How do I install my pneumatic Graco Reactor?

Regardless of which polyurethane foam or polyurea coatings you will be spraying, you must first install your pneumatic Graco Reactor. This step-by-step guide contains the information you need to set up and safely operate your machine.

This step-by-step guide walks you through installing your pneumatic Graco Reactor. This document is not replacing the manual, and for a full overview of safety instructions please see the manual.

1. Fix the Reactor.
   1. Place your Reactor on a level surface and mount it on the floor with 3/8 in (10 mm) bolts, unless the system needs to remain portable.
      • Place two bolts through the 2 in (50 mm) deep caster bushings in the rear.
      • Place two bolts through the 3-5/8 in (10-15 mm) deep caster bushings in the front.
   2. Use the wheel kit, if you need to move the machine.
2. Determine the power source.
   1. Your Reactor can be wired to three types of power source:
      • 200-240 V ac, 1-phase (2-wire + ground/PE)
      • 200-240 V ac, 3-phase Delta (3-wire + ground/PE)
      • 350-415 V ac, 3-phase Wye (4 wire + ground/PE) (nominal line-to-neutral voltage: 200-240 V ac)
3. Connect the electrical cord.
   1. Disregard the terminal numbers on the disconnected switch blocks. Wire to the positions shown. Terminals will accept up to #8 AWG (10 mm2) conductors.
   2. Turn the cover fasteners 90° counterclockwise with a flat screwdriver.
   3. Lift and pull the front cover away.
   4. Feed the power cord through the strain relief on the right side of the unit.
   5. Push the black die release lever down to release the contacts block for easy wiring. The strain relief accepts cords from 0.59 to 1.0 in (15-25 mm) diameter.
   6. NOTE: A-XP1 disconnect cannot be detached from the frame.
   7. Connect the power leads to the power disconnect switch.
   8. Snap the contacts block back onto the switch.
   9. Tighten the strain relief nut.
   10. Connect the ground wire to the ground lug.
   11. Replace the lower front cover and reinstall the two screws retained in step 1.
   12. Connect the power leads to the terminals:
       1. 200-240 V ac, 1-phase - Use a screwdriver to connect the two power leads to the top two middle terminals as shown. Connect green to the ground. Disregard the terminal numbers on the disconnect switch blocks.
       2. 200-240 V ac, 3-phase Delta - Use a screwdriver to connect the three power leads to the top three left terminals as shown. Connect green to the ground.
       3. 350-415 V ac, 3-phase Wye - Use a screwdriver to connect four power leads to the top terminals as shown. Connect neutral only to N. Connect green to the ground.
4. Install the power jumpers.
   1. Turn the screws counterclockwise on the upper part of the cover until they stop.
   2. Pull the door up and out.
   3. Push the red jumpers from the storage bag firmly into the positions shown for your power configuration. A flat-blade screwdriver can be used under the ridge on the side of the jumper to remove it.
   4. Replace the front cover.
5. Reposition the heater jumpers (if necessary)
   1. Your Reactor is shipped with heaters wired for 6000 watts. To reposition the heater jumpers for 3000 watts, change the jumper positions as shown below.
      1. Turn the screws counterclockwise on the upper part of the cover and pull to remove them.
      2. Push the red jumpers from the storage positions firmly into the positions shown for your power configuration. A flat blade screwdriver can be used under the ridge on the side of the jumper to remove it.
      3. Replace the lower front cover.
6. Ground all equipment. 
   1. 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.
      1. Reactor: The Reactor is grounded through the power cord.
      2. Spray gun: Connect the whip hose ground wire to the fluid temperature sensor. Do not disconnect the ground wire or spray without the whip hose.
      3. Fluid supply containers: Follow your local code.
      4. The object being sprayed: Follow your local code.
      5. Solvent pails used when flushing: Follow your local code. Use only metal pails, which are conductive, placed on a grounded surface. Do not place the pail on a non-conductive surface, such as paper or cardboard, which interrupts grounding continuity.
      6. To maintain grounding continuity when flushing or relieving pressure, hold a metal part of the spray gun firmly to the side of a grounded metal pail, then trigger the gun.
7. Set up the ISO pump lubrication system.
   1. Prepare the isocyanate pump lubrication system:
      1. 1 Lift the lubricant reservoir out of the bracket and remove the cap from the reservoir.
      2. Fill the lubricant reservoir 3/4 full with Graco Throat Seal Liquid (TSL – part 206995).
      3. Thread the lubricant reservoir onto the cap assembly and place it into the bracket.
   2. The lubrication system is now ready for operation; no priming is required.
8. Connect the fluid supply hoses.
   1. Connect the material supply hoses to the inlets of the proportioning unit:
      1. Connect the fluid inlet ball valves and Y-strainers to the pump inlets.
      2. Ensure the A- and B- inlet ball valves on the proportioning unit are closed. 
      3. Connect and tighten the B-supply hose to the 3/4 in (19 mm) NPT swivel fitting on the B-inlet ball valve, and to the resin transfer pump.
      4. Connect and tighten the A-supply hose to the 1/2 in (12.7 mm) NPT swivel fitting on the A-inlet ball valve, and to the isocyanate transfer pump.
9. Connect the main air supply.
   1. Connect the main air supply to the air inlet 1/2 in (12.7 mm) NPT valve at the air filter.
10. Connect the recirculation lines.
    1. If circulating fluid back to the supply drums, make sure to use a high-pressure hose rated to withstand the maximum working pressure of this equipment.
       1. Connect the high-pressure hose to the relief fittings of both pressure relief/spray valves.
       2. Route the hose back to the component A and B drums. 
       3. Alternate the recirculation hoses.
       4. This requires adapter fittings:
          1. 249508 - ISO (A) (moisture guard) red hose, 1/4 in (6 mm) ID; #5 JIC fittings (m x f); 35 ft (10.7 m) long
          2. 249509 - Resin (B) blue hose, 1/4 in (6 mm) ID; #6 JIC fittings (m x f); 35 ft (10.7 m) long
11. Install the fluid temperature sensor (FTS)
    1. Install the fluid temperature sensor between the heated main hose and the heated whip hose. See the heated hose manual for instructions.
12. Connect the heated hose.
    1. The fluid temperature sensor and whip hose must be used with the heated hose. The hose length, including the whip hose, must be at least 60 ft (18.3 m).
       1. Turn the main power OFF.
       2. Assemble the heated hose sections, the fluid temperature sensor, and the whip hose. See the heated hose manual for instructions.
       3. Connect the A and B hoses to the A and B outlets on the Reactor fluid manifold. The hoses are color-coded: red for component A (ISO), blue for component B (resin). Fittings are sized to prevent connection errors. Manifold hose fittings allow the use of 1/4 (6 mm) in and 3/8 (9.5 mm) in ID reactor heated fluid hoses.
       4. Connect the heated hose airline to the proportioned air hose.
       5. Connect the FTS cables.
       6. Connect the wires:
    • Proportioners with termination box (TB):
      1. Connect the hose power wires to the terminal block on the termination box.
      2. Remove the box cover and loosen lower strain relief.
      3. Route the wires through the strain relief and fully insert them into the terminal block (A and B hose wire positions are not important).
      4. Torque the terminal connector screws to 35-50 in-lb (4.0-5.6 N•m).
      5. Fully tighten the strain relief screws and replace the cover.
    • Proportioners with electrical splice connectors:
      1. Connect the electrical connectors (NN).
      2. Be sure the cables have slack when the hose bends.
      3. Wrap the cable and electrical connections with electrical tape.
13. Connect the whip hose.
    1. Close the gun fluid inlet valves A and B.
    2. Connect the whip hose to the gun or gun fluid manifold:
       1. Probler P2 guns: Connect the hoses to the inlet valves.
       2. Fusion guns: Connect the hoses to the inlet manifold. Do not connect the manifold to the gun.
    3. Overlap the A and B component hoses and attach them to the gun or gun manifold fittings as shown.
    4. Tighten the fittings of the A and B component hoses. Ensure the hose remains flat after the fittings are tightened. Loosen and retighten the fittings if necessary, to eliminate any torque on the hoses.

Refer to the manual for further directions: