Graco Reactor E-10, Instructions-Parts List Manual

Page 1: ...o materials including epoxies polyurethane foam and polyurea coatings Not for use in explosive atmospheres See page 4 for a list of models and maximum working pressures Important Safety Instructions Read all warnings and instructions in this manual Save these instructions ...

Page 2: ...pressor Controls 12 Setup 13 Startup of Heated Units 19 Spraying Dispensing 20 Pause Heated Units 21 Pressure Relief Procedure 22 Shutdown 22 Maintenance 23 Flushing 24 Troubleshooting 26 Status Codes 26 Troubleshooting Chart 29 Repair 35 Before Beginning Repair 35 Recirc Spray Valves 36 Displacement Pump 37 Control Module 39 Fluid Heaters 44 Pressure Transducers 44 Drive Housing 45 Cycle Counter ...

Page 3: ...on Manuals are available at www graco com Fluid Heater Part No Description 311210 Instruction Parts Manual English Fusion Air Purge Plural Component Gun Part No Description 309550 Instruction Parts Manual English Displacement Pump White Material Part No Description 311076 Instruction Parts Manual English Static Mixer Kit Part No Description 313122 Instruction Parts Manual English ...

Page 4: ... E 10 For faster assistance please have that information ready before calling Customer Service See page 14 for detailed electrical requirements Reactor E10 4 1 Volts Electrical Connection Maximum Working Pressure psi MPa bar 256765 120 V 15 A cord motor 15 A cord heaters 15 A cord compressor 2000 14 140 ...

Page 5: ...fluids you are using Store hazardous fluid in approved containers and dispose of it according to applicable guidelines PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you from serious injury includ ing eye injury inhalation of toxic fumes burns and hearing loss This equipment includ...

Page 6: ...d result in death serious injury and property damage EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury This equipment is for professional use only Do not leave the work area while equipment is energized or under pressure Turn off all equipment and follow the Pressure Relief Procedure in this manual when equipment is not in use Do not exceed the maximum working pressure or temperatur...

Page 7: ...moved Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure in this manual Dis connect power or air supply BURN HAZARD Equipment surfaces and fluid that s heated can become very hot during operation To avoid severe burns do not touch hot fluid or equipment Wait until equip ment fluid has cooled completely WARNING ...

Page 8: ...monitors fluid pressures and alerts the opera tor if errors occur See STATUS Indicator page 10 for further information An air compressor provides and regulates air pressure for the spray gun Reactor E 10 has two recirculation speeds slow and fast and an adjustable pressure out put Slow Recirculation Slow circulation results in a higher temper ature transfer in the heater so hoses and gun heat up q...

Page 9: ...ure Gauges J Recirc Spray and Overpressure Relief Valves K Control Panel see FIG 2 page 10 L Electric Motor and Drive Housings M Suction Tubes N Recirculation Tubes P Air Line outlet R Outlet Hose Connections S Recirculation Tube Connections T Fluid Temperature Sensors U Air Filter Moisture Separator FIG 1 Component Identification C N D K L E T F M N M U P A B G J H H S S R ...

Page 10: ...F ST HP TD TD TI7016a Icon Setting Function Stop Park Stops motor and auto matically parks pumps Slow Recirc Slow recirculation speed Fast Recirc Fast recirculation speed Pressure Adjust Adjusts fluid pressure to gun in spray mode Table 1 Status Codes see also the label on back of the control enclosure Code No Code Name 1 Pressure imbalance between A and B sides 2 Unable to maintain pressure setpo...

Page 11: ...uit breaker Heater Temperature Controls See FIG 3 Control knobs HC set tempera ture of component A and B heaters Indicator lights HL turn on when thermostats are heat ing and off when heater reaches setpoint Fluid Temperature Sensors and Displays See FIG 2 Fluid temperature sensors T monitor actual temperature of component A and B fluid going to spray gun Temperatures are then displayed TD Unit is...

Page 12: ... Switch Circuit Breaker Switch CP turns power on to compressor and regulator The switch includes a 20 A circuit breaker Air Compressor Controls Pressure Gauge PG indicates set air pres sure by regulator Regulator AR sets desired air pressure FIG 4 AR PG CP ...

Page 13: ...ork Be sure your installation complies with all National State and Local safety and fire codes 3 Ground system a Reactor E 10 grounded through power cord b Generator if used follow your local code Start and stop gener ator with power cord s discon nected c Spray gun grounded through the supplied fluid hoses connected to a properly grounded Reactor E 10 Do not operate without at least one grounded ...

Page 14: ...uired Wire Size Up to 50 ft 15 m Up to 100 ft 30 m Two cord heated models AWG 14 AWG 12 Cords must be 3 conductor grounded rated for your environment FIG 5 Use Three Separate Circuits 1 Ensure no other high amp loads are connected while running Reactor E 10 To verify separate circuits plug in Reactor E 10 or a worklight and cycle breakers on and off 1 2 To avoid electric shock always unplug all co...

Page 15: ...rovided with the hose bundle On heated units with Fusion guns con nect the supplied ball valve and quick disconnect coupler to the gun air hose then connect the coupler to the gun air fitting 6 Turn on air compressor Turn on air compressor power Set regu lator to desired output pressure as indi cated on the gauge Air Filter Moisture Separator Z is equipped with an automatic moisture drain 7 Flush ...

Page 16: ...acing suc tion tubes in pails Fill wet cups through slots in plate or loosen screws and swing plate aside TI6985a 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 dur ing operation Shut off Motor Power before filling wet cup Using a drill and mixing blade mix filled or separated materials...

Page 17: ...Use second strap for B side c Latch straps SR together in front of pails P A B G EB SR SR SR A B 11 Purge air and flush fluid from lines a Remove both recirculation tubes N from the pails and secure each one in a dedicated waste container W b Set function knob to Stop Park c Plug in power cord s See TABLE 2 page 14 d Turn on Motor Power N A B W ...

Page 18: ... both recir culation tubes P set function knob to Stop Park h Replace recirculation tubes in pails i On nonheated units purge the hoses through the gun without a static mixer installed For heated units continue with Startup of Heated Units page 19 Nonheated units are ready to spray dis pense Go to Spraying Dispensing page 20 O ...

Page 19: ...llow equipment to cool completely before touching it Wear gloves if fluid temperature exceeds 110 F 43 C 1 Perform Setup pages 13 18 2 Set function knob to Slow Recirc or Fast Recirc 3 Turn on Heater Power 4 Temporarily set heater control knobs to maximum setting OR 5 Circulate through heaters until tempera ture readouts display desired tempera ture 6 Adjust heater control knobs as neces sary for ...

Page 20: ...alanced reduce pressure of higher component by slightly turning Recirc Spray valve for that component toward Recirc until gauges show balanced pressures The pressure imbalance alarm Status Code 1 is inactive for 10 sec after entering spray pressure mode to allow time to balance pressures Watch gauges for 10 sec to be sure pres sure holds on both sides and pumps are not moving 5 Open gun fluid mani...

Page 21: ...uip ment is ready to spray To bring the hose and gun back to spray temperature after a brief break use the fol lowing procedure 1 Engage piston safety lock 2 Set function knob to Slow Recirc Fusion Fusion 3 Set Recirc Spray valves to Recirc until temperature readouts come back up 4 If you stop spraying for more than 2 min utes when using an impingement mix gun close gun fluid valves A and B Doing ...

Page 22: ...inutes use the following procedure If you will be shut down for more than 3 days first see Flushing page 24 1 Follow all steps of Pressure Relief Pro cedure at left 2 If using an impingement mix gun close gun fluid valves A and B Doing this will keep the internal parts of the gun cleaner and prevent crossover 3 Shut off Heater Power heated units only 4 Shut off Motor Power 5 Shut off Compressor Po...

Page 23: ...storage area or if material may separate or settle out over time If using an impingement mix gun close gun fluid valves A and B when not spraying Doing this will keep the internal parts of the gun cleaner and prevent crossover Clean gun mix chamber ports and check valve screens regularly See gun manual If using an Fusion Air Purge impingement mix gun always grease the gun after use until purge air...

Page 24: ...th a storage fluid such as Bayer Mesa moll plasticizer or at minimum clean motor oil Flush equipment only in a well ventilated area Do not spray flammable fluids Do not turn on heaters while flushing with flamma ble solvents 1 Engage piston safety lock Close fluid valves A and B Leave air on Fusion 2 Set function knob to Stop Park 3 Shut off Heater Power heated units only Allow system to cool 4 Un...

Page 25: ...to gun instruction manual Purge Gun Hoses Disconnect hoses from gun and secure back into the tanks for thorough cleaning with solvent Turn Recirc Spray valve A to Spray Open gun into waste container A Set function knob to Slow Recirc until hose is flushed Set function knob to Stop Park Repeat for B side 11 Set function knob to Stop Park 12 Solvent flushing is a two step process Go back to step 4 d...

Page 26: ... at mixer mani fold if using disposable mixer gun kit Status Code 2 Pressure Deviation from Setpoint Unit senses pressure deviation from setpoint and warns or shuts down depending on set tings of DIP switches 3 and 4 If equipment cannot maintain enough pressure for a good mix with an impingement mix gun try using a smaller mix chamber or nozzle To turn off automatic shutdown and or tighten pressur...

Page 27: ...e 1 and 2 Settings DIP Switch and Function Left Right default setting DIP Switch 1 If selected causes shutdown or displays a warning if there is a pressure imbalance exceeds selection made in DIP Switch 2 WARNING SHUTDOWN DIP Switch 2 If selected causes shutdown if A and B pressure imbal ance is greater than 500 psi 3 5 MPa 35 bar 60 if 800 psi 5 6 MPa 56 bar running 800 psi 5 6 MPa 56 bar 70 if 8...

Page 28: ...Temperature Motor is running too hot 1 Motor temperature too high Reduce pres sure duty cycle gun tip size or move Reac tor E 10 to a cooler location Allow 1 hour for cooling 2 Check fan operation Clean fan and motor housing Status Code 7 No Cycle Counter Switch Input Have not received input from cycle counter switch for 10 seconds after selecting Recirc mode 1 Check cycle counter switch connectio...

Page 29: ...vement Shorted armature Replace motor page 47 Check motor commutator for burn spots black pitting or other dam age Remove motor Have motor shop resurface commutator or replace motor page 47 Failed control board Replace board See page 42 Fan not working Loose fan cable Check that cable is connected at fan and at J9 on control board See pages 49 and 42 Defective fan Test and replace if necessary pag...

Page 30: ...l Leaking gun shutoff Repair See gun manual Pressure is higher on B side dur ing startup of recirculation espe cially in High Recirc mode This is normal Component B is typically higher viscosity than component A until the material is heated during recirculation No action required One gauge shows half as many pulses as the other when pumps are cycling Loss of pressure on downstoke Intake valve is l...

Page 31: ...er from control board Remove access panel Check if board LED is lighted If not replace board page 42 Inadequate power to control board Check that power supply meets requirements Loose power cable Check cable connections page 42 Motor Power switch circuit breaker tripped Display is powered from Motor Power circuit breaker Cycle Motor Power off then on to reset breaker Wrong temperature displayed F ...

Page 32: ...V Heater on one side shuts off early or continuously during recircula tion Y strainer is plugged on that side Clean or replace strainer page 23 Fluid inlet valve 52 closed Open valve B side pump is not priming Running pump too fast Put finger over recirculation tube while running to build pressure and release Repeat as neces sary Piston ball check is stuck in open position Low air output at gun Ai...

Page 33: ...Excessive head pressure com pressor hums Moisture frozen in air supply line Wait for air pressure to bleed to zero Electrical air unloader stuck closed Replace electrical air unloader Open air regulator install air line Complete Setup on page 13 Compressor thermal switch is open Ensure ambient tempera ture is below 115 F 46 C Move sprayer to shaded cooler area Low compressor performance Worn compr...

Page 34: ...Troubleshooting 34 313221A ...

Page 35: ...cian connect power and ground to main power switch ter minals see page 13 Be sure to shut off all power to the equipment before repairing 1 Flush if possible see page 24 If not possi ble clean all parts with solvent immediately after removal 2 Set function knob to Stop Park 3 Shut off Motor Power Disconnect power supply 4 Shut off Heater Power Allow equipment to cool before repairing 5 Relieve pre...

Page 36: ... and gas ket 503b are positioned inside each valve cartridge 503 3 Apply PTFE pipe sealant to all tapered pipe threads before reassembling 4 Reassemble in reverse order following all notes in FIG 8 FIG 8 Recirc Spray Valves 1 505 504 503 501 502 507 510 509 503a 503b Heated Models Torque to 250 in lb 28 N m 1 2 Use blue threadlocker on valve cartridge threads into manifold 2 Part of item 503 3 3 3...

Page 37: ... Relieve pressure page 22 1 Loosen nut 34 and remove suction tube 31 34 31 E 30 32 33 35 If pump is not generating any pressure the intake ball check may be stuck closed with dried material If the pump is not generating pressure on the downstroke intake ball check may be stuck open Either of these conditions can be serviced with the pump in place 2 Disconnect suction tube 3 Remove intake valve by ...

Page 38: ...al 311076 for pump repair and parts 6 Install pump in reverse order of disassem bly following all notes in FIG 9 Clean strainer 51 Reconnect suction tube and outlet D lines 7 Tighten fluid outlet fitting D then tighten locknut 218 by hitting firmly with a non sparking hammer 8 Set function knob to Slow Recirc Purge air and prime See page 17 FIG 9 Displacement Pump D 16 217 1 Flat side faces up Tig...

Page 39: ...and Sensor Heated Units Only 2 Remove temperature sensor 424 a Loosen setscrew 22 on thermowell housing 21 See FIG 10 on page 40 b Pull sensor 424 out of thermowell housing c Work sensor and wire out of cable channel between tanks It may be eas ier to remove one tank See page 36 3 Remove access cover 39 from back of control module 4 Disconnect temperature display power cable from J14 or J15 at bot...

Page 40: ... 416a and pull function knob 416 off potentiome ter 404 shaft 5 Remove nut N part of 404 and detent plate 415 6 Install new potentiometer 404 in reverse order Position potentiometer so slot S is horizontal Position knob 416 so pointer P faces up Install knob on shaft so slot S engages alignment pin in knob Push knob onto shaft against detent spring before tightening setscrews 416a 7 Reconnect pote...

Page 41: ...el Shown 405 416a 416 416a 415 417 406 407 408 412 411 410 409 403 421 401 404 402 410 TI6979a 424 402 413 CS FC 424 FC CS N These items are not included on the nonheated display 416a 416a 416 404 415 N P S Detail of Function Knob Potentiometer TI7076a ...

Page 42: ... off Status code motor not running LED blinks status code Check motor before replacing board See Electric Motor page 47 1 See Before Beginning Repair page 35 Relieve pressure page 22 Apply thermal compound between the square steel piece on the back of the board and the main aluminum plate Order Part No 110009 Thermal Com pound Table 5 Control Board Connectors see FIG 12 Board Jack Pin Description ...

Page 43: ... Cable Red Black Yellow Yellow Red Black Black White Jumper 1 2 3 4 5 6 7 8 9 10 J15 J14 J3 J8 J2 Black Red White Pressure Transducer A Pressure Transducer B CONTROL BOARD 249434 120 V 249432 240 V Black Sheath Black Sheath Gray Sheath Gray Sheath Gray Sheath Black Phone Cable and Plug Temperature Sensor B Temperature Sensor A Temperature Display B Temperature Display A 2 pin red connectors 2 pin ...

Page 44: ...new transducer 58 FIG 13 6 Install transducer in heater or manifold Mark board end of cable with tape red transducer A blue transducer B 7 Route cable through channel to control module 8 Connect transducer cable at board see FIG 12 page 43 Fluid heater repair and parts information is included in manual 311210 which is supplied with heated units To replace a pressure transducer see at right 1 See B...

Page 45: ...bell MB 5 Push drive housing 215 onto motor 201 Install screws 220 6 Install drive housing covers 221 on A side 227 on B side and screws 207 Pumps must be in phase both at same position in stroke 1 See Before Beginning Repair page 35 Relieve pressure page 22 Examine connecting rod 216 If rod needs replacing first remove the pump 219 page 37 CAUTION Do not drop gear reducer 214 and crank shaft 210 ...

Page 46: ...tall cover with switch on B side TI7028a 223 0 6 in 15 2 mm from inside edge 1 0 in 25 4 mm from inside bottom edge FIG 14 Drive Housing Crankshaft must be in line with crankshaft at other end of motor so pumps move up and down in unison 1 207 227 206 221 218 229 217 220 222 207 219 207 201 215 216 208 steel 209 bronze 211 bronze 210 214 213 bronze 212 steel 213 bronze 234 ...

Page 47: ...e FIG 18 e Thread motor power switch harness out bottom of control module and cable channel to free motor 5 Remove screws holding motor to bracket Lift motor off unit Installation 1 If replacing motor install fan assembly and fan mount threaded bushing on new motor 2 Place motor and fan on unit Thread motor switch harness into control module 3 Fasten motor with screws underneath Do not tighten yet...

Page 48: ... back louvers from unit 4 Disconnect air fitting from compressor Remove compressor from unit Follow instructions provided with your repair kit 5 Disconnect electrical connection from sole noid valve To repair compressor use Compressor Service Kit 256779 Refer to Thomas Compressor manual provided Replace compressor piston assembly use Kit 256779 FIG 15 FIG 16 FIG 17 ...

Page 49: ...crews holding fan to shield 206 Install new fan in reverse order 3 If voltage is not correct check fan cable connection at J9 on control board see FIG 12 page 43 Replace brushes worn to less than 1 2 in 13 mm Brushes wear differently on each side of motor check both sides Brush Repair Kit 248186 is available kit includes instruction sheet 406582 Motor commutator should be smooth If not resurface c...

Page 50: ...3221A Parts Part No 256765 120 V 15 A Heated Proportioner 35 34 33 31 36 77 32 30 2 27 51 6 49 11 52 53 25 44 42 43 42 40 40 41 22 23 21 29 28 25 6 7 8 17 18 16 9 26 4 5 6 10 3 16 11 13 12 14 24 20 6 70 71 19 1 15 ...

Page 51: ...1 Compressor 11 67 64 54 55 68 37 38 39 45 47 48 48 23 46 67 76 Compressor Solenoid Valve Pressure Gauge Air Filter Regulator 39 Attach ground wires to grounding stud on 1 1 1 Compressor Wiring Diagram Airline Diagram grounding stud ...

Page 52: ... 2 38 106115 WASHER lock hi collar 3 39 112913 NUT hex 2 40 154636 WASHER flat 4 41 116411 SPRING compression 2 42 116477 WASHER flat nylon 4 43 116478 WHEEL pneumatic 2 44 101242 RING retaining ext 2 45 BOLT hex 3 8 16 0 75 in 1 46 PANEL end 1 47 PANEL end 1 48 117501 SCREW mach slot hex wash hd 8 49 BRACKET filter air 1 50 104641 FITTING bulkhead 1 51 162453 FITTING 1 4 npsm x 1 4 npt 1 52 11762...

Page 53: ...hd 8 32 x 3 8 in 10 mm 12 208 116074 WASHER thrust steel 2 209 107434 BEARING thrust bronze 2 210 248231 CRANKSHAFT KIT 2 211 180131 BEARING thrust bronze 2 212 116073 WASHER thrust steel 2 213 116079 BEARING thrust bronze 4 214 287057 GEAR REDUCER KIT 2 215 287055 DRIVE HOUSING KIT 2 216 287053 CONNECTING ROD KIT 2 217 196762 PIN straight 2 218 195150 NUT jam pump 2 219 PUMP displacement A side s...

Page 54: ... 405 119930 INDICATOR status LED 1 406 249434 BOARD control 120 V units only 1 407 15G230 CABLE harness 1 408 107156 SCREW machine pan hd 7 409 113505 NUT keps hex hd 10 410 119898 BULKHEAD FITTING cable 2 411 101765 GROMMET 1 412 116773 CONNECTOR plug 1 413 WIRE jumper 2 414 15G279 LABEL display 1 415 15G053 PLATE detent 1 416 249453 KNOB function includes item 416a 1 416a 101118 SCREW set no 10 ...

Page 55: ...5F870 MANIFOLD recirculation 1 502 189285 LABEL caution 4 503 239913 VALVE recirc spray includes items 503a 503b 2 503a 15E022 SEAT 1 503b 111699 GASKET 1 504 224807 BASE valve 2 505 187625 HANDLE valve drain 2 506 111600 PIN grooved 2 508 100483 TEE 3 8 18 npt 2 509 166863 ADAPTER 3 8 npt x 1 4 npt 1 510 162453 NIPPLE 1 4 npsm x 1 4 npt 3 ...

Page 56: ...seat and gasket 249494 POTENTIOMETER control knob 249434 BOARD control 120 V units only 246123 TRANSDUCER pressure PUMP displacement white PUMP displacement red 256779 KIT repair compressor Part Description 119869 DISPLAY temperature with sensor 119857 FUSE heater over temperature 119797 THERMOSTAT heater 15F770 HEATER ELEMENT 120 V units only Part Description 256563 KIT static mixer includes Fusi...

Page 57: ...Accessories 313221A 57 ...

Page 58: ...Dimensions 58 313221A Dimensions 21 25 in 539 75 mm 43 5 in 1105 mm 27 in 685 8 mm ...

Page 59: ... red fluid 0 00088 gal 0 0033 liter Overpressure Relief Recirc Spray valves automatically relieve excessive fluid pressure back to supply tanks Heater Power 120V models 850 W each 1700 W total Sound Pressure 78 7 dB A in fast circulation mode 84 5 dB A at 2000 psi 14 MPa 140 bar 0 72 gpm 2 7 lpm Sound Power per ISO 9614 2 88 6 dB A in fast circulation mode 94 4 dB A at 2000 psi 14 MPa 140 bar 0 72...

Page 60: ...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 ...