Instructions - Parts Portable Plural Component Sprayer E-8p 3A1602G EN For spraying 1:1 mix ratio formulated no-heat polyurethane foams and dispensing 1:1 mix ratio polyurea joint-fill materials. For professional use only. Not approved for use in European explosive atmosphere locations. 2000 psi (14 MPa, 138 bar) Maximum Working Pressure See page 3 for a list of models. Important Safety Instructions Read all warnings and instructions in all supplied manuals. Save all instructions.
Contents Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Proportioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Important Two-Component Material Information . 7 Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 7 Material Self-ignition . . . . . . . . . . . . . . . . . . . . . .
Systems Systems Part Maximum Working Pressure, psi (MPa, var) Proportioner (see Proportioners) Hose Part Gun Model Length Model Fusion™ Part AP9082 2000 (14, 140) 259082 24M653 50 (15.2) CS9082 P29082 AP9083 2000 (14, 140) 2000 (14, 140) 2000 (14, 140) 259082 259082 259083 24M653 24M653 24M653 50 (15.2) 50 (15.2) 50 (15.
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, 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.
Warnings WARNING FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion: • Use equipment only in well ventilated area. • Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc). • Keep work area free of debris, including solvent, rags and gasoline.
Warnings WARNING 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 Pressure Relief Procedure and disconnect all power sources. BURN HAZARD Equipment surfaces and fluid that’s heated can become very hot during operation.
Important Two-Component Material Information Important Two-Component Material Information 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.
Overview Changing Materials • When changing materials, flush the equipment multiple times to ensure it is thoroughly clean. • Check with your material manufacturer for chemical compatibility. • Most materials use ISO on the A side, but some use ISO on the B side. • Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the B (resin) side. Overview The Reactor E-8p is a portable, electric-powered, 1:1 mix ratio proportioner.
Component Identification Component Identification C BACK VIEW L FRONT VIEW J Q A N F B D L E Q P M G H TI17121a FIG.
Controls and Indicators Controls and Indicators Status Indicator Motor/Pump Control Function Knob Power Switch Status Codes + - I - - TI17123b FIG. 2: Controls and Indicators Power Switch STATUS Indicator Powers the Reactor E-8p on and off. Indicates system status, including power and error codes. Motor/Pump Control Function Knob • Indicator steady on: power switch is turned on.
Setup Setup Location • • Grounding The Reactor E-8p should always be used on a level surface. Do not expose the Reactor E-8p to rain. Electrical Requirements The equipment must be grounded. Grounding reduces the risk of static and electric shock by providing an escape wire for the electrical current due to static build up or in the event of a short circuit. Reactor E-8p: grounded through power cord. Improper wiring may cause electric shock or other serious injury if work is not performed properly.
Setup Lock/Unlock Handle Install 38 mm Spout Adapter Lock the handle when the sprayer is moved, laid on its side, or turned upside down. The sprayer is supplied with a 40 mm spout adapter. Install 38 mm spout adapters if necessary. Unlock 1. Loosen containment knob. To unlock the handle, remove lanyard and locking pin from cart handle. Pull on handle to extend cart handle and move sprayer. 2. Remove suction tube caps and place in containment tray. 3.
Setup Install Optional Recirculation Kit 552 Use Hose Recirculation Kit 24M654 to help evenly distribute heat when using supplemental heaters and circulate material through the fluid manifold, out to the gun, and back to the material supply container. See Accessories, page 50. 509 510 Apply thread sealant to all non-swiveling pipe threads. NOTICE To prevent cross-contamination of fluids and equipment parts, never interchange component A (isocyanate) and component B (resin) parts or containers.
Setup Connect Fluid Hoses Connect Main Air Supply Connect fluid supply hoses to outlet hose connections (FIG. 9 and FIG. 10). Red hoses for component A (ISO), blue for component B (RES). Fittings are sized to prevent connection errors. Connect other end of hoses to A and B inputs of gun. NOTE: The Reactor E-8p requires 4 scfm (0.112 m3/min) compressed air for the air operated spray guns to work correctly.
Setup A Recirculation A (ISO) B Recirculation A (ISO) Air B (RES) Compressed Air Line B (RES) Recirculation Gun Manifold Kit 249523 (only compatible with Fusion Air Purge Gun) 601 604 605 607 607 605 604 602 603 2 TI7134A FIG.
Setup Fill Wet-cups Recirculate Material Keep the felt washers in the pump wet-cups saturated with Graco ISO pump oil, Part No. 217374. The lubricant creates a barrier between the ISO and the atmosphere. The standard system circulates material from the fluid manifold back to the supply container. To circulate material from the gun back to the material supply container, purchase and install Hose Recirculation Kit 24M654. See Install Optional Recirculation Kit on page 13.
Setup 6. Set function knob to Slow Recirc or Fast Recirc Purge Air and Flush Fluid . + - OR 1. Insert inlet tubes into pails of solvent. + - TI17128b FIG. 15 7. When material exits both recirculation tubes, set the function knob to Stop/Park . TI17126a 8. Set the Recirc/Spray valves to Spray. FIG. 17 2. Insert recirculation tubes into waste containers. 3. Set function knob to Stop/Park. TI17132a FIG. 16 + - TI17127b FIG. 18 4. Plug in power cord. O O I I 5. Turn on power.
Setup 7. Set function knob to Slow Recirc or Fast Recirc Connect Fluid Inlet Tubes . 1. Loosen containment knob. + - OR + - TI17128b FIG. 21 8. When clean solvent exits both recirculation tubes, set the function knob to Stop/Park 2. Remove suction tube caps and place in containment tray. 3. Insert each fluid inlet tube through the pour spout on the appropriate five-gallon pail. Tighten the ring to the pour spout. . 9. Insert inlet tubes into pails. See Connect Fluid Inlet Tubes, page 18.
Spraying Spraying NOTE: For air operated guns, air is supplied to spray gun with gun piston safety lock engaged and gun fluid manifold valves A and B closed (if present). NOTE: If using the Manual 2K gun, refer to the Manual 2K gun instruction manual. 6. Check fluid pressure gauges to ensure proper pressure balance. If imbalanced, reduce pressure of higher component by slightly turning Recirc/Spray valve for that component toward Recirc, until gauges show balanced pressures.
Pressure Relief Procedure Pressure Relief Procedure Shutdown NOTE: For longer breaks (more than 10 minutes), use the following procedure. If you will be shut down for more than three days, perform the Flushing procedure, page 22, first. Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from splashing or moving parts. NOTE: If using the Manual 2K gun, refer to the Manual 2K gun instruction manual. 1. Engage piston safety lock.
Maintenance 5. Use solvent to wipe down fluid inlet tubes. 6. Install suction tube caps on each fluid inlet tube and rest in the containment tray. Tighten the containment knob to press the bracket against the fluid inlet tubes. TI17458a Maintenance • Check pump wet-cups fluid level daily. Refer to Fill Wet-cups, page 16. • Do not overtighten packing nut/wet-cup. Throat u-cup is not adjustable. • Keep component A from exposure to moisture in atmosphere, to prevent crystallization.
Flushing Flushing 3. Remove both recirculation tubes from material pails and secure each one to a dedicated waste container. Flush equipment only in a well-ventilated area. Do not spray flammable fluids. • Generally, flush if you will be shut down for more than 3 days. Flush more often if material is moisture sensitive and humidity is high in the storage area, or if material may separate or settle out over time.
Flushing 9. Purge gun hoses. a. Disconnect hoses from gun and secure to a pail of solvent. b. Turn Recirc/Spray valve A to Spray. TI17136a FIG. 45 c. Open gun into waste container A. d. Set function knob to Slow Recirc until hose is flushed. e. Set function knob to Stop/Park f. . Repeat for B side. 10. Set function knob to Stop/Park . 11. Solvent flushing is a two step process. Go back to step 3, drain solvent, and flush again with fresh solvent. 12.
Troubleshooting Troubleshooting Status Codes Determine the status code by counting the number of times the status indicator blinks. 2. Reduce pressure of higher component by slightly turning Recirc/Spray valve for that component toward Recirc, until gauges show balanced pressures. In this example, B side pressure is higher, so use the B side valve to balance pressures. STATUS Indicator TI17137a FIG. 47 I - NOTE: Turn Recirc/Spray valve only enough to balance pressure.
Troubleshooting Status Code 1 and 2 Settings OFF 1 2 3 4 1. Locate switch SW2 on the control board. 2. Set the four DIP switches to the desired positions. See FIG. 48 and Table 2. TI7023a 1 2 3 4 ON (Default) TI7024a FIG. 48.
Troubleshooting Status Code 6: High Motor Temperature Motor is running too hot. 1. Motor temperature too high. Reduce pressure duty cycle, gun tip size, or move Reactor E-8p 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 Recirculation Mode. 1.
Troubleshooting Troubleshooting Chart Plug in power cord. I I Motor does not operate. Power turned on with function knob set to a run position. , to reset breaker. O then on O I Cycle Motor Power off I No power. Solution O O Reactor E-8p does not operate. Cause O Problem Set function knob to Stop/Park , then select desired function. Fan not working. Pump output low. One side doesn’t come up to pressure in spray mode. 3A1602G Loose connection on control board.
Troubleshooting Problem Cause Solution Pressure is higher on one side when setting pressure with function knob. Pump intake valve partially plugged. Clean pump intake valve. See page 31. Air in hose. Fluid is compressible. Purge air from hose. Unequal size hoses or unequal hose construction. Use matching hoses, or balance pressures before spraying. Unequal viscosities. Check that A and B chemicals are within the chemical manufacturer’s specified application temperature range.
Troubleshooting Problem A side rich; lack of B side. B side rich; lack of A side. 3A1602G Cause Solution A side gauge is low. B side restriction downstream of gauge. Check gun check valve screen, mix module, or mix manifold restrictor. B side gauge is low. B side material supply problem. Check B side inlet strainer and pump intake valve. A side gauge is low. A side material supply problem. Check A side inlet strainer and pump intake valve. B side gauge is low.
Repair Repair Before Beginning Repair Recirculation/Spray Valves 1. See Before Beginning Repair, page 30. Relieve pressure, page 20. Repairing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly. Have a qualified electrician connect power and ground to main power switch terminals, see page 11. Be sure to shut off all power to the equipment before repairing. 1. Flush if possible, see page 22.
Repair Displacement Pump To remove entire pump assembly Displacement pump repair and parts information is included in manual 311076, which is supplied with your unit. NOTE: Use drop cloth or rags to protect Reactor E-8p and surrounding area from spills. 1. Loosen nut and press the inlet tube down away from the pump intake valve. 2. Disconnect swivel (32) from pump outlet and loosen swivel at the fluid manifold. Turn the fluid outlet line out of the way of the sprayer.
Repair Replace Function Knob/Potentiometer 4. Carefully lay sprayer on it’s side on a level surface. Rotate sprayer and rest upside down on cart handle. NOTE: Always use two people when lifting the sprayer up on to a workbench. 1. See Before Beginning Repair, page 30. Relieve pressure, page 20. 2. Insert pin through cart handle and lock with lanyard. 5. Remove four screws (10) and control board cover (61) to expose the control board (12). 6. Disconnect potentiometer wires from J2 on control board (12).
Repair Control Board Power Bootup Check NOTE: There is one red LED (D11) on the board. Power must be on to check. See FIG. 58 for location. Function is: • • • • Startup: 1 blink for 60 Hz, 2 blinks for 50 Hz. Motor running: LED on. Motor not running: LED off. Status code (motor not running): LED blinks status code Table 3: Control Board Connectors (see FIG.
Repair LINE P1 Motor Power On/Off (20 A Breaker) P2 J1 Black Twin Flat Cable Motor Fan J9 Black J11 J4 Red Yellow Yellow Red Black Status Indicator Black Sheath CONTROL BOARD J7 Black White Jumper Jumper not used Cycle Counter 1 2 3 4 5 6 7 8 9 10 Function Knob J11 (120 V Board) 249434 (120 V) OFF 1 2 3 4 ON SW2 (see page 25 to adjust settings) J10 not used J2 Black Red White J8 Black Sheath J3 Pressure Transducer A Black Phone Cable and Plug Pressure Transducer B FIG.
Repair Pressure Transducers Drive Housing Removal 1. See Before Beginning Repair, page 30. Relieve pressure, page 20. 2. Insert pin through cart handle and lock with lanyard. 1. See Before Beginning Repair, page 30. Relieve pressure, page 20. 3. Carefully lay sprayer on it’s side on a level surface. Rotate sprayer and rest upside down on cart handle. 1. Loosen nut and press the fluid inlet tube down away from the pump intake valve.
Repair 6. Disconnect cart handles. a. Remove screws (42) from handle (37). b. Hold pin (40) and remove screw (10). c. Gently tap the top-center of the handle with a rubber mallet until the handle is disengaged from the drive housing. d. If removing both drive housings, complete steps 6a-6c on the other handle to remove the entire cart handle assembly. NOTE: B side crankshaft (210) includes the cycle counter magnet (224). When reassembling, be sure to install crankshaft with magnet on B side.
Repair Cycle Counter Switch Replacement NOTE: B side drive housing cover (227) includes the cycle counter switch (223), mounted in the cover. When reassembling, be sure to install cover with switch on B side. Feed the cable under the electric motor and through the grommet and connect to the control board. 223 0.6 in. (15.2 mm) from inside edge 1.0 in. (25.
Repair Electric Motor 10 (x4) 61 Test Motor If motor is not locked up by pumps, it can be tested using a 9 V battery. 1. Open recirculating valves, disconnect J4 or J11 from control board, see FIG. 58, page 34. 13 (x7) 2. Touch jumpers from battery to motor connections. Motor should turn slowly and smoothly. Removal 12 10 (x4) 1. See Before Beginning Repair, page 30. Relieve pressure, page 20. 2. Carefully lay sprayer on it’s side on a level surface.
Repair Installation See FIG. 62, page 38. 1. If replacing motor, install fan assembly and fan mount threaded bushing on new motor. 2. Place cart (1), with motor plate (8) installed, on bottom of the motor and fan. Feed motor cables through grommet. Motor Brushes NOTE: 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 287735 is available; kit includes instruction sheet 406582. Motor commutator should be smooth.
Repair Spout Adapter 3. Connect 38 mm or 40 mm spout adapter. The sprayer is supplied with a 40 mm spout adapter. Follow these instructions to install 38 mm spout adapters or repair the A and B side spout adapters. See Pour Spout Adapter, page 49 for parts. 1. Loosen containment knob. a. Place spout adapter (404) on a flat level surface. Place retaining ring (405) above housing base (403) and insert the bottom of the housing in the spout adapter (404). b.
Parts Parts 120 V and 240 V Fusion Air Purge System Packages 120 V and 240 V Fusion CS System Packages 120 V and 240 V P2 System Packages 120 V and 230 V Manual 2K System Packages 102 103 101 System with Air Operated Gun shown System Package Volts Description AP9082 AP9083 CS9082 CS9083 P29082 P29083 24R151 24R154 120V 240V 120V 240V 120V 240V 120V 240V Fusion Air Purge Proportioner Package Fusion Air Purge Proportioner Package Fusion CS Proportioner Package Fusion CS Proportioner Package P2 Prop
Parts 259082 (120V) and 259083 (240V), Bare Proportioner 27 36 (2x) 29 2 34 (2x) 2 33 (2x) 2 31 (2x) 2 32 (2x) 1 29 (4x) 65 28 29 66 2 48 (2x) 62 30 (2x) 3 49 (2x) 6 47 (2x) 53 (2x) 29 1 3 35 (2x) 3 3 57 51 (2x) 52 (4x) 29 63 73 67 1 1 Apply sealant to threads. 2 Apply sealant to all non-swiveling pipe threads. 3 Apply lubricant to all o-rings and bolt-wheel connection (3, 91).
Parts 259082 (120V) and 259083 (240V), Bare Proportioner (continued) 92▲ 19 10 (4x) 94 3 20 61 21 13 (7x) 12 4 10 (4x) 3 18 17 2 86 16 8 11 (4x) 64 86 14 87 85 15 22 16a 3A1602G 23 TI17472a 43
Parts 259082 (120V) and 259083 (240V), Bare Proportioner (continued) 43 39 37 (2x) 40 (2x) 1 1 88 (2x) 41 (4x) 10 (2x) 43 (2x) 38 42 (2x) 1 44 9 5 (2x) 1 3 84 (2x) 29 (2x) 1 54 (2x) 55 (2x) 83 5 1 91 (2x) 82 7 (4x) 56 (2x) 4 1 90 3 44 3 (2x) 80 81 89 3A1602G
Parts 259082 (120V) and 259083 (240V), Bare Proportioner (continued) Ref.
Parts 24L885, 120 V Bare Proportioner 24L979, 240 V Bare Proportioner ‡221 201 207 208* 209* 210* 224 215‡ 223 211* 220‡ 227 204 37 †213 202 207‡ †212 †214 †213 222‡ 203 ◆216 205 218 219 220‡ 217◆ 207‡ TI17473a Ref.
Parts 3/8 in. ID x 50 ft Insulated Hose Bundle without Recirculation Lines with Air Hose, 24M653 0 Ref. 301 301 302 (Ref) 302 305 302 303 303 305 306 Part Description Qty 1 16V331 HOSE, fluid (component A), moisture guard; grounded, 3/8 in. (9.5 mm) ID; no. 5 JIC fittings (mxf); 50 ft (15 m) 24M671 HOSE, fluid (component B); 3/8 in. 1 (9.5 mm) ID; no. 6 JIC fittings (mxf); 50 ft (15 m) 261535 HOSE, air; 3/8 in. (9.
Parts Recirculation Manifold, 24J147 Ref. 3 506 505 3 504 3 503 1 503a 4 503b 4 501 502 503 2 3 501 507 502 Part Description Qty 24K993 MANIFOLD, recirculation 111763 ELBOW; 1/4 npt (mbe) 239914 VALVE, recirc/spray; includes items 503a, 503b 503a 15E022 . SEAT 503b 111699 .
Parts Pour Spout Adapter Part Ref.
Suggested Spare Replacement Parts Suggested Spare Replacement Parts Manual 2K Gun Part 24K984 246385 24K983 113641 239914 24L002 24G886 24G887 24K999 24L006 249855 Pail Heater, 16U623 246010 24M115 24M114 24M052 24M053 16H615 Description DRYER, desiccant STRAINER, pump inlet SWITCH, motor power, with circuit breaker GAUGE, pressure, fluid; sst VALVE, recirc/spray; includes seat and gasket POTENTIOMETER, control knob BOARD, control; 120 V units only BOARD, control; 240 V units only TRANSDUCER, pressure
Dimensions Dimensions 34.58 in. (87.8 cm) 24.12 in. (61.3 cm) 15.06 in. (38.
Dimensions 52 3A1602G
Technical Data Technical Data Reactor E-8p Maximum fluid working pressure Electrical requirements Generator Size Maximum Ambient Temperature Maximum Output at 340 cycles/min Output per Cycle (A and B) Overpressure Relief US Metric 2000 psi 14 MPa, 138 bar Model 259082: 120 Vac, 1 phase, 50/60 Hz, 1800 W; requires a single dedicated 15 A circuit 2500 W minimum 110°F 43°C 12 lb/min 5.4 kg/min .00352 gal. (.
Graco Standard Warranty 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.
