Graco Reactor 2 Spray Foam and Polyurea Equipment User's Manual

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Graco Reactor 2 Spray Foam and Polyurea Equipment User's Manual | Manualzz




Spray Foam and Polyurea Equipment




Advancing the industry

Like you, we want consumers to be completely satisfied with their investment in spray foam insulation and polyurea coatings. Graco’s goal is to provide equipment advancements that help you and your crews apply materials accurately, as the material suppliers intended.

We want to help you grow your business. That’s why Graco developed the next generation in spray foam and polyurea technology – the Reactor 2.

Revolutionize the way you run your business

Each feature in the Reactor 2 was strategically designed to help your business, with innovations that help your operation run smoothly. Software and hardware enhancements for better spray performance. New technologies that add to your bottom line.


Reactor gives you:

• Better control – with Graco InSite

remote reporting, you can manage your business wherever you are

• Better documentation – automatically collect job log data and spray parameters – lets you confirm the job was sprayed to specifications

• Better fleet and crew management

• Better cost containment and forecasting

• Compact footprint – more room in your spray rig

• Ergonomic design – easier to service

• Advanced circuit boards

• Better spraying performance compared to traditional electric Reactor systems

• Troubleshooting made quick and easy with QR codes

Reactor 2. Available in stand-alone and integrated systems.

Reactor 2. Available in stand-alone and integrated systems.








Reactor Top 10 List

1. Advanced control technology

• Tracks, monitors and saves project data

• Data can be downloaded onto a USB drive for further analysis

• Easy to view data display

• Stores up to 24 chemical recipes

• Drum level indicators

2. Graco InSite Remote Reporting Technology

• Transmits real-time job activity you can view on your smart phone, tablet or computer

• Lets you control your business wherever you are

3. Troubleshooting made easy

• On-screen troubleshooting with QR code shortcuts to web-based advanced troubleshooting info

• Results in less downtime

4. Compact design

• 40% smaller footprint than a traditional Reactor E-30


5. Ergonomics

• Easy to reach, conveniently-placed electronics

6. Troubleshooting Y-strainer

• Analog temperature and pressure gauges

7. Sacrificial surge protector

• Protects your electronics against excessive power spikes

• Extra sacrificial surge protector included with Reactor 2 to get you back up and running immediately

8. Advanced circuit boards

• Handles power fluctuations

• Minimizes pressure fluctuations on pump changeover

• Result is a smooth, consistent spray performance similar to hydraulic systems

9. Brushless electric motor

• Improved control and performance

• No maintenance

• Longer life

10. Three-year warranty

• Covers user display module, control boards and electric motor

• One of the best in the industry







A Closer Look at Reactor


Documentation to help protect your business

Tracking project data has never been easier. With Reactor 2, you can easily create job logs for each job you do. You can track the name and date of each job, material temperatures, ambient temperatures and spray pressures – in short, everything you need to confirm that the chemical was sprayed within the recommended range.

Precise material application

Reactor 2 lets you store up to 24 recipes, so switching materials is fast, easy and trouble-free. You reduce human error in entering set points – instead you spray material as material suppliers intended.

Try it now!

Troubleshooting made easy

In the past, if you saw an unusual error code on your ADM, you might need to look it up.

Reactor 2 features a new troubleshooting screen that displays a QR code. You simply scan the QR code with a smart phone or smart device, and it takes you right to a website that provides up-to-date advanced troubleshooting information. You’re up and running more quickly.

Advanced control technology

Tracks project information

• Advanced Display module (ADM) tracks, monitors and saves project information

• Data can be downloaded onto a USB drive for further analysis

Easy to view data display

• Drum fluid levels – let you know if you are running low on material

• System events such as startup and shutdown times

• Daily chemical output

Stores material settings to get you up and running faster

• Saves key setup data such as temperatures and pressure set points for up to 24 chemical recipes

Reduces downtime with QR codes

• Error messages via QR codes explain the problem and provide solutions

Flexible system settings

• If chemicals are low, or if pressure imbalance occurs, you can program the system to shut down automatically

Better spraying performance

Reactor 2 uses software in the motor control module to intelligently smooth out pressure fluctuations on pump changeovers that are inherent to an electric driven machine. The result is a smooth, even spray that is characteristic of a hydraulic machine.

Sleek design means more room in your spray rig

Reactor 2 is designed with a 40% smaller footprint than a traditional Reactor E-30.

Which gives you extra working space in your trailer for extra gear, another Reactor

– or maybe even another set of chemicals.

vs. traditional Reactor E-30

Ergonomic setup makes it easier to service

Electronics on the Reactor 2 are located at the top of the system’s cabinet.

It’s all within easy reach – more convenient and less awkward to get at than previous Reactor systems.

Advanced circuit boards for peace of mind

Graco designed the electronics in the Reactor 2 to a stringent electronics reliability standard. These boards can withstand power spikes and surges.

Sacrificial surge protector

As an added level of protection, Graco also added a sacrificial surge protector to the system. If there is an excessive spike, you only have to replace this smaller, less expensive part – not the whole electronics board. All Reactor 2 models include a spare sacrificial surge protector to get you back up and running immediately.


Graco InSite

Remote Reporting Technology


The power to control your business – wherever you are

If you need to manage multiple jobsites, spend time away from the jobsite, or just want a better way to record what goes on at the jobsite, Graco InSite is your answer.

Graco InSite is remote reporting technology that lets you track jobsite activity in real time via a PC or smart device. From your smart phone, tablet or computer, see at a glance if your crews are spraying and what time they began. Verify that all spray parameters are correct.

Monitor exactly how much material is being used, and do it from anywhere you can access the Internet.

Control the direction of your business

The information Graco InSite gathers can save you money, help you bid jobs more accurately and troubleshoot problems more quickly, saving lost overhead and revenue. The data it collects is automatically stored. This data can be invaluable if you need to show that you sprayed material according to the manufacturer’s specifications.

Most importantly, Graco InSite offers peace of mind that your jobs are running smoothly, your workers are productive, and you can leave the jobsite to pursue more important business matters.

Ambient Temperature Probe

• Early warning system to alert you if

chemicals are getting too cold

Inlet Temperature

• Records temperature and pressures of A and B materials for early troubleshooting diagnosis

• Available on Reactor 2 Elite models only

Status lights

• Red, yellow and green say at a glance if machines are off, idling or spraying

View a demo at

GPS Locator for Fleet

• See the actual GPS location of all spray rigs

GPS Locator

• See the actual GPS location of each spray rig

Job Log,

Data Usage Log, Event Log

• Use icons to access and download detailed reports

Temperature and

Pressure Set-points

• Rest assured that conditions are fine

Volume and Hours of Use

• See how much chemical each crew has sprayed and how long it took

Better fleet and crew management

• Know when Reactors are running, idling or off

• Track productivity by crew or Reactor

• Avoid human error and time wasted by manual logging

• Follow your Reactors with

GPS tracking

• Recognize unauthorized or after-hours use of Reactors or materials

• Receive real-time alerts to deviations and other parameters you define

• Receive a daily email summarizing the previous day’s performance totals

Better cost containment and forecasting

• Know when equipment is ready for maintenance by using lifetime cycle logs

• Save lost revenue and downtime by having real-time, factual information at your fingertips that can help you get up and running fast performance totals

Better customer service

• Help troubleshoot issues remotely

and get machines up and running faster

• Provide more accurate job estimates,

basing it on actual data from prior jobs

Better protection for your future

• Have documented data showing spray parameters for every job

• Offer a final job report to customers

as an additional service

• Recognize when it’s time to hire

additional crews and expand your fleet

• Schedule appointments with potential

customers, knowing that you can still

check on your jobsites wherever you go


It’s simple cellular technology

Graco InSite works by transmitting your data using the local cellular network, where it is stored in the cloud. You can then view the data on your smart phone, tablet or computer via the internet.

Data is transmitted to you in real time, making it possible to receive current information on jobsite performance. If no cell connection is available near the jobsite, the information is stored on the Reactor and transmitted when a connection is established.

Meet 2-Track Solutions, LLC

Graco InSite is a collaboration between Graco and

2-Track Solutions, LLC, an established leader in web-based vehicle intelligence and asset tracking.

The partnership combines expertise in equipment, hardware, software development, data storage and cellular technology. Graco InSite is a subscriptionbased service; your subscription can be paid monthly or annually.

Graco InSite is standard on Elite packages or can be purchased as an accessory kit and installed easily on most existing electric and hydraulic Reactors.

View a demo now!



Ordering Information and Technical Specifications

Reactor Elite models include:

• Graco InSite Remote Reporting Technology

• Inlet pressure and temperature sensor

(interfaces with Graco InSite)

• Xtreme-Wrap

Scuff Guard on heated hoses for

Reactor 2 packages

Reactor standard models include:

• Graco InSite upgradable

(will not include inlet temperature and pressure)

• No inlet pressure and temperature sensor

• Standard scuff guard on heated hoses with

Reactor packages

Three-Year Extended Warranty

We stand behind every piece of equipment we manufacture with one of the industry’s strongest warranties. Spray with the confidence that you will probably never need to use

Graco’s warranty, but if you do we will be there.

Reactor 2 offers a three-year extended warranty on control boards, display module and electric motor. See product manuals for specific warranty details.




warr anty



Graco InSite

Fluid Inlet Sensors

Max Working Pressure psi

(Mpa, bar)


Reactor 2 E-30 Elite Reactor 2 E-30

Yes No


2000 (13.8, 138)


2000 (13.8, 138)

Ordering Information


Select 230V-1ph — 78;

230V-3ph — 50; or 400V-3ph — 34


Select 230V-1ph — 100;

230V-3ph — 62; or 400V-3ph — 35

Heated hose, 50 ft (15 m)

Heated hose, 10 ft (3 m)



AP Gun

Fusion CS Gun




With 10 kW heater:

272110 (Bare)

AP2110 (AP Pkg)

CS2110 (CS Pkg)

P22110 (P2 Pkg)

With 15 kW heater:

272111 (Bare)

AP2111 (AP Pkg)

CS2111 (CS Pkg)

P22111 (P2 Pkg)






With 10 kW heater:

272010 (Bare)

AP2010 (AP Pkg)

CS2010 (CS Pkg)

P22010 (P2 Pkg)

With 15 kW heater:

272011 (Bare)

AP2011 (AP Pkg)

CS2011 (CS Pkg)

P22011 (P2 Pkg)






Max Hose Length

Max Fluid Temp



Operation manual

Repair manual

Reactor 2 E-XP2




3500 (24.1, 241)

With 15 kW heater:

272112 (Bare)

AP2112 (AP Pkg)

P22112 (P2 Pkg)



246101 no



310 ft (94 m)

190°F (88°C)

30 lb (13.6 kg)/min)

355 lb (161 kg)



310 ft (94 m)

190°F (88°C)

30 lb (13.6 kg)/min)

355 lb (161 kg)



310 ft (94 m)

190°F (88°C)

2.0 gpm (7.6 lpm)

350 lb (159 kg)



*Each model can be wired for all voltages: 230V-1ph; 230V-3ph; 400V-3ph

Elite Reactor 2 E-XP2



3500 (24.1, 241)

With 15 kW heater:

272012 (Bare)

AP2012 (AP Pkg)

P22012 (P2 Pkg)



246101 no


310 ft (94 m)

190°F (88°C)

2.0 gpm (7.6 lpm)

350 lb (159 kg)





Integrated Systems

Ready for the jobsite or spray rig – right out of the box

A complete system for polyurethane foam or polyurea applications, the integrated series of Reactor systems combines an electric Reactor and a diesel generator into one package. Complete turnkey models are also available with an integrated air compressor.

Look what the integrated system can do for you:

Saves diesel fuel costs

– on average of $7,000 annually*

Improves productivity

– with advanced, easy to use controls

Eliminates guesswork

– the system is totally engineered and tested by Graco

Eliminates costly power issues

– associated with shore power and low cost generators

Start spraying sooner

– with improved heating capacity

Improves spray performance

– with consistent pressure at the gun

Saves time

– it’s easy to install into a spray rig since it’s prewired with components already selected and installed

Reduces fuel costs even more

– compact, portable design fits into a smaller trailer and a smaller trailer means a smaller truck


Try the ROI calculator

Smaller generator saves fuel costs

The integrated series of Reactor Systems uses the heat from the diesel engine to heat the A and B materials. Depending on the model, this eliminates or significantly reduces the need for electrical heaters – reducing your fuel costs. Here’s how:

• The system pulls heat from the engine to heat the

A and B materials

• Since there are no heaters (or only small heaters) on the equipment, this reduces the electrical demands of the generator, allowing a smaller generator to be used

• The system’s smaller 22 kw generator uses less fuel than a standard 30 or 40 kw generator

• You benefit from an annual fuel savings on average of $7,000*

* By replacing a standard 40 kw generator with a 20 kw generator, the system’s fuel needs are greatly reduced. Savings are an estimate only. Actual savings may vary.

Technology Delivers Fuel Savings

Innovative design re-purposes wasted heat and saves energy

Graco’s patent pending dual coolant loop design ensures that the A and B materials are isolated from the engine coolant.

This unique design also provides constant, steady temperature control for superior heating performance.

Engine coolant loop

Engine coolant goes through heat exchanger 1 and transfers the heat from the engine to the coolant in the secondary loop.

Graco’s controls turn the radiator fan on when additional cooling is required.

Secondary coolant loop –

Coolant in the secondary loop continually circulates when valve C is open, maintaining a consistent temperature. When material heating is required, valve C closes, and valves A and B open. This allows the coolant in the secondary loop to go through heat exchangers

2 and 3, thereby transferring the heat to the A and B materials.

Did you know...

Fast material heating gets you up and running quicker

With just one pass through the heat exchanger, materials can be heated to a Delta T

(change in temperature) of 100°F (56°C) (140°F on units with heaters) . That’s 25% greater than a standard Reactor model. Because of this better

Delta T performance, you don’t have to wait as long for materials to preheat.


Advanced Technologies Save Time and Energy


Recovery System

• Recovers heat from the engine coolant and transfers it to the

A and B materials

Fluid Inlet Sensor

• Measures chemical inlet pressure and temperature

• Allows troubleshooting of fluid supply

Integrated Air Control Panel

• Controls A and B feed pumps, agitator and gun

• One air line connection means less plumbing, less hoses and less assembly time

Compact Design

• Lightweight design lets you use a smaller trailer and truck, saving you fuel costs

• Built-in pallet for easy transport

• 4 ft (1.2 m) wide by 5 ft (1.5 m) deep



• Easy to access

• Analog temperature and pressure gauges are standard


• Battery not included

Booster Heat

• 4000 watt heater

(included on high- heat systems only)

Gen Set Controls

• Integrated controls allow for convenient and easy start up

• Engine monitoring functionality

Compressor Start/

Stop Switch

• Convenient access to control compressor

Advanced Controls

• Stores up to 24 material recipes

• Troubleshooting made easy with QR codes

• USB downloadable job data

• User settable pressure imbalance and low chemical shutdown


Motor Control

• Consistent pressure at the gun for improved spray performance

• Low-pulse design reduces pump change-over fluctuation

Fuel Tank

• 22-gal (83 liter) capacity

• Can be remote mounted

Distribution Panel

• Easy to service electrical controls and breakers

• Pre-wired auxiliary breakers provided for compressor and other auxiliary equipment

Refrigerated Air Dryer

• Efficiently removes water from supply air

Graco InSite - Remote Reporting Technology

• Transmits real-time job activity

• Tracks critical job data

• Logs spray data per job, providing proof of

installation parameters

*Integrated Air Compressor

• Hydrovane rotary vane compressor

• Tankless air compressor

*Standard on some models

Gen Set

• 29 HP Perkins engine

• 22 kW Mecc Alte alternator

• Smaller engine reduces fuel consumption

Visit for more information on the Graco Reactor 2 E-30i or E-XP2i


Ordering Information and Technical Specifications



Model Reactor 2

E-30i Elite

Reactor 2 E-30i


Elite with heat


Reactor 2 E-XP2i

Elite with heat


Reactor 2 E-30i



Reactor 2 E-30i

Elite with heat


Reactor 2 E-XP2i


Elite with heat

Yes Graco InSite Yes

Max Working Pressure 2000 psi (138 bar, 13.8 MPa)

2000 psi (138 bar, 13.8 MPa)

310 ft (94 m)

3500 psi (240 bar, 24.0 MPa)

310 ft (94 m)

2000 psi (138 bar, 13.8 MPa)

310 ft (94 m)

2000 psi (138 bar, 13.8 MPa)

310 ft (94 m)

3500 psi (240 bar, 24.0 MPa)

310 ft (94 m) Max Hose Length 310 ft (94 m)

Max Fluid Temperature 150°F (65°C)

Max Output

190°F (87°C) 190°F (87°C)

30 lb (13.6 kg)/min 30 lb (13.6 kg)/min 2 gpm (7.6 lpm)

150°F (65°C) 190°F (87°C) 190°F (87°C)

30 lb (13.6 kg)/min 30 lb (13.6 kg)/min 2 gpm (7.6 lpm)


Heater Wattage

Auxiliary Power


Auxiliary Power


Air Dryer



1750 lb (794 kg)


52 amps @ 240V

120V or 240V, 1-ph



1800 lb (816 kg)

4000 W

35 amps



@ 240V

Perkins 404-22G, 2.2 L, 29 HP

1800 lb (816 kg)

4000 W

35 amps



@ 240V

Mecc Alte 22 kW, 240V, 1-ph, 60 Hz, pancake style

2200 lb (998 kg)


22 amps @ 240V

120V or 240V, 1-ph

2250 lb (1021 kg) 2200 lb (998 kg)

4000 W

5 amps @ 240V

Hydrovane 5 HP, 16 cfm, 240V, 1-ph, 60 Hz

Hankison refrigerated 22 scfm, 115V, 1-ph, 60 Hz

Perkins 404-22G, 2.2 L, 29 HP

4000 W

5 amps @ 240V

Mecc Alte 22 kW, 240V, 1-ph, 60 Hz, pancake style

Ordering Information:

Base Machine

Gun Options Fusion


AP Pkg


CS Pkg



(246102 gun)


(CS02RD gun)

P2 Pkg P22079

(GCP2R2 gun)

Operation Manual

Repair Manual





(246102 gun)


(CS02RD gun)


(GCP2R2 gun)





(246101 gun)



(GCP2R1 gun)





(246102 gun)


(CS02RD gun)


(GCP2R2 gun)





(246102 gun)


(CS02RD gun)


(GCP2R2 gun)





(246101 gun)



(GCP2R1 gun)



*Packages include spray hose, whip hose and gun **Packages with Remote Display also include kit part number 24K338

† Available auxiliary current will be less when the engine is de-rated for site altitude. Reduce the available auxiliary current by 2.5 amps 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.

Reactor Accessories

Graco InSite Remote Reporting Technology

24T280 Graco InSite Retrofit Kit. Compatible with the following Reactor 2 models: E-30, E-XP2.

24T278 Graco InSite Retrofit Kit. Compatible with the following Reactor models: E-20 TM , E-30,

E-XP1 TM , E-XP2, H-25 TM , H-40 TM , H-50 TM , H-XP2 TM and H-XP3 TM

24T279 Graco InSite Retrofit Kit. Compatible with the following first generation integrated Reactor models: E-30i, E-XP2i.

16X521 Extension cable, 25 ft (7.5 m)

Hoses and Hose Accessories

Protect your hoses with Xtreme-Wrap Scuff Guard. For all Reactor 2 models.

24T243 10 ft (3 m) Wrap Kit

24T244 50 ft (15 m) Wrap Kit

24Y240 3/8 in x 50 ft (9.5 mm x 15 m) Hose, 2000 psi (138 bar, 13.8 MPa) with RTD and Xtreme-Wrap Scuff Guard

24Y241 3/8 in x 50 ft (9.5 mm x 15 m) Hose, 3500 psi (240 bar, 24.0 MPa) with RTD and Xtreme-Wrap Scuff Guard

24K240 3/8 in x 50 ft (9.5 mm x 15 m) Hose, 2000 psi (138 bar, 13.8 MPa) with RTD, w/ Scuff Guard

24K241 3/8 in x 50 ft (9.5 mm x 15 m) Hose, 3500 psi (240 bar, 24.0 MPa) with RTD, w/ Scuff Guard

246050 1/4 in x 10 ft (6.3 mm x 3 m) Whip Hose, 2000 psi (138 bar, 13.8 MPa)

246055 1/4 in x 10 ft (6.3 mm x 3 m) Whip Hose, 3500 psi (240 bar, 24.0 MPa)

24N450 50 ft (15 m) RTD cable

24K207 Fluid Temperature Sensor with RTD

For list of all hose options, visit

Additional Kits and Accessories

Hose Rack Kit


For integrated Reactor 2 systems.

Supports 310 feet (94 m) of heated hose. (Some assembly required).

15V551 ADM Protective Covers, 10 pack

15M483 Remote Display Protective Covers, 10 pack

24U177 Feed Pump Shut Down Kit

24M174 Drum Level Dip Sticks, for standard 55-gal drums

For Reactor 2 stand-alone models

24U314 Wheel Kit, includes wheels, handle and brackets,

Reactor 2 stand-alone only

24U315 Air Manifold Kit, Reactor 2 stand-alone only

For integrated Reactor 2 systems

24U176 Complete air compressor, refrigerated air dryer, frames, fastener and all electrical and air connections included. Assembly required.

24K333 Fuel Tank/Battery Move Kit

24K337 Light Tower Kit

24U181 Booster Heat Kit, to reach temperatures above 140°F (60°C)

For more parts and accessories, see Graco Catalog 349104.

Remote Display Kit 24U174

The convenience of having control at the gun. For both integrated and stand-alone Reactor 2 systems.

With a Remote Display*, your sprayer/operator can:

• Adjust temperatures and pressures

• Turn heat zones and motor on and off

• View and clear alarms and warnings

• Place pump in park mode

• View drum level indicator

• Communicate with ADM at the equipment

*Additional CAN cable required, hose bundles available



Founded in 1926, Graco is a world leader in fluid handling systems and components. Graco products move, measure, control, dispense and apply a wide range of fluids and viscous materials used in vehicle lubrication, commercial and industrial settings.

The company’s success is based on its unwavering commitment to technical excellence, world-class manufacturing and unparalleled customer service. Working closely with qualified distributors, Graco offers systems, products and technology that set the quality standard in a wide range of fluid handling solutions. Graco provides equipment for spray finishing, protective coating, paint circulation, lubrication, and dispensing sealants and adhesives, along with power application equipment for the contractor industry. Graco’s ongoing investment in fluid management and control will continue to provide innovative solutions to a diverse global market.



P.O. Box 1441

Minneapolis, MN 55440-1441

Tel: 612-623-6000

Fax: 612-623-6777



Worldwide Headquarters

Graco Inc.

88-11th Avenue N.E.

Minneapolis, MN 55413



European Headquarters

Graco N.V.

Industrieterrein-Oude Bunders

Slakweidestraat 31

3630 Maasmechelen,


Tel: 32 89 770 700

Fax: 32 89 770 777



Graco Australia Pty Ltd.

Suite 17, 2 Enterprise Drive

Bundoora, Victoria 3083


Tel: 61 3 9468 8500

Fax: 61 3 9468 8599


Graco Hong Kong Ltd.

India Liaison Office

Room 443, Augusta Point

Regus Business Centre 53

Golf Course Road

Gurgaon, Haryana

India 122001

Tel: 91 124 435 4208

Fax: 91 124 435 4001


Graco Hong Kong Ltd.

Shanghai Representative Office

Building 7

1029 Zhongshan Road South

Huangpu District

Shanghai 200011

The People’s Republic of China

Tel: 86 21 649 50088

Fax: 86 21 649 50077


Graco K.K.

1-27-12 Hayabuchi


Yokohama City, Japan 2240025

Tel: 81 45 593 7300

Fax: 81 45 593 7301


Graco Korea Inc.

Shinhan Bank Building

4th Floor #1599

Gwanyang-Dong, Dongan-Ku,

Anyang-si, Korea 431-060

Tel: 82 31 476 9400

Fax: 82 31 476 9801




Call today for product information or to request a demonstration.


(1-877-844-7226) or visit us at

Graco Inc. is registered to I.S. EN ISO 9001

North America

Customer Service


Fax 877-340-6427

©2014 Graco Inc. 348986 Rev. A 01/14 All written and visual data contained in this document are based on the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice. All other brand names or marks are used for identification purposes and are trademarks of their respective owners.


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