Graco Fusion, 248597248647, 248603 Instructions-parts List Manual

Instructions-Parts
310648P
Solvent Purge Plural Component Gun
For use with non-flammable foam and polyurea. For professional use only. Not for use in explosive atmospheres.
Important Safety Instructions
Read all warnings and instructions in thismanual. Save these instructions.
EN
248597, Series A
Solvent Purge Manual Spray Gun
248647, Series B
Machine Mount Spray Valve with Manual Solvent Purge
248603, Series A
3500 psi (24.2 MPa, 242 bar) Maximum Fluid Working Pressure 80-130 psi (0.55-0.9 MPa, 5.5-9.1 bar) Air Inlet Pressure Range 200°F (94°C) Maximum FluidTemperature 3500 psi (24.2 MPa, 242 bar) Maximum Solvent Working Pressure
TI5006c
TI4965b
II 2 G
Contents
Manual Conventions ........................3
OverallView ...............................6
Important Isocyanate (ISO) Information ........7
Material Self-ignition ......................8
Keep Components A and B Separate .........8
Moisture Sensitivity of Isocyanates ...........8
Foam Resins with 245 fa Blowing Agents ......9
Changing Materials .......................9
Grounding ................................9
Piston Safety Lock ........................10
Loss of Air Pressure .......................10
Conversion Kit 248603 .....................11
Mounting an Automatic Gun .................12
Mounting to a rod .......................12
Mounting to a stationary support robotic arm . . 12
Connecting Airline and Accessories .........12
Setup ....................................13
Hand Drilling of Mix Modules ................15
To balance pressure and flow at the mix gun . . 15
CheckValve Filter Option .................15
Tools required ..........................15
Operation ................................17
Spraying ..............................17
Flushing with Solvent Purge Assembly .......17
Shutdown ................................18
Daily Shutdown .........................18
Shutdown for More than a Day .............18
Pressure Relief Procedure ..................19
Optional Configurations ....................21
Optional Fluid Manifold Position ............21
Optional Hose Position ...................22
Maintenance ..............................23
Supplied Tool Kit ........................23
Keep Gun Clean ........................23
As Needed ............................23
Daily .................................23
Weekly to Monthly .......................23
Flush Gun .............................24
Clean Outside of Gun ....................24
Clean Air Cap ..........................24
Clean SprayTip .........................24
Clean Muffler ...........................24
Clean Fluid Manifold .....................24
Clean Mixer ............................24
Clean Slip-Fit Polycarballoy Mix Module ......25
Troubleshooting ...........................26
Theory of Operation ......................28
Cutaway View ..........................29
Repair ...................................30
Tools Required ..........................30
Lubrication .............................30
Disassemble Front End ...................30
Reassemble Front End ...................
Slip-Fit Polycarballoy Mix Module ...........34
Rear Rod Seal ..........................36
Adjust Rear Rod Seal ....................37
CheckValves ...........................38
Piston and Purge Rod ....................39
Piston Safety Lock .......................41
AirValve...............................41
Solvent Purge Assembly ..................42
Static Mixer Assembly ....................43
Parts ....................................45
248597 and 248647 Solvent Purge Plural
Component Spray Guns, and 248603
Conversion Kit .......................45
248597 Solvent Purge Manual Spray Gun ....46
248597 Solvent Purge Manual Spray Gun ....47
248647 Machine Mount SprayValve
with Manual Solvent Purge .............48
248647 Machine Mount SprayValve
with Manual Solvent Purge .............49
Slip-Fit Polycarballoy Mix Module Kits ........50
GunandPalmGrips .....................50
Drill Bit Kits ............................51
Gun Repair Kits ...........................52
CheckValve Filter Screen Kits (10 per kit) ....52
DrillBitKit .............................52
Model 248647 Mounting Dimensions ..........53
Technical Data ............................54
Graco Standard Warranty ...................56
Graco Information .........................56
32
2 310648P

Manual Conventions

Warning Caution
Manual Conventions
WARNING
A warning alerts you to possible serious injury or death if you do not follow instructions.
Symbols, such as fluid injection (shown), alert you to a specific hazard and direct you to read the indicated hazard warnings on pages 4-5.
CAUTION
A caution alerts you to possible equipment damage or destruction if you do not follow instructions.
Note
A note indicates additional helpful information.
Component Labels
Depending on chemistry and material manufacturer, individual fluid components havedifferent labels. Some­times (A) is the ISO or hardener. Sometimes (A) is the RESIN or filled side. For the purpose of these valves and this manual, (A) refers to the ISO, or hardener, which will most often be the minor volume side. (B) refers to the RESIN side, which normally contains the fillers and is the major volume side.
310648P 3
Warning
WARNING
PERSONAL PROTECTIVE EQUIPMENT
Always wear appropriate personal protective equipment and cover all skin when spraying, servicing equipment, or when in the work area. Protective equipment helps prevent serious injury, including
long-term exposure; inhalation of toxic fumes, mists or vapors; allergic reaction; burns; eye injury and hearing loss. This protective equipment includes but is not limited to:
A properly fitting respirator,which may include a supplied-air respirator, chemically impermeable gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory authority.
Protective eyewear and hearing protection.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled or swallowed.
Read Safety Data Sheet (SDS) for handling instructions and to know the specific hazards of the flu­ids you are using, including the effects of long-term exposure.
When spraying, servicing equipment, or when in the work area, always keep work area well venti­lated and always wear appropriate personal protective equipment. See PersonalProtective Equip- ment warnings in this manual.
Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
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).
Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
Keep the work area free of debris, including solvent, rags, and gasoline.
Ground equipment and conductive objects. See Grounding, page 9.
Hold gun firmly to side of grounded pail when triggering into pail.
Use only grounded hoses.
If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.
Keep a fire extinguisher in the work area.
4 310648P
Warning
WARNING
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks,or ruptured components will pierce skin. This maylook like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
Do not point the gun at anyone or at any part of the body.
Do not put your hand over the spray tip.
Do not stop or deflect leaks with your hand, body, glove, or rag.
Do not “blow back” fluid; this is not an air spraysystem.
Follow Pressure Relief Procedure, page 19, when you stop spraying and before cleaning, check­ing, or servicing equipment.
Use lowest possible pressure when flushing, priming, or troubleshooting.
Engage piston safety lock when not spraying.
Tighten all fluid connections before operating the equipment.
Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. High pres­sure hose cannot be recoupled; replace the entire hose.
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 equipment/fluid has cooled completely.
EQUIPMENT MISUSE HAZARD
Misuse can cause serious injury or death.
For professional use only.
Use equipment only for its intended purpose. Call your Graco distributor for information.
Read manuals, warnings, tags, and labels before operating equipment. Follow instructions.
Check equipment daily. Repair or replace worn or damaged parts immediately.
Do not alter or modify equipment. Use only Graco parts and accessories.
Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. SeeTechnical Data in all equipment manuals.
Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings.
Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
Do not kink or overbend hoses or use hoses to pull equipment.
Comply with all applicable safety regulations.
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical reaction and equipment rupture, and result in death, serious injury, and property damage.
310648P 5

Overall View

OverallView
K
P
L
F
C
M
D
T
W
R
N
X
Y
V
G
B
A
H
Key:
A A Side Fluid Valve (ISO) B B Side Fluid Valve (RESIN) C Air Cap D Air Line Quick Coupler E Muffler F Fluid Housing G Gun Fluid Manifold H Handle J Optional Air Inlet K Cleanoff Air Valve L Piston Safety Lock M SolventPurge Assembly
S
U
J
N Optional Fluid Inlets (A Side Shown) P Lock Ring R Fluid Inlet Swivels (A Side Shown) S Trigger T Gun Air Whip Hose U Air Valve V Solvent Purge Valve W Static Mixer X RAC tip
Y Solvent Fluid Inlet
E
TI4966b
6 310648P

Important Isocyanate (ISO) Information

Important Isocyanate (ISO) Information
Isocyanates (ISO) are catalysts used in two component materials.
Isocyanate Conditions
Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and atom­ized particulates.
Read and understand the fluid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific hazards and precautions related to isocyanates.
Use of isocyanates involvespotentially hazardous procedures. Do not spraywith this equipment unless you are trained, qualified, and have read and understood the information in this manual and in the fluid manufacturer’s application instructions and SDS.
Use of incorrectly maintained or mis-adjusted equipment may result in improperly cured material.which could cause off gassing and offensive odors. Equipment must be carefully maintained and adjusted according to instructions in the manual.
To prevent inhalation of isocyanate mists, vapors and atomized particulates, everyone in the work area mustwear appropriaterespiratory protection.Alwayswear aproperly fittingrespirator,which mayinclude a supplied-air respirator.Ventilatethe workarea accordingto instructions inthe fluid manufacturer’sSDS.
Avoid all skin contact with isocyanates. Everyone in the work area must wear chemically impermeable gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local reg­ulatory authority. Follow all fluid manufacturer recommendations, including those regarding handling of contaminated clothing. After spraying, wash hands and face before eating or drinking.
Hazard from exposureto isocyanates continues after spraying.Anyonewithout appropriate personal pro­tective equipment must stay out of the work area during application and after application for the time period specified by the fluid manufacturer. Generally this time period is at least 24 hours.
Warn others who may enter work area of hazard from exposure to isocyanates. Follow the recommen­dations of the fluid manufacturer and local regulatory authority. Posting a placard such as the following outside the work area is recommended:
TOXIC FUMES
HAZARD
DO NOT ENTER DURING
SPRAY FOAM APPLICATION OR FOR ___ HOURS AFTER
APPLICATION IS COMPLETE
DO NOT ENTER UNTIL:
DATE: TIME:
310648P 7
____________ ____________
Important Isocyanate (ISO) Information
For all applications except spray foam
Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors,and atomized particulates.
Read and understand the fluid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific hazards and precautions related to isocya­nates.
Use of isocyanates involves potentially hazardous procedures. Do not spray with this equipment unless you are trained, qualified, and have read and understood the information in this manual and in the fluid manufacturer’s application instructions and SDS.
Use of incorrectly maintained or mis-adjusted equipment may result in improperly cured material. Equipment must be carefully maintained and adjusted according to instructions in the manual.
To prevent inhalation of isocyanate mists, vapors, and atomized particulates, everyone in the work area must wear appropriate respiratory protection. Alwayswear a properly fitting respirator, which may include a supplied-air respirator. Ventilate the work area according to instructions in the fluid manufac­turer’s SDS.
Avoid all skin contact with isocyanates. Everyone in the work area must wear chemically impermeable gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory authority. Follow all fluid manufacturer recommendations,including those regardinghandling of contaminated clothing. After spraying, wash hands and face before eating or drinking.

Material Self-ignition

Keep Components A and B Separate

Cross-contamination can result incured material influid lines which could cause serious injury or damage equipment. To prevent cross-contamination:
Never interchange component A and component B wetted parts.
Neveruse solventon oneside if ithas been contam­inated from the other side.

Moisture Sensitivity of Isocyanates

Exposure to moisture (such as humidity) will cause ISO to partially cure, forming small, hard, abrasive crystal that becomesuspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity.
NOTICE
Partially cured ISO will reduce performance and the life of all wetted parts.
Always use a sealed container with a desiccant dryer in the vent,or a nitrogen atmosphere. Never store ISO in an open container.
Keep the ISO pump wet cup or reservoir (if installed) filled with appropriate lubricant. The lubricant creates a barrier between the ISO and the atmosphere.
Use only moisture-proof hoses compatible with ISO.
Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.
Always lubricate threaded parts with an appropri­ate lubricant when reassembling.
Some materials may become self-igniting if applied too thick.Read material manufacturer’s warnings and Safety Data Sheet (SDS).
8 310648P
NOTE:The amount of film formation and rate of crystal­lization varies depending on the blend of ISO, the humidity, and the temperature.

Grounding

Foam Resins with 245 fa Blowing Agents

Some foam blowing agents will froth at temperatures above 90°F (33°C) when not under pressure, especially if agitated. To reduce frothing, minimize preheating in a circulation system.

Changing Materials

NOTICE
Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime.
When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.
Always clean the fluid inlet strainers after flushing.
Check with your material manufacturer for chemi­cal compatibility.
When changing between epoxies and urethanes or polyureas, disassemble and clean all fluid com­ponents and change hoses. Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the B (resin) side.
Grounding
WARNING
Read warnings, page 4.
Check your local electrical code and proportioner man­ual for detailed grounding instructions.
Solvent line must be Graco approved grounded hose. Primary ground is through the grounded solvent supply
hose. Ensure that solvent supply pump is properly grounded. Ensure continuity from the spray tip to grounded solvent
hose when using static mixers and tips other than sup­plied with gun.
310648P 9

Piston Safety Lock

Piston Safety Lock
Engage piston safety lock whenever you stop spray­ing, to avoid accidental triggering.
WARNING
Read warnings, page 5.
To engage piston safety lock: push knob in and turn
clockwise.When engaged, piston safety lock allows some purge rod movement but shuts off fluid flow and gun cannot spray.
TI3850a
To disengage piston safety lock: push knob in and
turn counterclockwise until it pops out.

Loss of Air Pressure

In event of loss of air pressure while gun is triggered, gun will continue to spray. To shut off gun, do one of the following:
Push hard or hit end of safety lock, to engage piston safety lock.
TI5003a
Close fluid valves A and B.
TI4967b
TI3849a
10 310648P

Conversion Kit 248603

A Standard Mechanical Purge Gun can be converted into a Solvent Purge Gun with this kit.
1. Relieve pressure. See manual 309856.
2. Flush Gun, page 24.
Conversion Kit 248603
7. Liberallylubricate piston o-rings.Install spacer (61)
onto piston assembly. Reinstall piston. Shaft is keyed for proper assembly. Push firmly to seat pis­ton. Rotate piston/purge rod assembly clockwise with nut driver until piston is fully seated.
3. Disassemble front end of gun. Refer to manual
309856.
4. Disassemble the piston and purge rod assembly
from the gun, see Piston and Purge Rod in man­ual 309856.
5. Remove purge rod (31) from assembly and place
spacer (62) onto purge rod.
31
62
61
61
TI4988a
Spacer (61) is optional. For more forward travelof piston, remove spacer.
8. Install piston safety lock assembly until bottomed
out.
TI3847a
TI4989a
9. Reassemble the fluid housing onto the front end of
the gun. See Reassemble Front End, page 32,
6. Reassemble purge rod and piston assembly until
positive stop on purge rod spacer (62).
310648P 11
steps 1 through 6.

Mounting an Automatic Gun

Mounting an Automatic Gun

Mounting to a rod Mounting to a stationary

support robotic arm
1. To mount the gun on a 1/2 in. diameter rod, insert
the bar (A) through the hole in the gun body as shown.
ti5007b
To mount gun to stationary support or robot arm, see
mounting hole dimensions, page 53.
Two .128 in. alignment pin holes
Four M5 x 0.08 in. (6.3 mm) holes
2. Secure the gun to the bar by tightening 1/4 in. - 20
mounting screws.

Connecting Airline and Accessories

P
I - Activation P - Purge/Clean-off O - Deactivation
I
O
Two 1/4 ­20 unc holes
ti4751b
1. On the gun air supply line, install an air pressure
regulator.
A minimum of 80 psi (0.55 MPA, 5.5 bar) air pressure must be supplied to the gun for proper operation.
A four-wayair valve, which exhausts cylinder air in both directions, is required.
2. On the gun air supply line, install a bleed-type air
shutoff valve downstream of the gun air regulator.
12 310648P
3. On the main air line, install a bleed-type air shutoff
valve.
Clean off air
Three 1/8 npt
ports (air inlet)
I
P
O
I - Activation P - Purge/Clean-off O - Deactivation
Gun actuation
Gun deactuation
ti4751b

Setup

Setup
1. Read Hand Drilling of Mix Modules, page 15,
before performing setup procedure.
2. Assemble gaskets (40c), static mixer assembly
(40), o-ring (40d), adapter (41), and RAC tip and guard (9, 63) assembly to fluid housing on front end of gun.
40, 40d
41
9, 63
Solvent purge knob (V) and inlet (Y) can be rotated in any direction.
40c
VY
TI5033b
3. Close fluid valves A and B.
5. Engage piston safety lock (L), page 10.
L
TI3850a
6. Connect gun air whip hose (T) and air valve (U) to
main air hose. Attach fluid manifold (G) to gun.
T
G
To change position of fluid manifold or use optional fluid inlets, see pages 21 and 22.
U
TI4968b
7. Connect air line to quick coupler (D). Turn on air.
Open air valve (U). Air valve (K) should be screwed tight.There is no clean off air to adjust on
TI2411A
the solvent purge gun.
K
4. Connect A (ISO) and B (RESIN) fluid hoses to fluid
manifold (G).
B (RESIN)
G
U
D
J
A (ISO)
TI2417A
310648P 13
To use optional air inlet (J), see page 22.
TI4969b
Setup
8. To adjust purge rod position, follow piston and
purge rod disassembly instruction on page 39.
9. Attach Gracoapproved groundedfluid supply hose
to solvent inlet (Y). Make sure solvent purge valve (V) is closed before pressurizing the solvent hose.
Y
To avoid getting mixed coating material in the sol­vent purge valve and line.
Pressurize the solvent line before trigger­ing the gun.
Have an adequate solvent supply before spraying.
Keep air purged out of solvent hose.
Install an accessory check valve at purge valve inlet.
Never trigger gun with solvent valve open.
V
TI5004b
12. Disengage piston safety lock (L), page 10.
L
TI3849a
13. Turn RAC tip (X) to spray position.
X
TI5096b
14. Test spray onto cardboard. Adjust pressure,
temperature, or orifice size to get desired results. If applying materials that are greater than 1:1 ratio, follow the instructions for increas­ing orifice size, see Drilling of Mix Modules, page 15.
10. Turn on proportioner.
TI3861a
11. Open B (RESIN) fluid valve. Then open A (ISO)
fluid valve.
15. Apply layer of lubricant over front of gun and
lock ring, or use gun cover to prevent overspray buildup and ease disassembly.
16. Gun is ready to spray.
B
A
14 310648P
TI4970b

Hand Drilling of Mix Modules

Hand Drilling of Mix Modules
To balance pressure and
flow at the mix gun
Graco only makes 1:1 ratio mix modules. When apply­ing a material that is different than 1:1 it is necessary to modify the mix module to allow more material through the larger part side.
The actual size of the orifice required is dependent on
many factors such as material viscosity, shear, ratio tip size, etc. For example, a 2:1 material by volume does not necessarily require the diameter on the larger part side to be doubled.

CheckValve Filter Option

See Check Valve Filter Screens, page 52. Gun is shipped with 80 mesh filters on both the A and B check valves. 40 mesh (quantity 2) and 60 mesh (quantity 2) filters are included with the gun. For wider ratio materi­als it is advisable to decrease the filter size on the larger part side to decrease pressure drop.
4. Locate the larger part side (typically the B [RES]
port at rear of Polycarballoy Mix Module).
Polycarballoy Mix Module cross section.
NOTE: View is not to scale.
A(ISO)
TI3876a
B (RES)
Mix Module XF1313

Tools required

Assorted Drill Bit Kit 119386
Pin Vise 117661 Two XF1313 Polycarbolloy mix modules are
included with the gun. Additional mix modules are available, see page 50.
Larger Modules XF3535, XF4747, XF5757 are available but not included with gun.
1. Follow Pressure Relief Procedure, page 19.
2. Flush Gun, page 24.
3. Remove Polycarballoy Mix Module, see page 34.
5. Open up resin porting to raise ISO pressure. Start-
ing with the smallest drill bit size,drill into port. For drill bit sizes, see Drill BitTable, page 16.
B (RES)
117661 Pin Vise
TI3862a
310648P 15
Hand Drilling of Mix Modules
When drilling, be careful not to allow bit to come in contact with ID of mix module.
The largest drill size that can be used on the XF1313 mix module is #56. To get more flow, order a larger mix module: XF3535, XF4747, XF5757
6. Reassemble gun, page 34.
7. Check pressure gauges. A (ISO) and B (RES)
gauges should balance at the required pressure, flow, and temperature operation points.
8. If ISO gauge still reads lower than the RESIN,
repeat steps 1 through 7. Use the next drill bit size for drilling the B (RES) port on the mix module.
9. If you get the system pressure balanced but do not
have enough flow at the gun, drilling port A (ISO) may be necessary. Drill port A (ISO) out to next size. Repeat steps 1 through 8 to bring the pres­sure gauges back into balance.
Module Port Drill Bit Size
A B
Drill BitTable
Drill Bit Sizes
# size Diameter (in.) Diameter (mm)
81 0.013 0.33 80 0.0135 0.34 79 0.0145 0.37 78 0.016 0.41 77 0.018 0.46 76 0.02 0.51 75 0.021 0.53 74 0.0225 0.57 73 0.024 0.61 72 0.025 0.64 71 0.026 0.66 70 0.028 0.71 69 0.0292 0.74 68 0.031 0.79 67 0.032 0.81 66 0.033 0.84 65 0.035 0.89 64 0.036 0.92 63 0.037 0.94 62 0.038 0.97 61 0.039 0.99 60 0.04 1.02 58 0.042 1.07 56 0.0465 1.18
A (ISO)
TI3863a
10. Repeat drilling until system pressures are bal-
anced.
11. After system pressures are balanced, record the
final drill bit sizes for each port in the chart below. Use this information when it is time to replace the Polycarballoy Mix Module.
16 310648P

Operation

Operation

Spraying

1. To spray, turn RAC tip (X) to spray position.
X
2. Close solvent purge knob (V).
V
TI5004b
2. Turn RAC tip (X) to clean position.
TI5097b
X
TI5096b
3. Hold gun into a grounded metal pail, holding a
metal part of fluid manifold firmly to side of pail.
4. Open the solvent purge knob (V) to introduce sol-
vent to the static mixer assembly.
3. Trigger gun to spray.
WARNING
Read warnings page, 4.

Flushing with Solvent Purge Assembly

1. Detrigger the gun and engage safety lock.
V
TI5110b
5. When static mixer and tip are clean, close solvent
purge knob (V).
V
For more thorough static mixer cleaning, remove the spray tip.
Minimize the amount of flushing time. Do not atomize solvent.
TI5004b
310648P 17
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