenance procedures, follow Table 1: Frequency of Oil Changes Pressure Relief Procedure, page 37.
Maintenance Vent Holes flushing out any isocyanate residue at the start of dispensing operations. Keep the vent holes on the back of the electrical cabinet open. 1. Follow the Pressure Relief Procedure, page 37. Grease Circulation Valves 2. Close the fluid inlet valve (XA) at the pump inlet. This prevents material from being pumped while Clean the grease circulation valves weekly.
Maintenance Change ISO Pump Throat Seal 4. When the TSL fluid system is flushed clean, fill it with fresh TSL fluid. Lubricant (TSL) Fluid 5. Thread the reservoir (R) onto the cap (H) assembly Check the condition of the TSL fluid daily. Change the and place it in the bracket.
Related Manuals, page 3. 2. A QR code screen will be displayed. Scan the QR code with your smart phone to be sent directly to online troubleshooting for the active error code. Otherwise, go to help.graco.com and search for the active error. X021141EN...
Troubleshooting LED Status Descriptions The following tables describe the meaning of LED statuses for the TCM, HCM, ADM, and System. Table 2: TCM Module LED Status Descriptions See Temperature Control Module (TCM), page 26. Conditions Description TCM Status Green Solid Power applied to module Yellow Flashing Active communication...
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.
Performance Charts Heater Performance Chart Delta T in M = 15.3 kW degrees F N = 20.4 kW (degrees C) FLOW rate in gpm (lpm) *Heater performance data is based on testing with 10 wt. hydraulic oil and 230V across heater power wires. Internally Heated Hose Pressure Setpoint Adjustment Internally heated hoses experience additional pressure drop when compared to externally heated hoses of the same inner diameter.
Technical Specifications Technical Specifications Reactor 3 Proportioning Systems, H-30 Metric Maximum Fluid Working Pressure 2000 psi 1.4 MPa, 14 bar Maximum Fluid Temperature 180°F 82.2°C 14.1 kg/min Maximum Flow Rate 31 lb/min Maximum Heated Hose Length 320 ft 97 m Approximate Output per cycle (A+B) 0.074 gal...
Page 67
Technical Specifications Reactor 3 Proportioning Systems, H-50 Metric Maximum Fluid Working Pressure 2000 psi 1.4 MPa, 14 bar Maximum Fluid Temperature 180°F 82.2°C 24 kg/min Maximum Flow Rate 53 lb/min Maximum Heated Hose Length 420 ft 128 m Approximate Output per cycle (A+B) 0.074 gal...
Page 68
Technical Specifications Reactor 3 Proportioning Systems, H-XP2 Metric Maximum Fluid Working Pressure 3500 psi 24.1 MPa, 241 bar Maximum Fluid Temperature 180°F 82.2°C 6.8 lpm Maximum Flow Rate 1.8 gpm Maximum Heated Hose Length 320 ft 97 m Approximate Output per cycle (A+B) 0.042 gal...
Technical Specifications Reactor 3 Proportioning Systems, H-XP3 Metric Maximum Fluid Working Pressure 3500 psi 24.1 MPa, 241 bar Maximum Fluid Temperature 180°F 82.2°C 11.4 lpm Maximum Flow Rate 3.0 gpm Maximum Heated Hose Length 420 ft 128 m Approximate Output per cycle (A+B) 0.042 gal...
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.
Graco Extended Warranty for Reactor® 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 X021141EN...
Page 72
Original instructions. This manual contains English. MM X021141EN Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA Copyright 2025, Graco Inc. All Graco manufacturing locations are registered to ISO 9001. www.graco.com...
Need help?
Do you have a question about the Reactor 3 and is the answer not in the manual?
Questions and answers