Graco 332636D Reactor 2 Elite Integrated Proportioning System Users Manual System, Operation, English

2015-04-02

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Operation

Reactor® 2 Elite Integrated
Proportioning System

332636D
EN

Electric, Heated, Integrated Plural Component Proportioning System With Integrated Generator. For
spraying polyurethane foam and polyurea coatings. For professional use only. Not approved for use in
explosive atmospheres or hazardous locations. Not for outdoor use.
Important Safety Instructions. Read all warnings and instructions in
this manual. Save these instructions.

PROVEN QUALITY. LEADING TECHNOLOGY.

Contents
Warnings ........................................................... 3
Important Isocyanate Information......................... 8
Models............................................................... 10
Approvals........................................................... 12
Accessories........................................................ 12
Supplied Manuals............................................... 13
Related Manuals ................................................ 13
Typical Installation, without circulation.................. 14
Typical Installation, with circulation ...................... 15
Component Identification..................................... 16
Generator.................................................... 18
Proportioner Control Panel ........................... 19
Air Compressor............................................ 20
Advanced Display Module ............................ 21
Electrical Enclosure...................................... 26
Electrical Cabinet......................................... 27
Motor Control Module (MCM)........................ 28
Engine Control Module................................. 29
Load Center ................................................ 30
Temperature Control Module (TCM) Cable
Connections................................... 31
Circuit Breakers ........................................... 32
Overview............................................................ 34
Setup................................................................. 37
Locate Reactor ............................................ 37
Trailer Setup Guidelines............................... 38
Install Wall (optional).................................... 39
Connect Battery........................................... 41
Add Fuel ..................................................... 41
General Equipment Guidelines ..................... 42
Electrical Connections.................................. 42
Connect Feed Pumps................................... 42
Breathing Air................................................ 42
Connect Pressure Relief Lines...................... 43
Install Fluid Temperature Sensor .................. 43
Connect Heated Hose.................................. 43
Close gun fluid manifold valves A and
B ................................................... 44
Connect Whip Hose to Gun Or Gun Fluid
Manifold......................................... 44
Pressure Check Hose .................................. 44
Connect Remote Display Module.................. 44
Grounding ................................................... 45
Supply Wet Cups With Throat Seal Liquid
(TSL) ............................................. 46
Operation........................................................... 47
Initial System Setup ..................................... 47
Register and Activate the Graco Insite........... 48
2

Advanced Setup Screens ............................. 50
System 1..................................................... 51
System 2..................................................... 51
Recipes....................................................... 51
Run Mode ................................................... 53
Startup............................................................... 57
Fluid Circulation.................................................. 61
Circulation Through Reactor ......................... 61
Circulation Through Gun Manifold................. 62
Jog Mode .................................................... 62
Spraying ............................................................ 63
Spray Adjustments....................................... 64
Manual Hose Heat Mode.............................. 65
Shutdown........................................................... 67
Pressure Relief Procedure .................................. 69
Flushing............................................................. 70
System Errors .................................................... 71
Troubleshoot Errors ..................................... 72
Clear Alarm ................................................. 72
Maintenance ...................................................... 73
Preventative Maintenance Schedule ............. 73
Wetcup........................................................ 73
Fluid Inlet Strainer Screen ............................ 73
Coolant Filter............................................... 73
Grease Circulation Valves ............................ 73
ISO Lubrication Level................................... 73
Wiring Connections...................................... 73
Dust Protection............................................ 73
Coolant Levels............................................. 73
Compressor Maintenance............................. 73
Air Compressor Oil Level.............................. 73
Clean Heat Sink Fins.................................... 74
Engine Maintenance .................................... 74
Fuel Tank.................................................... 75
Flush Inlet Strainer Screen ........................... 75
Pump Lubrication System............................. 76
USB Data........................................................... 77
USB Logs.................................................... 77
System Configuration Settings...................... 78
Download Log Files...................................... 79
Custom Language File ................................. 79
Upload Procedure........................................ 80
Appendix A: Engine Control Module..................... 81
Dimensions........................................................ 84
Performance Charts............................................ 87
Technical Specifications...................................... 90
Graco Extended Warranty for Integrated
Reactor® 2 Components ....................... 93
332636D

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.

WARNING
ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can
cause electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before
servicing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes
and regulations.
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.
TOXIC FLUID OR FUMES

Exhaust contains poisonous carbon monoxide, which is colorless and odorless. Breathing
carbon monoxide can cause death.
• Do not operate in an enclosed area.
CARBON MONOXIDE HAZARD

Wear appropriate protective equipment when in the work area to help prevent serious injury,
including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective
equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent
manufacturer.
PERSONAL PROTECTIVE EQUIPMENT

332636D

3

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.
.
• Do not spray without tip guard and trigger guard installed.
• 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
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.
Get immediate surgical

treatment

Pressure Relief Procedure

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in
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 the work area. See
instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless
they are antistatic or conductive.
•
if static sparking occurs or you feel a shock Do not use
equipment until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
work area

Grounding

Stop operation immediately

4

.

332636D

Warnings

WARNING
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 conditions.
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.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material
supplier for compatibility.
PLASTIC PARTS CLEANING SOLVENT HAZARD

Many solvents can degrade plastic parts and cause them to fail, which could cause serious
injury or property damage.
• Use only compatible water-based solvents to clean plastic structural or pressure-containing
parts.
• See
in this and all other equipment instruction manuals. Read fluid and
solvent manufacturer’s MSDSs and recommendations.
Technical Data

332636D

5

Warnings

WARNING
EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated
system component. See
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 distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the
when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals
and create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• 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.
• Comply with all applicable safety regulations.
Technical Data

Pressure Relief Procedure

BATTERY HAZARD

The battery may leak, explode, cause burns, or cause an explosion if mishandled.
• Only use the battery type specified for use with the equipment. See
.
• Battery maintenance must only be performed or supervised by personnel knowledgeable of
batteries and the required precautions. Keep unauthorized personnel away from battery.
• When replacing the battery, use the same lead-acid automotive battery, with 800 CCA
minimum, specified for use with the equipment. See
.
• Do not dispose of battery in fire. The battery is capable of exploding.
• Follow local ordinances and/or regulations for disposal.
• Do not open or mutilate the battery. Released electrolyte has been known to be harmful to
the skin and eyes and to be toxic.
• Remove watches, rings, or other metal objects.
• Only use tools with insulated handles. Do not lay tools or metal parts on top of battery.
Technical Data

Technical Data

MOVING PARTS HAZARD

Moving parts can pinch, cut 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
and disconnect all power sources.
Pressure Relief Procedure

6

332636D

Warnings

WARNING
ENTAGLEMENT HAZARD

Rotating parts can cause serious injury.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Do not wear loose clothing, jewelry or long hair while operating equipment.
• Equipment can start without warning. Before checking, moving, or servicing equipment,
follow the
and disconnect all power sources.
Pressure Relief Procedure

BURN HAZARD

Equipment surfaces and fluid that is heated can become very hot during operation. To avoid
severe burns:
• Do not touch hot fluid or equipment.
CALIFORNIA PROPOSITION 65

The engine exhaust from this product contains a chemical known to the State of California to
cause cancer, birth defects or other reproductive harm.

332636D

7

Important Isocyanate Information

Important Isocyanate Information
Isocyanates (ISO) are catalysts used in two component materials.
Isocyanate Conditions

Spraying or dispensing 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 providing sufficient
ventilation in the work area. If sufficient ventilation
is not available, a supplied-air respirator is required
for everyone in the work area.
To prevent contact with isocyanates, appropriate
personal protective equipment, including
chemically impermeable gloves, boots, aprons,
and goggles, is also required for everyone in the
work area.
Material Self-Ignition

Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings
and material MSDS.

8

Keep Components A and B Separate

Cross-contamination can result in cured
material in fluid lines which could cause serious
injury or damage equipment. To prevent
cross-contamination:
•
interchange component A and component
B wetted parts.
• Never use solvent on one side if it has been
contaminated from the other side.
Never

Moisture Sensitivity of Isocyanates

Exposure to moisture (such as humidity) will cause
ISO to partially cure; forming 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
NOTICE

Partially cured ISO will reduce performance and
the life of all wetted parts.
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere.
store ISO in an open container.
• Keep the ISO pump wet cup or reservoir (if
installed) filled with appropriate lubricant. The
lubricant creates a barrier between the ISO and
the atmosphere.
• Use only moisture-proof hoses compatible with
ISO.
• Never use reclaimed solvents, which may
contain moisture. Always keep solvent
containers closed when not in use.
• Always lubricate threaded parts with an
appropriate lubricant when reassembling.
Never

332636D

Important Isocyanate Information

Foam Resins with 245 fa Blowing
Agents

Some foam blowing agents will froth at temperatures
above 90°F (33°C) when not under pressure,
especially if agitated. To reduce frothing, minimize
preheating in a circulation system.

332636D

Changing Materials
NOTICE

Changing the material types used in your
equipment requires special attention to avoid
equipment damage and downtime.
• When changing materials, flush the equipment
multiple times to ensure it is thoroughly clean.
• Always clean the fluid inlet strainers after
flushing.
• Check with your material manufacturer for
chemical compatibility.
• When changing between epoxies and urethanes
or polyureas, disassemble and clean all fluid
components and change hoses. Epoxies often
have amines on the B (hardener) side. Polyureas
often have amines on the B (resin) side.

9

Models

Models
Reactor 2 E-30i

All base systems include fluid inlet pressure and temperature sensors and Graco InSite™. For part numbers,
see Accessories, page 12.
Model
Base Machine
Maximum Fluid
Working Pressure
psi (MPa, bar)
Approximate Output
per Cycle (A+B) gal.
(liter)
Max Flow Rate lb/min
(kg/min)
Total System Load †
(Watts)
Voltage (phase)
Available Auxiliary
Current at Volts, 60
Hz*

E-30i

No Air Compressor/Dryer
E-30i with heat

E-30i

With

Air Compressor/Dryer
E-30i with heat

272079

272080

272089

272090

2000 (13.8, 138)

2000 (13.8, 138)

2000 (13.8, 138)

2000 (13.8, 138)

0.0272 (0.1034)

0.0272 (0.1034)

0.0272 (0.1034)

0.0272 (0.1034)

30 (13.5)

30 (13.5)

30 (13.5)

30 (13.5)

7,400

11,600

13,500

17,700

240 VAC (1)
52 Amps (240)

240 VAC (1)
35 Amps (240)

240 VAC (1)
22 Amps (240)
9 Amps (120)

240 VAC (1)
5 Amps (240)
9 Amps (120)

Fusion AP Package 

AP2079

AP2080

AP2089

AP2090

(Gun Part No.)

(246102)

(246102)

(246102)

(246102)

CS2079

CS2080

CS2089

CS2090

(CS02RD)

(CS02RD)

(CS02RD)

(CS02RD)

P22079

P22080

P22089

P22090

(GCP2R2)

(GCP2R2)

(GCP2R2)

(GCP2R2)

24Y240

24Y240

24Y240

24Y240

246055

246055

246055

246055

Fusion CS Package 
(Gun Part No.)

Probler P2 Package 
(Gun Part No.)

Heated Hose
50 ft (15 m)
Heated Whip Hose
10 ft (3 m)


Total system watts used by system, based on
maximum heated hose length of 310 ft (94.5 m)
for each unit.

*

Full load amps available for auxiliary equipment
when all bare-system components are operating
at maximum capabilities. Available auxiliary
current is based on 310 ft (94.5 m) of heated hose.
An additional 3.0 amps (240 VAC) of auxiliary
current is available for each 50 ft (15.2 m) section
of heated hose that is not used.
Auxiliary current at 120 VAC is available on CB08,
line 1 (circuit breaker pin 2), line 2 current at 120
VAC is used by the air dryer (circuit breaker pin 4).

10



Available auxiliary current will be less when the
engine is de-rated for site altitude. Reduce the
Available Auxiliary Current in the chart by 2.5
Amps (240 VAC) per 1000 ft (300 m) elevation
increments. If the available auxiliary current is
less than zero, the system configuration may not
support the full load at that altitude.



Includes Complete Air Compressor/Dryer Kit
24U176.
Refer to Circuit Breaker Configuration Options,
page 33.



See Approvals, page 12.



Packages include gun, heated hose, and whip
hose.

332636D

Models

Reactor 2 E-XP2i

All base systems include fluid inlet pressure and temperature sensors and Graco InSite™. For part numbers,
see Accessories, page 12.
Model

Base Machine
Maximum Fluid Working Pressure psi
(MPa, bar)
Approximate Output per Cycle (A+B)
gal. (liter)
Max Flow Rate gal/min (l/min)
Total System Load † (Watts)
Voltage (phase)
Available Auxiliary Current at Volts, 60
Hz*

No Air Compressor/Dryer
E-XP2i with heat

Air Compressor/Dryer
E-XP2i with heat

272081

272091

3500 (24.1, 241)

3500 (24.1, 241)

0.0203 (0.0771)

0.0203 (0.0771)

2.0 (7.6)
11,600

2.0 (7.6)
17,700

240 VAC (1)
35 Amps (240)

240 VAC (1)
5 Amps (240)
9 Amps (120)

Fusion AP Package 

AP2081

AP2091

(Gun Part No.)

(246101)

(246101)

P22081
(GCP2R1)
24Y241

P22091

(Gun Part No.)

24Y241

246055

246055

Probler P2 Package 
Heated Hose
50 ft (15 m)
Heated Whip Hose
10 ft (3 m)


Total system watts used by system, based on
maximum heated hose length of 310 ft (94.5 m)
for each unit.

*

Full load amps available for auxiliary equipment
when all bare-system components are operating
at maximum capabilities. Available auxiliary
current is based on 310 ft (94.5 m) of heated hose.
An additional 3.0 amps (240 VAC) of auxiliary
current is available for each 50 ft (15.2 m) section
of heated hose that is not used.
Auxiliary current at 120 VAC is available on line 1
(circuit breaker pin 2), line 2 current at 120 VAC is
used by the air dryer (circuit breaker pin 4).

332636D

With

(GCP2R1)



Available auxiliary current will be less when the
engine is de-rated for site altitude. Reduce the
Available Auxiliary Current in the chart by 2.5
Amps (240 VAC) per 1000 ft (300 m) elevation
increments. If the available auxiliary current is
less than zero, the system configuration may not
support the full load at that altitude.



Includes Complete Air Compressor/Dryer Kit
24U176.
Refer to Circuit Breaker Configuration Options,
page 33.



See Approvals, page 12.



Packages include gun, heated hose, and whip
hose.

11

Approvals

Approvals

Note

Intertek approvals apply to proportioning systems
without hoses.
Model

272079
272089

Proportioning System Approvals:

Heated hoses provided with a system or sold
individually are not approved by Intertek.

Accessories
Kit Number

15M483
9902471

Conforms to ANSI/UL Std. 73
Certified to CAN/CSA Std.
C22.2 No. 68

272080
272081
272090
272091

15V551
24K207
24K333
24K336
24K337
24L911
24M174
24U174
24U176
24U177
Cables

121006
9902471

Conforms to ANSI/UL Std. 499
Certified to CAN/CSA Std.
C22.2 No. 88

12

24N365
24N449

Description

Remote Display Module Protective
Covers (10 pack)
ADM Protective Covers (10 pack)
Fluid Temperature Sensor (FTS)
with RTD
Fuel Line and Cable Extension Kit
Hose Rack
Light Tower Kit
Pallet Support Kit
Drum Level Sticks
Remote Display Module Kit
Complete Air Compressor Kit
Feed Pump Shutdown Kit
150 ft (45 m) cable (for remote
display module)
RTD Test Cables (to aide resistance
measurements)
50 ft (15 m) CAN cable (for remote
display module)

332636D

Supplied Manuals

Supplied Manuals

Related Manuals

The following manuals are shipped with the Reactor.
Refer to these manuals for detailed equipment
information.
Manuals are also available at www.graco.com.

The following manuals are for accessories used with
the Reactor.

Manual

332636
333093

Description

Reactor 2 Elite Integrated
Proportioning System, Operation
Reactor 2 Elite Integrated
Proportioning System, Startup
Instructions
333094
Reactor 2 Elite Integrated
Proportioning System, Shutdown
Instructions
SEBU8311– Perkins® Engine, Repair-Parts
02
Access at www.perkins.com. Go
-

to Service and Support/manuals.
Select engine family and type code
“GN”.

Mecc Alte Self-Regulating Alternator
Series NPE, Repair-Parts
Access at www.meccalte.com.
Select “meccalte” logo / Download
/ Instruction Manuals. Select NPE
instruction manual on page 5. Go to
Support and enter serial number for
Parts List and Help Videos.

ST
15825–00
33227482

332636D

Contact Mecc Alte for warranty and
service

Air Compressor, Operation/Maintenance & Parts list.

Access at www.hydrovaneproducts.com. Go to Warranty & Service
tab and select “contact us” to
request manuals.

Refrigerated Air Dryer, Instruction
manual
Access from Service
Department (724) 746–1100 or
www.spx.com/en/hankison.

Component Manuals in English:

Manuals are available at www.graco.com.
System Manuals

332637

Reactor 2 Elite Integrated
Proportioning System, Repair-Parts
Electric Reactor Displacement Pump,
Repair-Parts
Heated Hose, Instructions-Parts
Circulation and Return Tube Kit,
Instructions-Parts
Feed Pump Kits, Instructions-Parts
Feed Pump Air Supply Kit,
Instructions-Parts
Fusion ™ AP Gun
Fusion ™ CS Gun
Probler P2 Gun

Displacement Pump Manual

309577

Feed System Manuals

309572
309852
309815
309827

Spray Gun Manuals

309550
312666
313213

Accessory Manuals

332733
3A1905
3A1906
3A1904
3A1903
332738
3A1907
3A2574

Air Compressor and Air Dryer Kit,
Instructions-Parts
Feed Pump Shutdown Kit,
Instructions-Parts
Light Tower Kit, Instructions-Parts
Fuel Tank/Battery Move Kit,
Instructions-Parts
Hose Rack, Instructions-Parts
Booster Heat Retrofit Kit,
Instructions-Parts
Remote Display Module,
Instructions-Parts
Pallet Support Kit, Instructions-Parts

13

Typical Installation, without circulation

Typical Installation,
without circulation

Figure 1
* Shown exposed for clarity. Wrap with tape during operation.
J
A
Reactor Proportioner
K
B
Heated Hose
L
C Fluid Temperature Sensor (FTS)
M
D Heated Whip Hose
N
E
Fusion Spray Gun
P
F
Gun Air Supply Hose
S
G Feed Pump Air Supply Lines
H Agitator Air Supply Line
14

Fluid Supply Lines
Feed Pumps
Agitator
Desiccant Dryer
Bleed Lines
Gun Fluid Manifold (part of gun)
Remote Display Module Kit (optional)
332636D

Typical Installation, with circulation

Typical Installation, with
circulation

Figure 2
* Shown exposed for clarity. Wrap with tape during operation.
J
A
Reactor Proportioner
K
B
Heated Hose
L
C Fluid Temperature Sensor (FTS)
M
D Heated Whip Hose
P
E
Fusion Spray Gun
R
F
Gun Air Supply Hose
S
G Feed Pump Air Supply Lines
H Agitator Air Supply Line
332636D

Fluid Supply Lines
Feed Pumps
Agitator
Desiccant Dryer
Gun Fluid Manifold (part of gun)
Recirculation Lines
Remote Display Module (optional)
15

Component Identification

Component Identification

Figure 3 Front View
BA Component A Pressure Relief Outlet
BB Component B Pressure Relief Outlet
DG Drive Gear Housing
DB Electrical Enclosure
EM Electric Motor
FA Component A Fluid Manifold Inlet
FB Component B Fluid Manifold Inlet
FM Reactor Fluid Manifold
GA Component A Pressure Gauge
GB Component B Pressure Gauge
GG Generator, page 18
HA Component A Hose Connection
HB Component B Hose Connection

16

HC
MP
PA
PB
PC
PT
SA
SB
SC
TA
TB

Heated Hose Electrical Connectors
Main Power Switch
Component A Pump
Component B Pump (behind Electrical
Enclosure)
Proportioner Control Panel, page 19
Pallet
Component A PRESSURE
Valve
RELIEF/SPRAY
Component B PRESSURE
RELIEF/SPRAY
Valve
Fluid Temperature Sensor (FTS) Cable
Component A Pressure Transducer
(behind gauge GA)
Component B Pressure Transducer
(behind gauge GB)

332636D

Component Identification

Figure 4 Back View
CP Circulation Pump
EC Electrical Cord Strain Relief
FF Y-strainer (includes pressure
gauge, temperature gauge, and
pressure/temperature sensor)
FH Booster Fluid Heater (not included with all
models)
FV Fluid Inlet Valve (A side shown)
HE Heat Exchangers (heat exchanger coolant
loop)

332636D

HM
LR
MM
SG
VA
VB
VC

Temperature Control Module (TCM) Cable
Connections, page 31
ISO Pump Lubricant Reservoir
Motor Control Module (MCM), page 28
Sight Glass
Component A Control Valve
Component B Control Valve
Bypass Control Valve

17

Component Identification

Generator

Figure 5
AF Air Filter
BE Battery (not supplied)
DF Diesel Fuel Filter
EA 12V Charge Alternator
EB Engine Coolant Expansion Bottle
EE Engine
ED Engine Oil Dipstick
ER Radiator
EX Exhaust
FD Fuel Shutoff Solenoid
FH Filter Housing
FJ Fuel Injector
FP Fuel Pump
FS Diesel Fuel Fill Cap
18

FT
GD
GL
HB
HE
HF
OD
OF
OL
OS
RC
RF
ST
TR
WS

Diesel Fuel Tank
Generator Power Distribution Box
Glow Plugs
Heat Exchanger Coolant Expansion Bottle
Heat Exchanger
Heat Exchanger Coolant Fill Bottle
Oil Drain
Oil Filter
Oil Fill
Oil Pressure Switch
Engine Coolant Radiator Cap
Radiator Fan
Starter
Coolant Temperature Sensor
Over-Temperature Switch
332636D

Component Identification

Proportioner Control Panel

PD
PE
PF*
PG*
PH*
PJ*
PK
PL
PM
PN
PP
PR
*

Advanced Display Module (ADM), page 21
Engine Control Module, page 29
Component A Feed Pump Air Outlet
Component B Feed Pump Air Outlet
Agitator Air Outlet
Gun Air Outlet
Component A Feed Pump Air Regulator
Component B Feed Pump and Agitator Air
Regulator
Gun Air Regulator
Component A Feed Pump Pressure Gauge
Component B Feed Pump and Agitator
Pressure Gauge
Gun Pressure Gauge
Not for breathing air use.

Figure 6

332636D

19

Component Identification

Air Compressor

Select models are supplied with an air compressor
and air dryer.

CA
CB
CC
CD
CE
CF

Air Compressor
Power Box
Air Compressor and Dryer On/Off Switch
Refrigerated Air Dryer
Air Dryer Drain Tube (bottom of refrigerated
air dryer; not shown)
Air Compressor Pressure Gauge

Figure 7

20

332636D

Component Identification

Advanced Display Module

The ADM display shows graphical and text
information related to setup and spray operations.
For detail on the display and individual screens, see
Run Mode, page 53, or Setup Mode.
Use the USB port on the ADM to download or upload
data. For more information about the USB data, see
USB Data, page 77.

NOTICE

To prevent damage to the softkey buttons, do not
press buttons with sharp objects such as pens,
plastic cards, or fingernails.

Figure 8 Front View

332636D

21

Component Identification

Table 1 : ADM Keys and Indicators

Key

Function

Press to startup or shutdown the system.
Startup/Shutdown
Key and Indicator

Stop

Soft Keys

Navigation Keys
Numeric Keypad

Cancel

Setup

Press to stop all proportioner processes. This Is not a safety or emergency stop.
Press to select the specific screen or operation shown on the display directly next to
each key.
•
•

Use to move from screen to screen.
Up/Down Arrows: Use to move among fields on a screen, items on a dropdown
menu, or multiple screens within a function.
Left/Right Arrows:

Use to input values.
Use to cancel a data entry field.
Press to enter or exit Setup mode.
Press to choose a field to update, to make a selection, to save a selection or value, to
enter a screen, or to acknowledge an event.

Enter

22

332636D

Component Identification

Figure 9 Back View
CJ Flat Panel Mount (VESA 100)
CK Model and Serial Number
CL USB Port and Status LEDs
CM CAN Cable Connection

CN
CP
CR
CS

Module Status LEDs
Accessory Cable Connection
Token Access Cover
Battery Access Cover

Table 2 ADM LED Status Descriptions

LED
System Status

USB Status (CL)

ADM Status (CN)

Conditions

Green Solid
Green Flashing
Yellow Solid
Yellow Flashing
Green Flashing
Yellow Solid
Green and Yellow Flashing
Green Solid
Yellow Solid
Red Steady Flashing
Red Random Flashing or Solid

332636D

Description

Run Mode, System On
Setup Mode, System On
Run Mode, System Off
Setup Mode, System Off
Data recording in progress
Downloading information to USB
ADM is busy, USB cannot transfer
information when in this mode
Power applied to module
Active Communication
Software upload from token in
progress
Module error exists
23

Component Identification

ADM Display Details
Power Up Screen

The following screen appears when the ADM is
powered up. It remains on while the ADM runs
through initialization and establishes communication
with other modules in the system.

System Mode

The current system mode is displayed at the lower
left of the menu bar.
Alarm/Deviation

The current system error is displayed in the middle of
the menu bar. There are four possibilities:
Icon

No Icon

Function

No information or no error has occurred
Advisory
Deviation
Alarm

Status

The current system status is displayed at the lower
right of the menu bar.
Navigating the Screens
Menu Bar

The menu bar appears at the top of each screen.
(The following image is only an example.)
Date and Time

The date and time are always displayed in one of
the following formats. The time is always displayed
as a 24-hour clock.
• DD/MM/YY HH:MM
• YY/MM/DD HH:MM
• MM/DD/YY HH:MM
Arrows

The left and right arrows indicate screen navigation.
Screen Menu

The screen menu indicates the currently active
screen, which is highlighted. It also indicates the
associated screens that are available by scrolling left
and right.

24

There are two sets of screens:
• The Run screens control spraying operations and
display system status and data.
• The Setup screens control system parameters and
advanced features.
Press
on any Run screen to enter the Setup
screens. If the system has a password lock, the
Password screen displays. If the system is not locked
(password is set to 0000), System Screen 1 displays.
Press
on any Setup screen to return to the
Home screen.
Press the Enter soft key
function on any screen.

to activate the editing

Press the Exit soft key
to exit any screen.
Use the other softkeys to select the function adjacent
to them.

332636D

Component Identification

Icons
Screen Icons

These are frequently used icons on the screens.
The following descriptions explain what each icon
represents.
Icon

Description

Component A
Component B
Estimated Supply Material
Hose Temperature
Jog Mode Speed
Engine Coolant Temperature
Pressure
Cycle Counter (press and
hold)
Advisory. See
System Errors, page 71 for
more information.
Deviation. See
System Errors, page 71 for
more information
Alarm. See
System Errors, page 71 for
more information

332636D

Softkey Icons

The following icons appear in the ADM, directly to
the left or right of the soft key which activates that
operation.
Icon

Function

Start Proportioner
Start and Stop Proportioner in Jog Mode
Stop Proportioner
Turn on specified heat zone.
Park component A pump
Enter Jog Mode. See Jog Mode, page 62
Reset Cycle Counter
(press and hold)
Select Recipe
Search
Move Cursor Left One Character
Move Cursor Right One Character
Toggle between upper-case, lower-case,
and numbers and special characters.
Backspace
Cancel
Clear
Troubleshoot Selected Error
Increase value
Decrease value
Next screen
Previous screen
Return to first screen
25

Component Identification

Electrical Enclosure

AAA Temperature Control Module (TCM)
AAB Motor Control Module (MCM)
AAC Enclosure Fan
AAD Circuit Breakers
MP Main Power Switch

26

332636D

Component Identification

Electrical Cabinet

AAM Hose Breaker
AAN Transformer
AAP Load Center
AAS Fan
AAU Wiring Terminal Blocks

332636D

27

Component Identification

Motor Control Module (MCM)

Figure 10
MB
1
2
3
4
5
6
7
8
9

Description

Module Status LEDs see LED Status Table
CAN Communication Connections
Motor Temperature
Engine Coolant Temperature
Heat Exchanger A Temperature
Heat Exchanger B Temperature
A Pump Output Pressure
B Pump Output Pressure
A Fluid Inlet Sensor
B Fluid Inlet Sensor

10
11
12
13
14
15
16

Accessory Output
Load Center
Pump Cycle Counter
Not Used
Graco Insite™
Motor Power Output
Main Power Input

MCM Rotary Switch Positions

0=E-30i
1=E-XP2i

Table 3 MCM Module LED (MB) Status Descriptions

LED
MCM Status

Conditions

Green Solid
Yellow Solid
Red Steady Flashing
Red Random Flashing or Solid

28

Description

Power applied to module
Active Communication
Software upload from token in
progress
Module error exists

332636D

Component Identification

Engine Control Module
NOTICE

To prevent damage to the softkey buttons, do not
press buttons with sharp objects such as pens,
plastic cards, or fingernails.
For more information about the engine control module,
see Appendix A: Engine Control Module, page 81.

Icon

Description

On
Auto
Off

Scroll
Page Select
Error Lamp

Figure 11

332636D

Function

Start Engine
Auto mode (not
used)
Stop all system
processes. Is
not a safety or
emergency stop.
Scroll through the
instruments or
recorded events
on the currently
displayed page
Toggle between
the information
page and the error
log page
Indicates error
is present on
generator

29

Component Identification

Load Center

LED

Related
Component

Fuel Shutoff
Solenoid (FS)
D2 Starter (ST)
Plugs
D3 Glow
(GL)
Fan
D4 Radiator
(RF)
D10 A Coolant Valve
D1

F3
F4
K1
K2
K3
K4
MV

30

Radiator Fan Fuse
Load Center Power Fuse
Fuel Relay
Starter Relay
Glow Plug Relay
Radiator Fan Relay
Manual Valve Switch

Color

Green
Red
Green
Green
Red

D12 B Coolant Valve Blue
Coolant Green
D14 Bypass
Valve
Valve
D23 Manual
Switch (MV) Red

ON-State

Fuel shutoff
solenoid on the
engine is open.
Starter is
cranking.
Glow plugs are
heating.
Radiator fan is
on.
A-side (red)
coolant valve is
open.
B-side (blue)
coolant valve is
open.
Bypass coolant
valve is open.
Manual valve
switch is in the
ON position.
Description

332636D

Component Identification

Temperature Control Module (TCM)
Cable Connections

Figure 12
1
Power Input
2
Heater Overtemperature
3
CAN Communications Connections
4
Power Out (ISO)
5
Power Out (Res)
6
Power Out (Hose)

332636D

7
8
9
10

Module Status LEDs (see
Advanced Display Module (ADM), page 21,
Boost
A Temperature (ISO)
(CN) forHeater
conditions
Boost Heater B Temperature (RES)
Hose Temperature

31

Component Identification

Circuit Breakers

P110 - Green/Yellow

P100 - Green/Yellow
P010 - Black
Black

Disconnect

P040 - Red

Blue

P030 - Black

Brown

FAN

P020 - Red

Red
Black

P050 - Black
P060 - Red
CT01

P090 - Green/Yellow
P080 - Red

Note

Not all wires are shown.

32

CB01
CB03
CB04

Breaker DIN Rail

NEUTRAL

Blulkhead Connector

Ground Bar

Figure 13 Circuit Breaker Connections Inside
Electrical Enclosure (DB)

CB05

TB12 TB11

15 A

P110 - Green/Yellow

P070 - Black

P100 - Green/Yellow

MCM 24N953

P090 - Green/Yellow

20 A

40 A

P080 - Red

20 A

P070 - Black

CB06

P060 - Red

CB07

P050 - Black

CB 08

P040 - Red

15 A

P030 - Black

30 A

K110 - Red

K100 - Black

P020 - Red

15 A

P010 - Black
K120 - White

24R754

Breaker Harness

TCM 24N750

CB02

5A

PS1

Ground Terminal
Ref.

CB01

Size

5A

Component

Power Supply, Fan,
Coolant Pump
Boost Heat A
CB02 15 A
Boost Heat B
CB03 15 A
Hose Heat
CB04 30 A
CB05 20 A
Motor Control
CB06* 40 A
Air Compressor/Open
CB07* 20 A
Open
CB08* 15 A
Air Dryer/Open
* Contact Graco for circuit breaker options.

332636D

Component Identification

Circuit Breaker Configuration Options

Figure 14 Circuit Breakers Inside Proportioner
Cabinet
Ref.

CB20

Size

50 A

Component

Heated Hose

Improper configuration can result in electric shock.
All electrical wiring must be done by a qualified
electrician and comply with all local codes and
regulations. See page 27 and 28 for correct circuit
breaker configuration.
See Circuit Breakers, page 32 for recommended
circuit breaker configuration.
Sub-Panel Options

Some customer changes are acceptable to
accommodate larger loads from auxiliary equipment
or a sub-panel. It is suggested that circuit breakers
CB07 be substituted to accommodate larger loads
or a sub-panel. The total auxiliary equipment
loads added to the configuration must be limited
to the system’s available auxiliary current. See
Models, page 10, for available auxiliary current at
240V, 60Hz.
See the Reactor repair manual for optional circuit
breakers and their current ratings. Circuit breakers
used must meet UL489 specifications.
Auxiliary Wiring Diagram Options.

Figure 15 Circuit Breakers Inside Alternator
Assembly
Ref.

CB10

Size

90 A

Component

120/240V Alternator

The generator supplies power in a 3-wire,
single-phase, mid-point neutral wiring configuration.
For 240 VAC loads, wire the load across the output
terminals of the circuit breaker. For 120 VAC loads,
wire the load between the neutral terminal blocks
below the circuit breaker to one pole of the circuit
breaker. See electrical diagrams in Reactor repair
manual.
Disable Booster Heat

Disable booster heat to allow use of power for
additional auxiliary power.
To replace or repair a circuit breaker, see the Reactor
2 Integrated Repair manual.

332636D

33

Overview

Overview
The system uses two coolant loops to use heat
released from the engine to heat the A and B
component material to the target temperatures
defined on the ADM (PD).

The engine coolant loop (gray) circulates heated
coolant from the engine (EE), through the heat
exchanger (HE), radiator (ER), and back to the
engine. Coolant in the proportioner coolant loop
(black) captures heat from the engine coolant loop
inside the heat exchanger (HE) near the radiator.

Figure 16 Engine Coolant Loop and Proportioner
Coolant Loop

34

332636D

Overview

The proportioner coolant loop circulates coolant
through secondary heat exchangers (HE) located
on the back of the proportioner to heat the A
and B component material before the material is
pressurized in the proportioner pumps (PA, PB). After
the A and B material has been heated in the heat
exchangers, the material enters the fluid manifold
(FM) and heated hose.

For models with a booster heater, the A and B
material enters the booster heater after the material
is pressurized in the proportioning pumps to heat the
material higher than 140°F (60°C).

Figure 17 A and B Component Material Flow

332636D

35

Overview

Coolant only flows through the secondary heat
exchangers when the heat exchanger control valves
(VA, VB) are open and the A and B component
temperatures are below the target temperatures set
on the ADM. See Fig 18.

When the control valves (VA, VB) close, the A
and B material has reached target temperature.
Coolant flows through the bypass control valve (VC),
circulation pump (CP), sight glass (SG), proportioner
coolant fill bottle (HF), and back to the heat exchanger
in the engine coolant loop. See Fig. 19.

Figure 18 Proportioner Coolant Loop — A and B
Valves Open (heating material)

Figure 19 Proportioner Coolant Loop — A and B
Valves Closed (not heating material)

36

332636D

Setup

3. Do not expose Reactor to rain or below 20°F
(-7°C).

Setup
NOTICE

Proper system setup, startup, and shutdown
procedures 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.

Do not remove or separate the proportioner, engine
assembly, or power distribution box from the pallet.
Failure to leave the component mounting intact will
cause heating efficiency degradation, and potential
unsafe wiring and grounding.
Locate Reactor

1. Install hose rack, if ordered. See manual 3A1903
for detailed instructions.
2. Locate Reactor on a level surface that is
nonporous and diesel resistant, such as diamond
plate.
Note

NOTICE

To ensure the heat exchanger control valves
open and close properly, do not store Reactor
below 20°F (-7°C).
4. If a wall will be installed between the proportioner
and generator, remove the fuel tank and battery
bracket. See Trailer Setup Guidelines, page 38.
5. To mount in a trailer, use forklift to move Reactor
by inserting the forks through the Reactor pallet
frame. It is recommended to lift from the engine
side. Bolt pallet directly to trailer frame.
Note

Use Pallet Support Kit 24L911 (rollers not
included) to relocate pallet to mounting
location when forks are unavailable. See
kit manual for instructions.
NOTICE

Keep the vent holes in the bottom of the
proportioner cabinet open. Make sure there is
unobstructed incoming air for the cooling fan at the
top of the proportioner cabinet that blows air up into
the electric motor. Failure to provide unobstructed
incoming air can cause the motor to overheat.

Leave at least 1 ft. (0.3m) distance from
the engine side of the pallet to any wall
for engine maintenance access.

332636D

37

Setup

Trailer Setup Guidelines

Route exhaust system away from combustible
materials to prevent materials from igniting or gas
recirculation into a wall, ceiling, or a concealed
space. Provide exhaust system guards to prevent
burns.
NOTICE

2. Provide radiator exhaust for Reactor. Use a 400
in.2 (258,064 mm2) minimum louver.
3. Provide air duct to connect radiator exhaust to
louver.
4. Provide a 400 in.2 ( 258,064 mm2) minimum fresh
air intake louver near the generator.
5. Remove red exhaust cap.
6. Provide a minimum 2 in. (50.8 mm) diameter
engine exhaust outlet with flexible pipe element.
Provide rain cap, or equivalent routing, to prevent
moisture from entering the metal exhaust pipe.

Provide recommended size louvers. Failure to do
so can damage the engine and void the engine
warranty.
Exhaust pipes that pass through flammable ceilings
must be guarded by vented metal thimbles that
extend at least 9 in. (228.6 mm) below and above
the roof and are at least 6 in. (152.4 mm) in diameter
larger than the exhaust pipe.
Exhaust pipes that pass through flammable walls
must be guarded by either:
• Metal ventilated thimble at least 12 in. (305 mm)
larger than the diameter of the exhaust pipe.
• Metal or other approved fireproofing materials
that provides at least 8 in. (203 mm) of insulation
between the exhaust pipe and flammable material.
Exhaust pipes not covered above must have at least Radiator Exhaust and Air Intake Louvers
9 in. (228.6 mm) of clearance from the outside of the Figure 20
exhaust pipe to adjacent flammable materials.
1. Provide sufficient lighting to safely operate and
maintain system equipment.

38

332636D

Setup

3. Remove fuel tank from the pallet.
a. Remove the mounting screws, supports, and
It is only possible to install a wall between the
spacers.
proportioner and generator for systems without an air
b. Disconnect inlet and outlet fuel lines from the
compressor.
fuel tank.
c. Use two people to lift fuel tank off of the pallet
• Temperature condition the trailer space where
and place where the fuel fill spout is easily
chemical is stored. Check with chemical
accessible.
manufacturer for chemical storage temperatures.
Note
• Reduce noise for the operator while the Reactor
is running.
Do not mount fuel tank in front of
the generator air intake or where it
The supplied fuel lines and battery cable may need
will limit opening and access to the
to be replaced if a wall is installed between the
electrical enclosure (DB).
proportioner and generator. Purchase the Fuel Line
and Battery Cable Extension Kit 24K333.
4. Install wall (IW) where the fuel tank was located.
Ensure there is at least 1.25 in. (31.75 mm)
1. If necessary drain coolant from system. See
between the wall and exhaust muffler. See
Reactor repair manual for complete instructions.
Fig. 22.
Coolant lines do not need to be disconnected to
install a wall.
Note
Note
To prevent an air pocket from forming
inside the coolant lines between the
Battery must be connected to starter to
proportioner and generator, ensure
drain coolant from system.
there is a constant rise in elevation if
2. Remove screws and battery bracket from the
the coolant lines are adjusted. Failure
pallet.
to have a constant rise in elevation will
reduce heating efficiency. See Fig. 23.
5. Reconnect inlet and outlet fuel lines.
6. Install spacers, supports, and screws through
the fuel tank and tighten to the floor. Torque to
40 ft-lbs (54 N•m).
7. Place battery bracket over fuel tank or near the
Reactor. Remove existing battery cables from
engine and replace with the cables provided from
the fuel line and battery cable extension kit.
8. Install mounting bolts through battery bracket and
tighten to the floor. Torque to 40 ft-lbs (54 N•m).
Install Wall (optional)

Benefits:

Note

Pads under the battery bracket help
stabilize the fuel tank during operation.
Remove Battery Bracket and Fuel Tank
Figure 21

332636D

39

Setup

Figure 22 Top View With Wall

Figure 23 Side View With Wall

40

332636D

Setup

Connect Battery

Improper battery installation or maintenance
may result in electric shock, chemical burns,
or explosion. Battery maintenance must only
be performed or supervised by personnel
knowledgeable of batteries and the required
precautions. Keep unauthorized personnel away
from batteries.
See Technical Specifications, page 90 for battery
requirements and recommended battery size.
1. Secure battery (not supplied) to bracket with
strap.

Engine Starter Connections
Figure 25
3. Cover battery terminals with plastic caps (PC)
attached to supplied battery cables.
4. Verify battery was connected properly by
pressing OFF on the engine control module
(PE) to “wake up” the controller screen. Do not
attempt to start the engine until all Setup steps
are complete. See Repair manual if engine
control module does not light up.
Add Fuel

Battery Connections
Figure 24
2. Connect battery cable from the engine starter
(ST) and chassis to the battery. Connect the
black cable to battery negative (-) and the red
cable to battery positive (+).

1. Remove fuel cap (FS) and fill fuel tank with no
more than 20 gallons (75 liters) of diesel fuel.
Replace cap. See Perkins engine manual for
approved diesel fuels.
2. Squeeze prime bulb (P) to prime engine. Press
the prime bulb repeatedly until fuel begins to
return to the fuel tank.

NOTICE

Always connect the red battery cable to battery
positive (+) and the black battery cable to the
battery negative (-). Failure to properly connect
the battery cable to the battery will damage the
fusible link when the engine control module is
turned ON. Do not bypass the fusible link when
damaged. The fusible link prevents damage
to other system components. See the system
repair manual for repair instructions.
Figure 26

332636D

41

Setup

General Equipment Guidelines

Maintain and inspect the generator, air compressor,
and other equipment per the manufacturer
recommendations to avoid an unexpected shutdown.
Unexpected equipment shutdown will cause voltage
fluctuations that can damage electrical equipment.

5. Connect air lines to proportioner. Ensure
components are properly connected to correct
location.

Electrical Connections

Connect air compressor, breathing air, and auxiliary
power electrical connections to the specified circuit
breakers. See Circuit Breakers, page 32.
1. Remove one or more knock-outs on side
of electrical enclosure, as required, and
route wires through for air compressor,
breathing air, and auxiliary equipment. See
Circuit Breaker Configuration Options, page 33,
for more information.
Connect Feed Pumps

For illustrations of a system with feed pumps, see
Typical Installation, with circulation, page 15 and
Typical Installation, without circulation, page 14.
1. Install feed pumps (K) in component A and B
supply drums.
2. Seal component A drum and use desiccant dryer
(M) in vent.
3. Install agitator (L) in component B drum, if
necessary.
4. Connect supply hoses from feed pumps to the
component A and component B material inlets
on the system. Ensure A and B inlet valves are
closed.

Ref

PF
PG
PH
PJ

Air Outlet

A Pump
B Pump
Agitator
Gun

Note

Agitator air supply (PH) includes a small
internal restriction orifice to limit the air
flow to minimize air compressor load.
Maximum supplied air flow is 2.0 scfm
(0.1 m3/min) at 100 psi (0.7 MPa, 7 bar).
Designed for use with Twistork agitator
224854. Do not use the agitator air outlet
(PH) for any other component.
Breathing Air

Breathing the air from the compressed air supply
can cause serious injury if inhaled.
• Only use an independent and approved
breathing air system with adequate air flow to
provide clean breathable air.
Note

Supply hoses from feed pumps should
be 3/4 in. (199 mm) ID.

42

332636D

Setup

Connect Pressure Relief Lines

Do not operate Reactor without all covers and
shrouds in place.
1.
Connect high pressure
hose (R) to relief fittings (BA, BB) of both
PRESSURE RELIEF/SPRAY valves. Route
hose back to component A and B drums. See
Typical Installation, with circulation, page 15.
2.
Secure supplied bleed tubes (N)
in grounded, sealed waste containers (H). See
Typical Installation, without circulation, page 14.
Recommended:

Alternately:

2. Assemble heated hose sections, FTS, and whip
hose.
3. Connect A and B hoses to A and B outlets on
Reactor fluid manifold (FM). Hoses are color
coded: red for component A (ISO), blue for
component B (RES). Fittings are sized to prevent
connection errors.
Note

Manifold hose adapters (HA, HB) allow
use of 1/4 in. and 3/8 in. ID fluid hoses.
To use 1/2 in. (13 mm) ID fluid hoses,
remove adapters from fluid manifold and
install as needed to connect whip hose.

Install Fluid Temperature Sensor

The Fluid Temperature Sensor (FTS) is supplied.
Install FTS between main hose and whip hose. See
Heated Hose manual for instructions.
Connect Heated Hose

See Heated Hose manual for detailed instructions on
connecting heated hoses.
Note

The FTS (C) and whip hose (D) must be used
with heated hose. Hose length, including
whip hose, must be 60 ft (18.3 m) minimum.
NOTICE

Apply grease on all system and hose fluid fittings.
This lubricates the threads and prevents material
from hardening on the threads.
1. Turn main power switch OFF

332636D

Figure 27
4. Connect cables (C). Connect electrical
connectors (V). Follow procedures in heated
hose manual. Be sure cables have slack
when hose bends. Wrap cable and electrical
connections with electrical tape.

.

43

Setup

5. Connect quick-disconnect pin fitting to 4 ft air
hose, shipped loose. Connect other hose end to
the gun air hose in the heated hose bundle. Push
pin fitting into the lowest air panel outlet (PJ).

Close gun fluid manifold valves A and
B

Connect Whip Hose to Gun Or Gun
Fluid Manifold

See hose manual for proper connections.
Pressure Check Hose

Figure 28

See hose manual. Pressure check for leaks. If
no leaks, wrap hose and electrical connections to
protect from damage.
Connect Remote Display Module

See Remote Display Module kit manual for
installation instructions.

44

332636D

Setup

Grounding

The equipment must be grounded to reduce the
risk of static sparking and electric shock. Electric
or static sparking can cause fumes to ignite or
explode. Improper grounding can cause electric
shock. Grounding provides an escape wire for the
electric current.
• Reactor System: System must be grounded with
an appropriately sized conductor to the trailer
or vehicle chassis or, if stationary, to true earth
ground. Remove bolt and braided cable from
pallet. Install grounding cable terminated with a
• Spray gun: connect whip hose ground wire to FTS.
ring terminal (cable and terminal not supplied)
See Install Fluid Temperature Sensor, page 43.
under braided cable. Reinstall bolt and torque
Do not disconnect ground wire or spray without
to minimum 25 ft-lbs (34 N∙m). An alternate
whip hose.
grounding location is to the ground bar in the
electrical enclosure. Follow all National, State, and • Fluid supply containers: follow your local code.
Local safety and fire codes.
• Object being sprayed: follow your local code.
• Solvent pails used when flushing: follow your local
code. Use only metal pails, which are conductive,
placed on a grounded surface. Do not place pail
on a nonconductive surface, such as paper or
cardboard, which interrupts grounding continuity.
• To maintain grounding continuity when flushing or
relieving pressure, hold a metal part of spray gun
firmly to the side of a grounded metal pail, then
trigger gun.

332636D

45

Setup

Supply Wet Cups With Throat Seal
Liquid (TSL)

•

Check felt washers
in packing nut/wet-cup (S) daily. Keep saturated
with Graco Throat Seal Liquid (TSL), Part No.
206995, to prevent material from hardening on
displacement rod. Replace felt washers when worn
or contaminated with hardened material.
Component B (Resin) Pump:

Pump rod and connecting rod move during
operation. Moving parts can cause serious injury
such as pinching or amputation. Keep hands and
fingers away from wet-cup during operation.
To prevent the pump from moving, turn the main
power switch OFF.
•

Keep reservoir (R)
filled with clean Graco Throat Seal Liquid (TSL),
Part 206995. Wet-cup piston circulates TSL
through wet-cup, to carry away isocyanate film on
displacement rod.

Component A (ISO) Pump:

Component B Pump

Figure 30

Figure 29 Component A Pump

46

332636D

Operation

Operation
1. Turn the main power switch ON. The Graco logo
will display until communication and initialization
is complete.

3. Verify the machine is active and the System
Status LED is illuminated green, see
Advanced Display Module (ADM), page 21. If
the System Status LED is not green, press the
ADM Power On/Off (A) button . The System
Status LED will illuminate yellow if the machine
is disabled.
Initial System Setup

2. Press the on/off button .

332636D

Perform the following tasks to fully setup your system.
1. Select pressure for the Pressure Imbalance
Alarm to activate. See System Screen , page 51.
2. Enter, enable, or disable recipes. See
Recipes Screen, page 56.
3. Set general system settings. See
Advanced Screen 1 — General, page 50.
4. Set units of measure. See
Advanced Screen 2 — Units, page 50.
5. Set USB settings. See
Advanced Screen 3— USB, page 50.
6. Set target temperatures and pressure. See
Targets, page 53.
7. Set component A and component B supply
levels. See Maintenance, page 54.
8. Ensure engine is at operating temperature on the
home screen.

47

Operation

Register and Activate the Graco Insite

1. Go to www.GracoInSite.com, click on “InSite
Login, then follow the instructions on the screen.
2. Find and record the 15 digit serial number from
the cellular box below.

Serial No.

Verify Module Status

To check the status of the cellular module, locate the status LEDs on the module then refer to the following
chart.
LED Status

Green flashing
Green solid
Orange flashing
Orange solid
Green and orange off

48

Description

Finding GPS location
GPS location identified
Cellular connection in process
Cellular connection established
Reactor power is OFF

332636D

Operation

Setup Mode

The ADM will start in the Run screens at the Home screen. From the Run screens, press to access the
Setup screens. The system defaults with no password, entered as 0000. Enter the current password then
press . Press
to navigate through the Setup Mode screens.
Set Password

Set a password to allow Setup screen access, see Advanced Screen 1 — General, page 50. Enter any
number from 0001 to 9999. To remove the password, enter the current password in the Advanced Screen –
General screen and change the password to 0000.

From the Setup screens, press

332636D

to return to the Run screens.

49

Operation

Advanced Setup Screens

Advanced setup screens enable users to set units, adjust values, set formats, and view software information
to scroll through the Advanced setup screens, Once in the desired
for each component. Press
Advanced setup screen, press to access the fields and make changes. When changes are complete press
to exit edit mode.
Note

Users must be out of edit mode to scroll
through the Advanced setup screens.

Advanced Screen 1 — General

Use this screen to set the language, date format,
current date, time, setup screens password (0000 –
for none) or (0001 to 9999), and screen saver delay.

Advanced Screen 3 — USB

Use this screen to disable USB downloads/uploads,
disable USB log errors, enter the maximum number
of days to download data, and how frequently USB
logs are recorded. See USB Data, page 77.

Advanced Screen 4— Software
Advanced Screen 2 — Units

Use this screen to set the temperature units, pressure
units, volume units, and cycle units (pump cycles or
volume).

50

This screen displays the software part number and
software version for the Advanced Display Module,
USB Configuration, Motor Control Module, and
Temperature Control Modules.

332636D

Operation

System 1

Recipes

Use this screen to set the activation pressure for the
Pressure Imbalance Alarm and Deviation, enable or
disable diagnostic screens, set the maximum and
minimum drum volume, and enable drum alarms.

Use this screen to add recipes, view saved recipes,
and enable or disable saved recipes. Enabled
recipes can be selected at the Home Run Screen. 24
recipes can displayed on the three recipe screens.

System 2

Use this screen to enable Manual Hose Mode and
inlet sensors, as well as setting the inlet sensor
low pressure alarm and low temperature deviation.
Manual Hose Mode disables the hose temperature
RTD sensor so the system can operate if the sensors
were to malfunction. Default settings are 10 psi (0.07
MPa, 0.7 bar) for low inlet pressure alarm and 50˚F
(10˚C) for low inlet temperature deviation.

332636D

51

Operation

Add Recipe

2. Use
to highlight the next field and use the
number pad to enter a value. Press to save.

1. Press and then use
to select a
Enable or Disable Recipes
recipe field. Press to enter a recipe name
(maximum 16 characters). Press to clear the 1. Press and then use
to select the
old recipe name.
recipe that needs to be enabled or disabled.
2. Use
to highlight the enabled check box.
Press to enable or disable the recipe.

52

332636D

Operation

Run Mode

The ADM will start in the Run screens at the “Home” screen. Press
Mode screens. .
Or press to access the Setup screens.

to navigate through the Run

Home — System Off

Home — System With Error

This is the home screen when the system is off.
This screen displays actual temperatures, actual
pressures at the fluid manifold, jog speed, coolant
temperature, and number of cycles.

Active errors are shown in the status bar. The error
code, alarm bell, and description of the error will
scroll in the status bar.
1. Press to acknowledge the error.
2. See Troubleshoot Errors, page 72 for corrective
action.
Targets

Use this screen to define the setpoints for the
A Component Temperature, B Component
Temperature, heated hose temperature, and
pressure.
Home — System Active

150°F (65°C)

Maximum A and B temperature for systems without
booster heat:

When the system is active, the home screen displays
180°F (82°C)
actual temperature for heat zones, actual pressures
at the fluid manifold, coolant temperature, jog speed,
10°F (5°C)
the number of cycles, along with all associated
above
the
highest
A
or
B
temperature
setpoint or
control soft keys.
180°F (82°C).
Use this screen to turn on heat zones, view
Note
coolant temperature, start the proportioner, stop the
If the remote display module kit is used,
proportioner, park the component A pump, enter jog
these setpoints can be modified at the gun.
mode, and clear cycles.
Maximum A and B temperature for systems with
booster heat:

Maximum heated hose temperature:

332636D

53

Operation

Maintenance

Use this screen to view daily and lifetime cycles or
gallons that have been pumped and gallons or liters
remaining in the drums.
The lifetime value is the number of pump cycles or
gallons since the first time the ADM was turned on.
The daily value automatically resets at midnight.
The manual value is the counter that can be manually
reset. Press and hold to reset manual counter.

All events and errors listed on this screen can be
downloaded on a USB flash drive. To download logs,
see Download Log Files, page 79.

Cycles

This screen shows daily cycles and gallons that have
been sprayed for the day.
All information listed on this screen can be
downloaded on a USB flash drive.

Events

This screen shows the date, time, event code, and
description of all events that have occurred on
the system. There are 10 pages, each holding 10
events. The 100 most recent events are shown. See
System Events
for event code descriptions.
54

332636D

Operation

System Events

Use the table below to find a description for all system non-error events. All events are logged in the USB
log files.
Event Code

EACX
EADA
EADB
EADH
EAPX
EARX
EAUX
EB0X
EBDA
EBDB
EBDH
EBPX
EBRX
EBUX
EC0X
ECDA
ECDB
ECDH
ECDP
ECDX
EL0X
EM0X
EP0X
EQU1
EQU2
EQU3
EQU4
EQU5
ER0X
EVUX

332636D

Description

Recipe Selected
Heat On A
Heat On B
Heat On Hose
Pump On
Jog On
USB Drive Inserted
ADM Red Stop Button Pressed
Heat Off A
Heat Off B
Heat Off Hose
Pump Off
Jog Off
USB Drive Removed
Setup Value Changed
A Temperature Setpoint Changed
B Temperature Setpoint Changed
Hose Temperature Setpoint Changed
Pressure Setpoint Changed
Recipe Changed
System Power On
System Power Off
Pump Parked
System Settings Downloaded
System Settings Uploaded
Custom Language Downloaded
Custom Language Uploaded
Logs Downloaded
User Counter Reset
USB Disabled

55

Operation

Errors

This screen shows the date, time, error code, and
description of all errors that have occurred on the
system.
All errors listed on this screen can be downloaded on
a USB flash drive.

Recipes

Use this screen to add recipes, view saved recipes,
and enable or disable saved recipes. Enabled
recipes can be selected at the Home Run Screen. 24
recipes can displayed on the three recipe screens.
Job Data

Use this screen to enter a job name or number.

56

332636D

Startup

3. Check fluid inlet filter screens.
Before daily startup, ensure that the
fluid inlet screens are clean. See
Flush Inlet Strainer Screen, page 75.

Startup

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. The following procedures ensure steady
voltage. Failure to follow these procedures will
cause voltage fluctuations that can damage
electrical equipment and void the warranty.
1. Check generator fuel level.
Running out of fuel will cause voltage fluctuations
that can damage electrical equipment.

2. Check coolant levels.
Inspect the level of coolant inside the engine
coolant expansion bottle (EB) and heat
exchanger coolant expansion bottle (HB).

HO
T

CO
LD

332636D

A
B
C
D

4. Check ISO lubrication reservoir.
Check level and condition of ISO lube daily. See
Pump Lubrication System, page 76.

5. Confirm main power switch is OFF before starting
generator.

T
HO

LD

CO

57

Startup

6. Press start button on the engine control
module twice to start the generator. Verify
voltages are displayed on engine control module
before moving to next step.
The controller will automatically begin glow plug
warming and crank operations. Allow engine to
reach full operating speed.

8. For first startup of new system, set system
settings on ADM in Setup Mode.
See Initial System Setup, page 47.
9. For first startup of new system, adjust air settings
to zero:
a. Close the main air shutoff valve (CK).

Note

Engine will not start if main power switch
is in the ON position.
b. Ensure all three air regulators are turned fully
counterclockwise.
7. Turn main power switch ON.

The ADM will display the following screen until
communication and initialization is complete.

58

332636D

Startup

10. Start the air compressor, air dryer, breathing
air, and other accessories. For systems with a
supplied air compressor: start the air compressor
by pressing start on the air compressor START
box (CB).

11. Open the main air shutoff valve (CK).

Circulation Through Reactor, page 61.
If you need to circulate material through
the heated hose to the gun manifold, see
Circulation Through Gun Manifold, page 62.
d. Turn both PRESSURE RELIEF/SPRAY
valves (SA, SB) to SPRAY .

e. Adjust A and B feed pump air regulators to
desired air pressure, on front of proportioner,
to start the feed pumps. Do not exceed 130
psi (0.2 MPa, 2 bar) to the A and B feed
pumps.
f. Open fluid inlet valves (FV). Check for leaks.

12. For first startup of new system, adjust all three air
regulators to desired pressures.

13. For first startup of new system, load fluid with
feed pumps.
a. Check that all
steps are complete.
See Setup, page 37.
b. If an agitator is used, open the agitator’s air
inlet valve.
c. If you need to circulate fluid through the
system to preheat the drum supply, see
Setup

332636D

Cross-contamination can result in cured
material in fluid lines which could cause
serious injury or damage equipment. To
prevent cross-contamination:
•
interchange component A and
component B wetted parts.
• Never use solvent on one side if it has
been contaminated from the other side.
Always provide two grounded waste
containers to keep component A and
component B fluids separate.
Never

59

Startup

g. Hold gun fluid manifold over two grounded
waste containers. Open fluid valves A and B
until clean, air-free fluid comes from valves.
Close valves.

Thermal expansion can cause
overpressurization, resulting in equipment
rupture and serious injury, including fluid
injection. Do not pressurize system when
preheating hose.
a. Press

to turn on hose heat zone.

The Fusion AP gun manifold is shown.

14. Press

to activate the system.

b. Wait for the engine to reach operating
temperature, indicated when the black arrow
is under the green area of the temperature
bar. The radiator fan will turn on when
operating temperature is reached.

15. Preheat the system:
This equipment is used with heated fluid which
can cause equipment surfaces to become very
hot. To avoid severe burns:
• Do not touch hot fluid or equipment.
• Do not turn on hose heat without fluid in
hoses.
• Allow equipment to cool completely before
touching it.
• Wear gloves if fluid temperature exceeds
110°F (43°C).

60

c. Wait for the hose to reach set point
temperature.

d. Press

to turn on A and B heat zones.

332636D

Fluid Circulation

Fluid Circulation
Circulation Through Reactor

3. Set PRESSURE RELIEF/SPRAY valves (SA,
SB) to PRESSURE RELIEF/CIRCULATION .

NOTICE

To prevent equipment damage, do not circulate
fluid containing a blowing agent without consulting
with your material supplier regarding fluid
temperature limits.
Note

Optimum heat transfer is achieved at lower
fluid flow rates with temperature set points at
desired drum temperature. Low temperature
rise deviation errors may result.
To circulate through gun
manifold and preheat hose, see
Circulation Through Gun Manifold, page 62.
1. Follow Startup, page 57.
To avoid injection injury and splashing, do not
install shutoffs downstream of the PRESSURE
RELIEF/SPRAY valve outlets (BA, BB). The
valves function as overpressure relief valves
when set to SPRAY
. Lines must be
open so valves can automatically relieve
pressure when machine is operating.
2. See Typical Installation, with circulation, page 15.
Route circulation lines back to respective
component A or B supply drum. Use hoses
rated at the maximum working pressure of this
equipment.

332636D

4. Set temperature targets. See Targets, page 53.
5. Press to circulate fluid in jog mode until
A and B temperatures reach targets. See
Jog Mode, page 62 for more information about
jog mode.
6. Press to turn on the hose heat zone.
7. Turn on the A and B heat zones. Wait until the
fluid inlet valve temperature gauges (FV) reach
the minimum chemical temperature from the
supply drums.
8. Exit jog mode.
9. Set PRESSURE RELIEF/SPRAY valves (SA,
SB) to SPRAY
.

61

Fluid Circulation

Circulation Through Gun Manifold
NOTICE

To prevent equipment damage, do not circulate
fluid containing a blowing agent without consulting
with your material supplier regarding fluid
temperature limits.
Note

Circulating fluid through the gun manifold
allows rapid preheating of the hose.
1. Install gun fluid manifold (P) on accessory
circulation kit (CK). Connect high pressure
circulation lines (R) to circulation manifold.

rated at the maximum working pressure of this
equipment.
3. Follow procedures from Startup, page 57.
4. Turn main power switch on
.
5. Set temperature targets. See Targets, page 53.
6. Press to circulate fluid in jog mode until
A and B temperatures reach targets. See
Jog Mode, page 62 for more information about
jog mode.
Jog Mode

Jog mode has two purposes:
• Speed fluid heating during circulation.
• Ease system flushing and priming.
.
1. Turn main power switch on
2. Press circulate to enter jog mode.
3. Press up or down
to change jog speed
(J1 through J20).
Note

The Fusion AP gun manifold is shown.
CK

Gun

Manual

246362
Fusion AP 309818
256566
Fusion CS 313058
2. Route circulation lines back to respective
component A or B supply drum. Use hoses

62

Jog speeds correlate to 3-60% of motor
speed, but will not operate over 700 psi
(4.9 MPa, 49 bar) for either A or B.
4. Press to start motor.
5. To stop the motor and exit jog mode press
or .

332636D

Spraying

6. Verify that the engine temperature is at least up
to the minimum operation temperature range.
The fan will start running when the engine has
reached maximum temperature.
7. Open fluid inlet valves.

Spraying

1. Engage gun piston safety lock and close gun
fluid inlet valves A and B.

Fusion

Probler

2. Attach gun fluid manifold. Connect gun air line.
Open air line valve.

3. Adjust the gun air regulator on the proportioner
control panel to desired gun air pressure. Do not
exceed 130 psi (0.2 MPa, 2 bar).
4. Set PRESSURE RELIEF/SPRAY valves (SA,
SB) to SPRAY
.

8. Press

to start motor and pumps.

9. Check fluid pressure gauges (GA, GB) to
ensure proper pressure balance. If imbalanced,
reduce pressure of higher component by
turning PRESSURE RELIEF/SPRAY
valve for that component toward PRESSURE
slightly

RELIEF/CIRCULATION
balanced pressures.

until gauges show

5. Check that heat zones are on and
temperatures and pressures are on target, see
Home screen, page 53

332636D

63

Spraying

10. Open gun fluid inlet valves A and B.

12. Pull gun trigger to test spray onto cardboard. If
necessary, adjust pressure and temperature to
get desired results.
Spray Adjustments

Fusion

Probler

Flow rate, atomization, and amount of overspray are
affected by four variables.
•
Too little pressure results
in an uneven pattern, coarse droplet size, low
flow, and poor mixing. Too much pressure results
in excessive overspray, high flow rates, difficult
control, and excessive wear.
•
Similar effects to fluid pressure
setting. The A and B temperatures can be offset to
help balance the fluid pressure.
•
Choice of mix chamber is based
on desired flow rate and fluid viscosity.
•
Too little clean-off air
results in droplets building up on the front of the
nozzle, and no pattern containment to control
overspray. Too much clean-off air results in
air-assisted atomization and excessive overspray.
Fluid pressure setting.

NOTICE

To prevent crossover on impingement guns,
open fluid manifold valves or trigger gun
if pressures are imbalanced.
11. Disengage gun piston safety lock.
never

Fluid temperature.

Mix chamber size.

Clean-off air adjustment.

Fusion

64

Probler

332636D

Spraying

Manual Hose Heat Mode

If the system produces the T6DH sensor error hose
alarm or the T6DT sensor error TCM alarm, use
manual hose heat mode until the hose RTD sensor
can be repaired.
Do not use Manual Hose Mode for extended periods
of time. The system performs best when the hose
has a valid RTD and can operate in temperature
control mode. If a hose RTD breaks, the first priority
is to fix the RTD. Manual Hose Mode can help finish
a job while waiting for repair parts.

4. Enter Run Mode and navigate to the Target
screen. Set the desired hose current.

Enable Manual Hose Mode

1. Disconnect the hose RTD sensor from the TCM.
2. Enter Setup Mode and navigate to System
Screen 2.

Hose Current Settings

Hose Current

Default
Maximum

20A
37A

Note

Until the RTD sensor is repaired, the
T6DH sensor error alarm will display
each time the system is powered up.
5. Navigate back to the Run Mode Home screen.
The hose now displays a current instead of a
temperature.
3. Select Enable Manual Hose Mode.
Note

When manual hose mode is enabled, the
manual hose mode advisory EVCH-V
will appear.

332636D

65

Spraying

Disable Manual Hose Mode

1. Enter Setup Mode and navigate to System 2
Screen and deselect Enable Manual Hose Mode,
or repair the hose RTD.

66

2. Manual hose mode is automatically disabled
when the system detects a valid RTD sensor in
the hose.

332636D

Shutdown

Shutdown
Immediate Shutdown

3. Set PRESSURE RELIEF/SPRAY valves (SA,
SB) to PRESSURE RELIEF/CIRCULATION .

NOTICE

To avoid system damage, follow daily shutdown
procedure. Use only for immediate shutdown.
For immediate shutdown, press:

4. Relieve pressure. See
Pressure Relief Procedure, page 69.
5. Press to park the Component A Pump. The
park operation is complete when green dot goes
out. Verify the park operation is complete before
moving to next step.

6. Press

Daily Shutdown

to deactivate the system.

NOTICE

Proper system setup, startup, and shutdown
procedures 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.
1. Press

7. Turn off the air compressor, air dryer, and
breathing air.

to stop the pumps.

2. Turn off all heat zones.

332636D

67

Shutdown

8. Close the main air shutoff valve.

10. Press

to stop the engine.

11. Close all fluid supply valves.
9. Turn main power switch OFF. Allow engine
cooling dwell time prior to shutting down the
engine.

12. Engage gun piston safety lock then close fluid
inlet valves A and B.
To prevent electric shock do not remove any
shrouds or open the electrical enclosure door.
240 V is still present in the system until the
engine has stopped.
NOTICE

Fusion

Probler

Allow engine cooling dwell time, per
manufacturer recommendations, prior to
shutdown. Dwell time will help engine
properly cool down after running at operating
temperature for any period of time. Stopping
the engine immediately after running it at
full load for an extended period of time can
cause the engine to overheat due to the lack of
coolant flow. See engine manual.

68

332636D

Pressure Relief Procedure

Route fluid to waste containers or supply tanks.
Pressure Relief Procedure 4. Turn
PRESSURE RELIEF/SPRAY valves (SA,
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 fluid and moving parts, follow the
Pressure Relief Procedure when you stop spraying
and before cleaning, checking, or servicing
equipment.

SB) to PRESSURE RELIEF/CIRCULATION
. Ensure gauges drop to 0.

5. Engage gun piston safety lock.

The Fusion AP gun is shown.

1. Relieve pressure in gun and perform gun
shutdown procedure. See gun manual.
2. Close gun fluid inlet valves A and B.

Fusion

Fusion

Probler

6. Disconnect gun air line and remove gun fluid
manifold.

Probler

3. Shut off feed pumps and agitator, if used.

332636D

69

Flushing

Flushing

To help 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.
• Flush out old fluid with new fluid, or flush out old
fluid with a compatible solvent before introducing
new fluid.
• Use the lowest possible pressure when flushing.
• All wetted parts are compatible with common
solvents. Use only moisture-free solvents.

70

To flush feed hoses, pumps, and heaters
separately from heated hoses, set PRESSURE
RELIEF/SPRAY valves (SA, SB) to PRESSURE
RELIEF/CIRCULATION
lines (N).

. Flush through bleed

To flush entire system, circulate through gun fluid
manifold (with manifold removed from gun).
To prevent moisture from reacting with
isocyanate, always leave the system filled
with a moisture-free plasticizer or oil. Do not
use water. Never leave the system dry. See
Important Isocyanate Information, page 8 .

332636D

System Errors

System Errors

Error

Description

A parameter critical to
the process has reached
System errors alert you of a problem and help
a level requiring the
prevent off-ratio spraying. When an error occurs the
system to stop. The
error information screen displays the active error
alarm needs to be
code and description.
addressed immediately.
The error code, alarm bell, and active errors will scroll
A parameter critical
in the status bar. For a list of the ten most recent
to the process has
errors see Errors, page 56.
reached a level requiring
attention, but not
sufficient enough to
stop the system at this
There are three types of errors that can occur. Errors
time.
are indicated on the display as well as by the light
A parameter that is
tower (optional).
not immediately critical
to the process. The
advisory needs attention
to prevent more serious
issues in the future.
To troubleshoot the active error, see
Troubleshoot Errors, page 72. See system
repair manual for non-error based troubleshooting.
Alarms

Deviations

Advisories

332636D

71

System Errors

Troubleshoot Errors

See system repair manual or visit help.graco.com for
causes and solutions to each error code.
To troubleshoot the error:
1. Press the soft key next to “Help With This Error”
for help with the active error.

Note

2. The QR code screen will be displayed. Scan
the QR code with your mobile device to be sent
directly to online troubleshooting for the active
error code. Otherwise, manually navigate to
help.graco.com and search for the active error.

Press or to return to the
previously displayed screen.
3. If no internet connection is available, see Error
Code Troubleshooting in the system repair
manual for causes and solutions for each error
code.
Clear Alarm

When a deviation or alarm occurs, be sure to
determine the error code before resetting it.
Note

If you forget which code occurred, go to
Errors, page 56, to view the last 200 errors
with date and time stamps.
If an alarm has occurred, correct the cause before
resuming operation. For error code troubleshooting,
see Troubleshoot Errors, page 72.
To acknowledge a deviation or clear an alarm, press
.

72

332636D

Maintenance

Maintenance

Prior to performing any maintenance procedures,
follow Pressure Relief Procedure, page 69.
Preventative Maintenance Schedule

Wiring Connections

Tighten all screw-type wiring connections in the
Electrical Enclosure (DB), Reactor cabinet, and air
compressor control box (if supplied) monthly.
Dust Protection

Use clean, dry, oil-free compressed air to prevent
dust buildup on control modules, control boards,
fans, and motor (under shield).

The operating conditions of your particular system
determine how often maintenance is required.
Establish a preventive maintenance schedule by
recording when and what kind of maintenance is
needed, and then determine a regular schedule for
checking your system.

Coolant Levels

Wetcup

Compressor Maintenance

Check the wet cup daily. Keep it 2/3 full with Graco
Throat Seal Liquid (TSL®) or compatible solvent. Do
not overtighten packing nut/wet cup.
Fluid Inlet Strainer Screen

Inspect fluid inlet strainer screens daily, see
Flush Inlet Strainer Screen, page 75.
Coolant Filter

Inspect filter in coolant filter housing monthly.
Replace filter semi-annually. See Repair manual.
Grease Circulation Valves

Grease circulation valves (SA, SB) with Fusion
grease (117773) weekly.
ISO Lubrication Level

Inspect ISO lubricant level and condition
daily. Refill or replace as needed. See
Pump Lubrication System, page 76.

332636D

Check coolant level inside both overflow tanks daily.
Flush and refill the coolant on both the engine and
heat exchanger coolant loop once a year. See
system repair manual for instructions.
Check that the oil level is visible in sight glass
weekly. Use only Hydrovane approved oil such as
Hydrovane Fluid Force Red 2000 oil or CompAir
CS-300. One gallon container (171101) is available
as an accessory.
Refer to the Hydrovane User Handbook for all service
schedule information.
Change oil and install
Hydrovane kit KO52 (includes air filter and two
gaskets).
Change oil and install Hydrovane
Kit KM52 (includes air filter, oil separator and
miscellaneous seals).
Hydrovane Top-Up kit KT53
(recommended for a complete rebuild completed by
a Hydrovane Service Center).
Every 2000 hours or 1 year:

Every 4000 hours:

Every 10000 hours:

Air Compressor Oil Level

• Daily check air compressor oil level through sight
glass.

73

Maintenance

Clean Heat Sink Fins

Engine Maintenance

Keep heat sink fins clean at all times. Clean them
using a dry cloth or compressed air.

The engine instructions that accompany your
unit detail specific procedures for maintenance of
the engine. Following the engine manufacturer’s
recommendations will extend engine work life.

Note

Do not use conductive cleaning solvents on
the module.

Daily

• Cooling System Coolant Level — Check
• Engine Air Cleaner Service Indicator — Inspect
• Engine Oil Level — Check
Every 500 Service Hours or 1 Year

Figure 31 MCM Heat Fins

• Engine Air Cleaner Element (Dual Element) —
Clean/Replace
• Engine Oil and Filter — Change
• Fuel System Filter — Replace
• Battery Voltage — Check. See
Appendix A: Engine Control Module, page 81.
Contact an Authorized Perkins Dealer or Distributor
for replacement filter elements. Refer to Perkins
engine part number GN66141N for compatible parts.

Figure 32 TCM Fins
Air Dryer Water Separator

•
•
•
•

Clean ambient air filter monthly or more often if air flow across the condenser is blocked.
Clean inlet strainer monthly or more often if rapid clogging occurs.
Replace separator/filter element yearly or more often if pressure drop across the dryer is excessive.
Check automatic condensate drain daily.

74

332636D

Maintenance

3. Remove the screen (A) from the strainer
manifold. Thoroughly flush the screen with
compatible solvent and shake it dry. Inspect the
Fuel quality is critical to the performance and to the
screen. No more than 25% of the mesh should
service life of the engine. Water in the fuel tank
be restricted. If more than 25% of the mesh is
can cause excessive wear to the fuel system. See
blocked, replace the screen. Inspect the gasket
the supplied Perkins engine manual for fuel tank
(B) and replace as required.
maintenance recommendations.
4. Ensure the pipe plug (D) is screwed into the
Flush Inlet Strainer Screen
strainer plug (C). Install the strainer plug with the
screen (A) and gasket (B) in place and tighten.
Do not overtighten. Let the gasket make the seal.
5. Open the fluid inlet valve, ensure that there are
no leaks, and wipe the equipment clean. Proceed
with operation.
The inlet strainers filter out particles that can plug the
pump inlet check valves. Inspect the screens daily as
part of the startup routine, and clean as required.
Isocyanate can crystallize from moisture
contamination or from freezing. If the chemicals used
are clean and proper storage, transfer, and operating
procedures are followed, there should be minimal
contamination of the A-side screen.
Fuel Tank

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 at the pump inlet and
shut off the appropriate feed pump. This prevents
material from being pumped while cleaning the
screen.
2. Place a container under the strainer base to catch
drain off when removing the strainer plug (C).

332636D

A
B

Figure 33

C
D

75

Maintenance

Pump Lubrication System

Check the condition of the ISO pump lubricant daily.
Change the lubricant if it becomes a gel, its color
darkens, or it becomes diluted with isocyanate.
Gel formation is due to moisture absorption by the
pump lubricant. The interval between changes
depends on the environment in which the equipment
is operating. The pump lubrication system minimizes
exposure to moisture, but some contamination is still
possible.
Lubricant discoloration is due to continual seepage of
small amounts of isocyanate past the pump packings
during operation. If the packings are operating
properly, lubricant replacement due to discoloration
should not be necessary more often than every 3 or
4 weeks.
To change pump lubricant:
1. Follow Pressure Relief Procedure, page 69.
2. Lift the lubricant reservoir (R) out of the bracket
and remove the container from the cap. Holding
the cap over a suitable container, remove the
check valve and allow the lubricant to drain.
Reattach the check valve to the inlet hose.
3. Drain the reservoir and flush it with clean
lubricant.

76

4. When the reservoir is flushed clean, fill with fresh
lubricant.
5. Thread the reservoir onto the cap assembly and
place it in the bracket.
6. The lubrication system is ready for operation. No
priming is required.

Pump Lubrication System
Figure 34

332636D

USB Data

USB Data
Each time a USB flash drive is inserted into the ADM
USB port, a new folder named DATAxxxx is created.
The number at the end of the folder name increases
each time a USB flash drive is inserted and data is
downloaded or uploaded.
Note

The ADM can read/write to FAT (File
Allocation Table) storage devices. NTFS,
used by 32 GB or greater storage devices,
is not supported.
USB Logs

During operation, the ADM stores system and
performance related information to memory in the
form of log files. The ADM maintains four log files:
• Event Log
• Job Log
• Daily Log
• System Software Log
• Blackbox Log
• Diagnostics Log
Follow Download Procedure, page 79, to retrieve
log files.
Event Log

The event log file name is 1–EVENT.CSV and is
stored in the DATAxxxx folder.
The event log maintains a record of the last 49,000
events and errors. Each event record contains:
• Date of event code
• Time of event code
• Event code
• Event type
• Action taken

332636D

• Event Description
Event codes include both error codes (alarms,
deviations, and advisories) and record only events.
Actions Taken includes setting and clearing event
conditions by the system, and acknowledging error
conditions by the user.

Job Log

The job log file name is 2–JOB.CSV and is stored
in the DATAxxxx folder.
The job log maintains a record of data points
based on the USB Log Frequency defined
in the Setup screens. The ADM stores the
last 237,000 data points for download. See
Setup - Advanced Screen 3 — USB, page 50, for
information on setting the Download Depth and USB
Log Frequency.
• Data point date
• Data point time
• A side heat exchanger temperature
• A side boost heater temperature
• B side heat exchanger temperature
• B side boost heater temperature
• Hose temperature
• Engine coolant temperature
• A side temperature setpoint
• B side temperature setpoint
• Hose temperature setpoint
• Inlet A side pressure
• Inlet B side pressure
• Pressure setpoint
• System lifetime pump cycle counts
• Pressure, volume, and temperature units
• Job name/number

77

USB Data

Daily Log

Blackbox Log File

The daily log file name is 3–DAILY.CSV and is stored
in the DATAxxxx folder.
The daily log maintains a record of the total cycle
and volume sprayed on any day that the system is
powered up. The volume units will be the same units
that were used in the Job Log.
The following data is stored in this file:
• Date that material was sprayed
• Time — unused column
• Total pump cycle count for day
• Total volume sprayed for day

Diagnostics Log File

System Software Log

The system software file name is 4–SYSTEM.CSV
and is stored in the DATAxxxx folder.
The system software log lists the following:
• Date log was created
• Time log was created
• Component name
• Software version loaded on the above component

78

The black box file name is 5–BLACKB.CSV and is
stored in the DATAxxxx folder.
The Blackbox log maintains a record of how the
system runs and the features that are used. This log
will help Graco troubleshoot system errors.
The diagnostics file name is 6–DIAGNO.CSV and is
stored in the DATAxxxx folder.
The Diagnostics log maintains a record of how the
system runs and the features that are used. This log
will help Graco troubleshoot system errors.
System Configuration Settings

The system configuration settings file name is
SETTINGS.TXT and is stored in the DOWNLOAD
folder.
A system configuration settings file automatically
downloads each time a USB flash drive is inserted
into the ADM. Use this file to back up system
settings for future recovery or to easily replicate
settings across multiple systems. Refer to the
Upload Procedure, page 80 for instructions on how
to use this file.

332636D

USB Data

Download Log Files
Note

System configuration setting files and custom
language files can be modified if the files
are in the UPLOAD folder of the USB flash
drive. See System Configuration Settings
File, Custom Language File, and Upload
Procedure sections.
Note

If needed, set the number of days to
download on the Advanced Setup Screen
3–USB in the ADM. USB log frequency can
only be changed before logging occurs.
1. Insert USB flash drive into USB port.
2. The menu bar and USB indicator lights “USB
Busy” to indicate that the USB is downloading
files. USB activity is complete when the “USB
Busy” screen prompt disappears or the flash
drive LED stops flashing.
3.
4.
5.
6.
7.
8.

9. Open DATAxxxx folder.
10. Open DATAxxxx folder labeled with the highest
number. The highest number indicates the most
recent data download.
11. Open log file. Log files open in Microsoft® Excel
by default as long as the program is installed.
However, they can also be opened in any text
editor or Microsoft® Word.
Note

All USB logs are saved in Unicode
(UTF-16) format. If opening the log
file in Microsoft Word, select Unicode
encoding.
Custom Language File

The custom language file name is DISPTEXT.TXT
and is stored in the DOWNLOAD folder.
A custom language file automatically downloads
each time a USB flash drive is inserted into the ADM.
If desired, use this file to create a user-defined set of
Note
custom language strings to be displayed within the
ADM.
Normal system spraying can continue
while download is in progress.
The system is able to display the following Unicode
characters. For characters outside of this set,
Remove USB flash drive from USB port.
the system will display the Unicode replacement
Insert USB flash drive into USB port of computer. character, which appears as a white question mark
The USB flash drive window automatically opens. inside of a black diamond.
If it does not, open USB flash drive from within • U+0020 - U+007E (Basic Latin)
Windows® Explorer.
• U+00A1 - U+00FF (Latin-1 Supplement)
Open GRACO folder.
• U+0100 - U+017F (Latin Extended-A)
Open the system folder. If downloading data
from more than one system, there will be more • U+0386 - U+03CE (Greek)
than one folder. Each folder is labeled with the • U+0400 - U+045F (Cyrillic)
corresponding serial number of the ADM (The
serial number is on the back of the ADM.)
Open DOWNLOAD folder.

332636D

79

USB Data

1. If necessary, follow the
to
automatically generate the proper folder structure
on the USB flash drive.
The custom language file is a tab-delimited text file
that contains two columns. The first column consists 2. Insert USB flash drive into USB port of computer.
of a list of strings in the language selected at the
time of download. The second column can be used 3. The USB flash drive window automatically opens.
If it does not, open USB flash drive from within
to enter the custom language strings. If a custom
Windows Explorer.
language was previously installed, this column
contains the custom strings. Otherwise the second 4. Open GRACO folder.
column is blank.
Open the system folder. If working with more
Modify the second column of the custom language file 5. than
one system, there will be more than one
as needed and the follow Upload Procedure, page 80 ,
folder
within the GRACO folder. Each folder is
to install the file.
labeled with the corresponding serial number of
the ADM. (The serial number is on the back of
The format of the custom language file is critical.
the module.)
The following rules must be followed in order for the
installation process to succeed.
6. If installing the system configuration settings
file, place SETTINGS.TXT file into the UPLOAD
• Define a custom string for each row in the second
folder.
column.
7. If installing the custom language file, place
Note
DISPTEXT.TXT file into the UPLOAD folder.
If the custom language file is used, you
8. Remove USB flash drive from the computer.
must define a custom string for each
entry in the DISPTEXT.TXT file. Blank
9. Install USB flash drive into the ADM USB port.
second-column fields will be displayed
10. The menu bar and USB indicator lights indicate
blank on the ADM.
that the USB is downloading files. Wait for USB
• The file name must be DISPTEXT.TXT.
activity to complete.
• The file format must be a tab-delimited text file
11. Remove USB flash drive from USB port.
using Unicode (UTF-16) character representation.
Note
• The file must contain only two columns, with
If the custom language file was installed,
columns separated by a single tab character.
users can now select the new language
• Do not add or remove rows to the file.
from the Language drop-down menu in
Advanced Screen 1 — General, page 50.
• Do not change the order of the rows.
Create Custom Language Strings

Download Procedure

Upload Procedure

Use this procedure to install a system configuration
file and/or a custom language file.

80

332636D

Appendix A: Engine Control Module

Appendix A: Engine
Control Module
Run Screens

There are seven run screens on the engine control module:
• Line-to-neutral voltage
• Line-to-line voltage
• Frequency
• Engine Speed
• Engine lifetime counter
• Battery voltage
Press to scroll through the run screens. Press to enter the Information screens.
Run Screen Layout

Inst
Icon

Instrumentation

Units

Alarm
Icon
Mode
Icon

Information Screens

From the Run Screen, press to enter the information screens. Press to scroll through the last five
generator events.
Press to return to the Run Screens.
Information Screen Layout

Alarm
Time of Event (Engine Units Icon
Run Hours)
Mode
Event
Icon
#

332636D

81

Appendix A: Engine Control Module

Mode Icons
Icon

Description

Details

Stopped

Engine is at rest and the unit is in stop mode.

Auto

Engine is at rest and the unit is in auto mode.

Manual

Engine is at rest and the unit is in manual run mode.

Timer animation

Engine is starting up.

Running animation Engine is running.

Instrumentation Icons

A small icon is displayed in the instrumentation icon area to indicate what value is currently being displayed.
Icon

82

Description

Details

Generator

Generator voltage and frequency screen

Engine Speed
Engine Lifetime
Counter
Event Log

Engine speed screen
Hours run

Unit Time

Unused feature

Event is being displayed.

332636D

Appendix A: Engine Control Module

Alarms

There are two types of alarms that can occur on the system. Alarms are indicated by an icon the Run and
Information screens. See the information screen to see the latest alarm.
Warning

When present on system, a warning alarm will stop the generator.
Shutdown

When present on system, a shutdown alarm will stop the generator.
Warning
Icon

Description

Battery High
Voltage
Battery Low
Voltage
Fail To Stop
Flexible Sensor

Details

The DC Supply has risen above the high volts setting level for the duration of
the high battery volts timer.
The DC Supply has fallen below the low volts setting level for the duration
of the low battery volts timer.
The module detected a condition that indicates that the engine is running when
it has been instructed to stop.
The flexible sensor warning alarm has been triggered.

Shutdown

Clear the alarm and remove the fault. Then press the stop button to reset the module.
Icon

Description

Details

Fail To Start

The engine has not fired after the preset number of start attempts.

Generator High
Voltage Shutdown
Generator Low
Voltage Shutdown
High Coolant
Temperature
Shutdown
Low Oil Pressure
Shutdown
Over Frequency
Shutdown
Under Frequency
Shutdown

The generator output voltage has risen above the preset level.

332636D

The generator output voltage has fallen below the preset level.
The module detects that the engine coolant temperature has exceeded the high
engine temperature shutdown setting after the Safety On timer has expired.
The engine oil pressure has fallen below the low oil pressure trip setting level
after the Safety On timer has expired.
The generator output frequency has risen above the preset level.
The generator output frequency has fallen below the preset level.

83

Dimensions

Dimensions

35

84

Figure

332636D

Dimensions

Figure 36

Figure 37

332636D

85

Dimensions

38 Floor Mount Hole Pattern

86

Figure

332636D

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.
Proportioners For Foam
2000
(138)

AR4242
(01)
AR5252
(02)

1500
(103)

PRESSURE
psi (bar)

AR6060
(03)

1000
(69)

AR7070
(04)

E-30i

500

(34) 0

332636D

5

(2.3)

10

(4.5)

15

(6.8)

20

(9.1)

25

(11.3)

FLOW lbs/min (kg/min)

30

(13.6)

35

(15.9)

40

(18.1)

87

Performance Charts

Proportioners For Coatings
Table 4 Fusion Air Purge, Round Pattern

3500
(241)

3000
(207)

2500

PRESSURE
psi (bar)

E-XP2i

AR2020
(000)

(172)

AR2929
(00)

2000
(138)

1500
(103)

AR4242
(01)

1000
(69)

500

(34) 0

0.5

1.0

(1.9)

1.5

(3.8)

FLOW gal./min (l/min)

2.0

(5.7)

(7.6)

Table 5 Fusion Air Purge, Flat Pattern

3500

(241, 24.1)

3000

(207, 20.7)

AF2929
(FTXX38 TIP)

2500

(174, 17.4)

PRESSURE
psi (bar)

AF2020
(FTXX24 TIP)

2000

(138, 13.8)

E-XP2i

AF4242
(FTXX38 TIP)

1500

(103, 10.3)

AF5252
(FTXX48 TIP)

1000

(69, 6.9)

500

(35, 3.5)

0

88

0.5

(1.9)

1.0

(3.8)

FLOW gal./min (l/min)

1.5

(5.7)

2.0

(7.6)

332636D

Performance Charts

Table 6 Fusion Mechanical Purge, Round Pattern

3500

(241, 24.1)

E-XP2i

3000

(207, 20.7)

XR2323
(RTM040)

2500

(174, 17.4)

PRESSURE
psi (bar)

XR2929
(RTM040)

2000

(138, 13.8)

MR3535
(RTM040)

1500

(103, 10.3)

XR3535
(RTM055)

1000

(69, 6.9)

MR4747
(RTM055)

XR4747
(RTM055)

500

(35, 3.5)

0

0.5

(1.9)

1

1.5

(3.8)

2.0

(5.7)

FLOW gal./min (l/min)

(7.6)

Table 7 Fusion Mechanical Purge, Flat Pattern

3500

(241, 24.1)

XF2323
(FTM424)

XF1313
(FTM424)

3000

(207, 20.7)

MF2929
(FTM424)

2500

(174, 17.4)

PRESSURE
psi (bar)

MF1818
(FTM424)

2000

(138, 13.8)

XF1818
(FTM424)

1500

MF4747
(FTM638)

XF2929
(FTM424)

(103, 10.3)

XF5757
(FTM638)

XF3535
(FTM638)

1000

(69, 6.9)

E-XP2i

MF5757
(FTM638)

MF3535
(FTM638)

500

(35, 3.5)

0

332636D

0.2

(0.7)

0.4

(1.5)

0.6

(2.3)

0.8

(3.0)

1

(3.8)

1.2

(4.5)

FLOW gal./min (l/min)

1.4

(5.3)

1.6

(6.0)

1.8

(6.8)

2.0

(7.6)

89

Technical Specifications
Reactor 2 Elite Integrated Proportioning Systems

Maximum Fluid Working Pressure

E-30i
E-XP2i

Maximum Fluid Temperature

E-30i
E-30i with booster heater
E-XP2i
Maximum Output

E-30i
E-XP2i

Maximum Heated Hose Length

Length

U.S.

Metric

2000 psi
3500 psi

14 MPa, 140 bar
24.1 MPa, 241 bar

150°F
180°F
180°F

65°C
82°C
82°C

30 lb/min
2 gpm

13.5 kg/min
7.6 lpm

310 ft

94 m

0.0272 gal.
0.0203 gal.

0.1034 liter
0.0771 liter

20° to 120°F

-7° to 49°C

Output per Cycle

A and B

E-30i
E-XP2i

Operating Ambient Temperature Range

Temperature

Auxiliary Power Available

Voltage
Engine

Model

Alternator

Model

Battery Requirements

120 Vac or 240 Vac, 60 Hz
Perkins 404–22G, 2.2 L, 29 HP
Mecc Alte 22 kW, 240 V, 1 PH, 60 Hz, pancake style

Voltage
Minimum Cold Cranking Amps

12 Vdc
800 CCA

Connection Type

Post Style

Recommended Battery Size

34

BC Group Number
Length
Width
Height

10.25 in.
6.81 in.
7.88 in.

Booster Heater Power

E-30i
E-30i with booster heat
E-XP2i

260 mm
173 mm
200 mm
None
4000 Watts
4000 Watts

Rotary Vane Air Compressor
Hydrovane Model V04 (PURS type), continuous run

Part No.

025CK10

Pressure

140 psi

Specifications
Required Features

0.9 MPa, 9.6 bar)
16 cfm
Thermal overload switch
Safety Relief Valve

Motor: Baldor

Part No.
Specifications
Required Features

EL1410–CUS
5 HP, 1735 RPM, 240 V, 1 Phase, OPSB
C face, lift rings,

Refrigerated Air Dryer

Hankison Model H1T20
Specifications
Required Features

115VAC, 1 Phase, 60 Hz, 22 scfm at 150 psi (1 MPa, 10.3 bar)
Pilot valve unloader

Noise

Sound Pressure measured per ISO-9614–2.

Sound
measured
3.1 ft (1Pressure
m), at 1500
psi (10 from
MPa,
103 bar), 2 gpm (7.6 lpm)
Fluid Inlets

Component A (ISO) and
Component B (RES)
Fluid Outlets

Component A (ISO)
Component B (RES)
Fluid Circulation Ports

Size
Maximum Pressure

91.0 dBA
3/4 NPT(f) with 3/4 NPSM(f) union
#8 (1/2 in.) JIC, with #5 (5/16 in.) JIC adapter
#10 (5/8 in.) JIC, with #6 (3/8 in.) JIC adapter
1/4 NPSM(m), with sst braided tubing
250 psi
1.75 MPa, 17.5 bar

Weight

E-30i
E–30i with compressor and dryer
E-30i with booster heat
heat,
E–30i
with booster
and dryer
compressor,
E-XP2i
E–XP2i
dryer with compressor and
Wetted Parts

Material

1750 lb
2200 lb
1800 lb
2250 lb
1800 lb
2200 lb

794 kg
998 kg
816 kg
1021 kg
816 kg
998 kg

stainless
steel, resistant
zinc platedo-rings,
carbonPTFE,
steel,ultra-high
brass,
Aluminum,
carbide,
chrome,
chemically
molecular weight polyethylene

Graco Extended Warranty for Integrated Reactor®
2 Components
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its
name to be free from defects in material and workmanship on the date of sale to the original purchaser for use.
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. This warranty applies only when the equipment is installed, operated and maintained in accordance
with Graco’s written recommendations.

Graco Part Number

24U050
24U051
24U831
24U832
24U855
24U854
All other Reactor 2 parts

Description

Electric Motor
Electric Motor
Motor Control Module
Motor Control Module
Heater Control Module
Advanced Display Module

Warranty Period

36 Months or 3 Million Cycles
36 Months or 3 Million Cycles
36 Months or 3 Million Cycles
36 Months or 3 Million Cycles
36 Months or 3 Million Cycles
36 Months or 3 Million Cycles
12 Months

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction,
damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper
maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco
be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures,
accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation,
operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized
Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace
free of charge any defective parts. The equipment will be returned to the original purchaser transportation
prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be
made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS
FOR A PARTICULAR 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.
Any action for breach of warranty hereunder must be brought within the latter of two (2) years of the date of
sale, or one (1) year the warranty period expires.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT,
MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not

manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of
their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of
these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco
supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold
hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices
and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be
drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en
Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou
en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information
For the latest information about Graco products, visit www.graco.com.
To place an order, contact your Graco Distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
For patent information, see www.graco.com/patents.
Original Instructions. This manual contains English. MM 332636
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision D, July 2014



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Title                           : 332636D - Reactor 2 Elite Integrated Proportioning System, Operation, English
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