Graco Reactor E-10 User manual

Instructions - Parts List

For spraying or dispensing 1:1 mix ratio materials, including epoxies,

polyurethane foam, and polyurea coatings. For professional use only.

Not approved for use in European explosive atmosphere locations.

See page 4 for a list of models and maximum working pressures.

Important Safety Instructions

Read all warnings and instructions in

this manual. Save these instructions.

Nonheated Package, with 2K

Ultra-Lite™Gun and Cold

Spray disposable mixer

TI6989b

Heated

Package, with

Fusion™Gun

TI6987b

311075R

2311075R

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . 3

Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Isocyanate Hazard . . . . . . . . . . . . . . . . . . . 9

Foam Self-ignition . . . . . . . . . . . . . . . . . . . 9

Moisture Sensitivity of Isocyanates . . . . . 9

Keep Components A and B Separate . . 10

Changing Materials . . . . . . . . . . . . . . . . . 10

Component Identification . . . . . . . . . . . . 11

Controls and Indicators . . . . . . . . . . . . . 13

Motor/Pump Control Function Knob . . . 13

STATUS Indicator . . . . . . . . . . . . . . . . . 13

Motor Power Switch/Circuit Breaker . . . 14

Heater Power Switch/Circuit Breaker . . 14

Heater Temperature Controls . . . . . . . . 14

Fluid Temperature Sensors and Displays .

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Startup of Heated Units . . . . . . . . . . . . . . 22

Heatup Guidelines . . . . . . . . . . . . . . . . 23

Heat Management Tips . . . . . . . . . . . . 23

Heating Foam Resins with 245 fa Blowing

Agents . . . . . . . . . . . . . . . . . . . . . . . 24

Spraying/Dispensing . . . . . . . . . . . . . . . . 25

Pause (Heated Units) . . . . . . . . . . . . . . . . 26

Refilling Tanks . . . . . . . . . . . . . . . . . . . . . 26

Pressure Relief Procedure . . . . . . . . . . .27

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . .27

Maintenance . . . . . . . . . . . . . . . . . . . . . . .28

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . .29

Troubleshooting . . . . . . . . . . . . . . . . . . . .31

Status Codes . . . . . . . . . . . . . . . . . . . .31

Troubleshooting Chart . . . . . . . . . . . . .34

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Before Beginning Repair . . . . . . . . . . . .39

Removing Supply Tanks . . . . . . . . . . . .39

Recirc/Spray Valves . . . . . . . . . . . . . . .40

Displacement Pump . . . . . . . . . . . . . . .41

Control Module . . . . . . . . . . . . . . . . . . .43

Fluid Heaters (if supplied) . . . . . . . . . . .48

Pressure Transducers . . . . . . . . . . . . . .48

Drive Housing . . . . . . . . . . . . . . . . . . . .49

Cycle Counter Switch Replacement . . .50

Electric Motor . . . . . . . . . . . . . . . . . . . .51

Motor Brushes . . . . . . . . . . . . . . . . . . .52

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Suggested Spare Replacement Parts . .68

Accessories . . . . . . . . . . . . . . . . . . . . . . .68

Dimensions . . . . . . . . . . . . . . . . . . . . . . . .69

Technical Data . . . . . . . . . . . . . . . . . . . . .70

Graco Standard Warranty . . . . . . . . . . . .72

Graco Information . . . . . . . . . . . . . . . . . .72

Related Manuals

311075R 3

Related Manuals

The following manuals are for Reactor E-10 components and accessories. Some are supplied

with your package, depending on its configuration. Part No. 253422 Compact Disk includes all

Reactor E-10 manuals. Manuals are also available at www.graco.com.

Systems

Displacement Pump

Part No. Description

311076 Instruction-Parts Manual (English)

Fluid Heater

Part No. Description

311210 Instruction-Parts Manual (English)

Fusion Air Purge Spray Gun

Part No. Description

309550 Instruction-Parts Manual (English)

Fusion Mechanical Purge Spray Gun

Part No. Description

309856 Instruction-Parts Manual (English)

Fusion CS Spray Gun

Part No. Description

312666 Instruction-Parts Manual (English)

2K Ultra-Lite Dispense Valve

Part No. Description

309000 Instruction-Parts Manual (English)

311230 2K Ultra-Lite Cold Spray and Joint Fill

Kits (English)

Part

Maximum

Working

Pressure,

psi

(MPa, bar) Proportioner

(see page 4)

Unheated

Hose

35 ft (10.6 m)

Gun

Model Part

AP9570 2000

(14, 140) 249570 249499 Fusion Air Purge 249810

AP9571 2000

(14, 140) 249571 249499 Fusion Air Purge 249810

AP9572 2000

(14, 140) 249572 249499 Fusion Air Purge 249810

CS9570 2000

(14, 140) 249570 249499 Fusion CS CS22WD

CS9571 2000

(14, 140) 249571 249499 Fusion CS CS22WD

CS9572 2000

(14, 140) 249572 249499 Fusion CS CS22WD

249806 2000

(14, 140) 249576 249633 2K Ultra-Lite™249834

249808 2000

(14, 140) 249577 249633 2K Ultra-Lite™249834

Models

4311075R

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.

* See page 16 for detailed electrical requirements.

Bare

Proportioner

Part, Series Volts * Electrical

Connection Application

Maximum

Working

Pressure,

psi

(MPa, bar) Approvals

249570, A 120 V 15 A cord

(motor)

15 A cord

(heaters)

• Polyurethane Foam

• Hot Polyureas

2000

(14, 140)

249571, A 240 V 10 A cord

(motor)

10 A cord

(heaters)

• Polyurethane Foam

• Hot Polyureas

2000

(14, 140)

249572, A 240 V 20 A cord

(motor and

heaters)

• Polyurethane Foam

• Hot Polyureas

2000

(14, 140)

249576, A 120 V 15 A cord

(motor only)

• Self-leveling Joint Fillers

• Cold Polyureas

2000

(14, 140)

249577, A 240 V 10 A cord

(motor only)

• Self-leveling Joint Fillers

• Cold Polyureas

2000

(14, 140)

9902471

Conforms to ANSI/UL

Std. 499 Certified to

CAN/CSA Std.

C22.2 No. 88

Conforms to ANSI/UL

Std. 73 Certified to

CAN/CSA Std.

C22.2 No. 68

9902471

Warnings

311075R 5

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.

WARNING

ELECTRIC SHOCK HAZARD

Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power cord before servicing equipment.

• Use only grounded electrical outlets.

• Use only 3-wire extension cords.

• Ensure ground prongs are intact on sprayer and extension cords.

• Do not expose to rain. Store indoors.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on

skin, inhaled, or swallowed.

• Read MSDSs to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to

applicable guidelines.

• Always wear chemically impermeable gloves when spraying, dispensing, or

cleaning equipment.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when

in the operating area of the equipment to help protect you from serious injury, includ-

ing eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment

includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

•Gloves

• Hearing protection

Warnings

6311075R

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.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop spraying and before

cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or

explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric

lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when

flammable fumes are present.

• Ground all equipment in work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do

not use equipment until you identify and correct the problem.

• Keep a fire extinguisher in the work area.

THERMAL EXPANSION HAZARD

Fluids subjected to heat in confined spaces, including hoses, can create a rapid

rise in pressure due to the thermal expansion. Over-pressurization can result in

equipment rupture and serious injury.

• Open a valve to relieve the fluid expansion during heating.

• Replace hoses proactively at regular intervals based on your operating condi-

tions.

PRESSURIZED ALUMINUM PARTS HAZARD

Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocar-

bon solvents or fluids containing such solvents in pressurized aluminum equipment.

Such use can cause serious chemical reaction and equipment rupture, and result in

death, serious injury, and property damage.

WARNING

Warnings

311075R 7

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• This equipment is for professional use only.

• Do not leave the work area while equipment is energized or under pressure. Turn

off all equipment and follow the Pressure Relief Procedure in this manual when

equipment is not in use.

• Do not exceed the maximum working pressure or temperature rating of the low-

est rated system component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See

Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s

warnings. For complete information about your material, request MSDS from dis-

tributor 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.

• 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.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Comply with all applicable safety regulations.

MOVING PARTS HAZARD

Moving parts can pinch or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or

servicing equipment, follow the Pressure Relief Procedure in this manual. Dis-

connect power or air supply.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation.

To avoid severe burns, do not touch hot fluid or equipment. Wait until equip-

ment/fluid has cooled completely.

WARNING

Overview

8311075R

Overview

The Reactor E-10 is a portable, electric-pow-

ered, 1:1 mix ratio proportioner, for use with a

wide variety of coatings, foams, sealants, and

adhesives. Materials must be self-leveling and

pourable, and may be applied with impinge-

ment mix spray guns, disposable mixer guns,

or flush-type mix manifolds.

Reactor E-10 is gravity-fed from 7 gal. (26.5

liter) supply tanks mounted on the unit. The

tanks are translucent to allow monitoring of

fluid level.

Severe duty, positive displacement reciprocat-

ing piston pumps meter fluid flow to the gun for

mixing and applying. When set to recirculation

mode, Reactor E-10 will circulate fluids back to

the supply tanks.

Heated models include separate thermostati-

cally controlled heaters for each fluid, and an

insulated hose bundle with circulation return

hoses. This allows the hoses and gun to be

preheated to the desired temperature before

spraying. Digital displays show the tempera-

tures of the two fluids.

An electronic processor controls the motor,

monitors fluid pressures, and alerts the opera-

tor if errors occur. See STATUS Indicator,

page 13, for further information.

Reactor E-10 has two recirculation speeds,

slow and fast, and an adjustable pressure out-

put.

Slow Recirculation

• Slow circulation results in a higher temper-

ature transfer in the heater, so hoses and

gun heat up quicker.

• Good for touchup or low flow spraying, up

to moderate temperature.

• Not used to circulate full tanks up to tem-

perature.

• Use with 245 fa blowing agent foams, to

minimize heat returned to tank and reduce

frothing.

Fast Recirculation

• Use to support higher flow rates or higher

temperatures by preheating the tanks.

• Agitates fluid within tanks, to avoid heating

only the fluid at the top of the tank.

• Use for flushing.

Pressure Adjust

Automatically maintains selected pressure out-

put for dispensing or spraying.

Isocyanate Hazard

311075R 9

Isocyanate Hazard

Foam Self-ignition

Moisture Sensitivity of

Isocyanates

Isocyanates (ISO) are catalysts used in two

component foam and polyurea coatings. ISO

will react with moisture (such as humidity) to

form small, hard, abrasive crystals, which

become suspended in the fluid. Eventually a

film will form on the surface and the ISO will

begin to gel, increasing in viscosity. If used,

this partially cured ISO will reduce perfor-

mance and the life of all wetted parts.

To prevent exposing ISO to moisture:

• Always use a sealed container with a desic-

cant dryer in the vent, or a nitrogen atmo-

sphere. Never store ISO in an open

container.

• Keep the felt washers in the pump wet-cups

saturated with Graco ISO pump oil, Part

No. 217374. The lubricant creates a barrier

between the ISO and the atmosphere.

• Use moisture-proof hoses specifically

designed for ISO, such as those supplied

with your system (see page 63).

• Never use reclaimed solvents, which may

contain moisture. Always keep solvent con-

tainers closed when not in use.

• Never use solvent on one side if it has been

contaminated from the other side.

• Always park pumps when you shutdown,

see page 27.

• Always lubricate threaded parts with Part

No. 217374 ISO pump oil or grease when

reassembling.

Spraying materials containing isocyanates

creates potentially harmful mists, vapors,

and atomized particulates.

Read material manufacturer’s warnings and

material MSDS to know specific hazards and

precautions related to isocyanates.

Prevent inhalation of isocyanate mists,

vapors, and atomized particulates by provid-

ing sufficient ventilation in the work area. If

sufficient ventilation is not available, a sup-

plied-air respirator is required for everyone in

the work area.

To prevent contact with isocyanates, appro-

priate personal protective equipment, includ-

ing chemically impermeable gloves, boots,

aprons, and goggles, is also required for

everyone in the work area.

Some materials may become self-igniting if

applied too thickly. Read material manufac-

turer’s warnings and material MSDS.

The amount of film formation and rate of

crystallization varies depending on the

blend of ISO, the humidity, and the tem-

perature.

Keep Components A and B Separate

10 311075R

Keep Components A

and B Separate

Changing Materials

• When changing materials, flush the equip-

ment multiple times to ensure it is thor-

oughly clean.

• Always clean the fluid inlet strainers after

flushing, see page 28.

• Check with your material manufacturer for

chemical compatibility.

• Most materials use ISO on the A side, but

some use ISO on the B side.

• Epoxies often have amines on the B (hard-

ener) side. Polyureas often have amines on

the B (resin) side.

NOTICE

To prevent cross-contamination of the equip-

ment’s wetted parts, never interchange com-

ponent A (isocyanate) and component B

(resin) parts.

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