The Latest Updates to Graco’s Reactor 2

Multiple updates have been implemented in Reactor 2 following work on single-point variable types and the detection methods required to define these conditions, enabling improved understanding of them. Flow meters are standard in Reactor 2 elite models E-30, H-30, H-40 and H-50. Ratio tolerance is set at 5%; however, it can be adjusted between 3% and 20%. Ratio alarms are disabled by default; however, they can be enabled from the Advanced Display Module (ADM) System setup menu. Due to the importance of pressure monitoring within the reactor ratio assurance system, customers wishing to detect possible ratio error situations should ensure that an inlet pressure monitoring system is also installed when adding flow meters to their systems. Reactor software has been updated to require inlet pressure monitoring and pressure imbalance alarms activated through the use of flow meters. Elite reactor models include an inlet pressure monitoring system as standard; however, in non-elite models, an inlet monitoring system must be added when using flow meters. For this reason, five new flow meter kits have been created to provide flow meters and the necessary inlet monitoring equipment for each reactor type. These reactor types are: E-30, E-30 elite, E-30i, H-30/40/50 and H-30/40/50 elite. Reactor 2 software has been updated to optimize inlet pressure monitoring for low-pressure alarms and a feature has been added to detect high inlet pressure problems. To minimize shutdown frequency as a result of certain ratio error situations arising from feed pump problems, Graco has developed new software for Reactor 2 E30 models. This software, called Reactor Smart Control, will automatically make adjustments in the reactor to prevent erroneous ratio distribution. Reactor Smart Control will be enabled as a default setting in new elite model electric reactors; however, it can be disabled from the ADM System setup menu. Reactor Smart Control turns the electric reactor design to its advantage. Electric reactor pumps are double-acting. This means the chemical is pumped from both the upstroke and downstroke of the pump. However, the chemical is only drawn into the pump during the fill stroke (upward direction). Graco's new Reactor Smart Control software runs the pump at the appropriate speed required to feed properly. This is achieved by monitoring inlet pressure transducers. When inlet pressure is insufficient to feed the chemical to the pump properly, the reactor operates more slowly on the upstroke. To compensate for the speed loss, the pump operates faster on the downstroke. Overall, gun pressure will only be affected in situations where feed is extremely restricted and cannot continue. This feature is only available on electric reactors. Hydraulic reactors require manual adjustment of hydraulic pressure to control pump speed. The software cannot be used on hydraulic models to compensate for feed pump problems.

The chart shows the benefits of using Reactor Smart Control mode.

Through the use of flow meters, accurate volumetric flow data is now obtained. This data is important in demonstrating correct material setup. By using the reactor application, customers can now view, save, send and print reports summarizing spray data including ratio. Multiple ratio reports are available in PDF or Excel format: ratio summary report, detailed report showing ratio, and ratio chart.

Gaining Competitive Advantage

As an insulation contractor, understanding spray foam setup parameters such as temperature, air pressure values and ratio is becoming increasingly important as time passes. Construction workers, homeowners and architects continue to demand more spray foam as insulation material preferences with each passing day. As a result, they become more informed about the process and ask questions to ensure the work is set up correctly. It is important to have the ability to monitor potential problems and possess the information needed to present setup proof in order to detect them with the right equipment. A contractor who understands potential problems, knows how to minimize the likelihood of them occurring and can quickly resolve them if they do occur distinguishes itself from competitors. Understanding Single-Point Variables It is important to understand the types of problems that could lead to a ratio error situation and the best method for detecting each problem. Graco recommends using a "Good, Better, Best" scale to determine the preferred detection method for each single-point variable:

• • Best: The preferred method for detecting the problem is equipment. This detection method will have the highest level of sensitivity to ensure detection is completed most quickly, • Better: Equipment detects the problem; however, detection may take longer. The problem may also need to be more serious for detection to occur, • Good: Equipment detects the problem; however, detection is completed over the longest period. This detection method has the least sensitivity and should not be relied upon as the primary detection method, • Not Applicable (NA): Equipment cannot detect this type of problem.

By utilizing inlet and outlet pressure monitoring and flow meters, Graco Reactor 2 can monitor these problems and shut down the ratio control if necessary. The operator can then make the necessary updates to eliminate the ratio error situation. The table below summarizes various single-point variables that could result in improperly rationed foam spraying.  

More Information

Graco's Reactor 2 Ratio Assurance System is an industry-leading solution that provides assurance that foam is sprayed correctly and puts both homeowners and applicators at ease. It eliminates costly repairs and returns and allows for rapid detection of equipment problems and foam ratio errors. Tom Vandevenne Product Sales Specialist Graco