Graco 309518P User Manual

Repair

™

Xtreme Mix

Plural Component Proportioner For spraying two-component protective coatings.

Not approved for use in explosive atmospheres.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions

See page 3 for model information, including maximum working pressure and approvals.

309518P

ENG

Contents

Xtreme Mix Models . . . . . . . . . . . . . . . . . . . . . . . . . 3

Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 4

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 7

Proper Lifting of Unit . . . . . . . . . . . . . . . . . . . . . . . . 8

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Metering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Turbine Alternator . . . . . . . . . . . . . . . . . . . . . . . . 9

Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Pump Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Replacing Air Filter Element . . . . . . . . . . . . . . . 16

User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Pneumatic Control . . . . . . . . . . . . . . . . . . . . . . 20

Pump Air Manifold . . . . . . . . . . . . . . . . . . . . . . . 22

Sampling Valve . . . . . . . . . . . . . . . . . . . . . . . . . 23

Metering Valve/Manifold Assembly . . . . . . . . . . 24

Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . 28

Pneumatic Schematic . . . . . . . . . . . . . . . . . . . . . . 30

Pneumatic/Sensor Connections . . . . . . . . . . . . . 31

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Metering Valve Manifold 245824 . . . . . . . . . . . . 41

Metering Valve Manifold 248843 . . . . . . . . . . . . 41

Sampling Valve 245143 . . . . . . . . . . . . . . . . . . 41

Repair Kit 249406 . . . . . . . . . . . . . . . . . . . . . . . 41

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 48

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 48

2 309518P

Xtreme Mix Models

WARNING

Do not install equipment approved only for non-hazardous location in a hazardous area. Substitution of components may impair intrinsic safety. See page 5.

Approved for Non-hazardous Location

Xtreme Mix Models

Xtreme

Mix

Part No. Series

233863 A 249274 45:1 King 4500 (31, 310) 233864 A 249275 56:1 King 5600 (38.6, 386) 233865 A 249276 68:1 King 6800 (46.9, 469) 233866 A 249277 80:1 King 7250 (50, 500) 233867 A 249278 45:1 Quiet King 4500 (31, 310) 233868 A 249279 56:1 Quiet King 5600 (38.6, 386) 233869 A 249280 68:1 Quiet King 6800 (46.9, 469) 233870 A 249281 80:1 Quiet King 7250 (50, 500)

*248842 A 249276 68:1 King

*Model 248842 is designed for remote feed pumps and a remote mix manifold. It does not include hoppers, mix

manifold, hose, or spray gun. Refer to manual 310794 for application layout.

Model 248842 is limited to 5000 psi (34.5 MPa, 345 bar) for use in “quick set” packages where heated hoses, whip hoses, and spray accessories are limited to 5000 psi (34.5 MPa, 345 bar). If all your downstream components are rated for 7000 psi (48 MPa, 483 bar), you can replace the standard relief valve with relief valve

113498.

Pump

Part No.

Pump

Description

Remote Mix

Maximum Working

Pressure

psi (MPa, bar) Approvals

5000 (34.5, 345)

309518P 3

Manual Conventions

WARNING

Hazard Symbol

Note

Additional helpful information.

WARNING: a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Warnings in the instructions usually include a symbol indicating the hazard. Read the general Warnings section for additional safety information.

CAUTION

CAUTION: a potentially hazardous situation which, if

not avoided, may result in property damage or destruction of equipment.

Components A and B

IMPORTANT!

Material suppliers can vary in how they refer to plural component materials.

Be aware that in this manual:

Component A refers to resin or major volume. Component B refers to catalyst (curing agent) or minor

volume.

Related Manuals

Component Manuals This manual available in following languages:

Manual Description

309535 Xtreme Mix Operation 311762 Xtreme Displacement Pump 309347 King Air Motor

or 309348 King Quiet Air Motor

312145 XTR Spray Gun 309524 VISCON HP Heater 309525 Heated Hose Kit 308981 Husky 716 Diaphragm Pump 309615 Heater Bracket Kit 309568 Remote Manifold Kit 310797 Remote Mix Manifold 310794 Remote Mix Proportioning Systems 310863 Feed and Flush Kits 309827 Air Supply Kits

Manual Language Manual Language

309518 English 309609 Italian 309564 French 309610 Finnish 309565 Brazilian

Portuguese 309566 Spanish 309612 Chinese 309567 German 309613 Korean 309608 Greek 309614 Japanese 310752 Dutch 310753 Norwegian 310777 Danish

309611 Swedish

4 309518P

Warnings

The following general warnings are related to the safe setup, use, grounding, maintenance, and repair of this equipment. Additional more specific warnings may be found throughout the text of this manual where applicable.

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.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Ground equipment and conductive objects in work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• 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.

ELECTRIC SHOCK HAZARD

Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment.

• Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Do not point 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 spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.

MOVING PARTS HAZARD

Moving parts can pinch 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 in this manual. Disconnect power or air supply.

309518P 5

Warning

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system com-

ponent. See Technical 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.

• Check equipment daily. Repair or replace worn or damaged parts immediately.

• Do not alter or modify equipment.

• For professional use only.

• Use equipment only for its intended purpose. Call your Graco distributor for information.

• 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.

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.

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 MSDS’s to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

•Gloves

• Hearing protection

RECOIL HAZARD

Gun may recoil when triggered and cause you to fall and be seriously injured if you are not standing securely.

6 309518P

Pressure Relief Procedure

WARNING

Follow Pressure Relief Procedure when you stop spraying and before cleaning, checking, servicing, or transporting equipment. Read warnings, page 5.

1. Engage trigger lock.

2. Press Stop .

SUPPLY AIR PRESSURE

PLURAL COMPONENT PROPORTIONER

3. Close main air shutoff valve on air supply line and on unit. Turn off air regulator.

4. Close fluid sampling and shutoff valves A and B.

6. Hold a metal part of the gun firmly to a grounded metal pail. Trigger gun to relieve pressure.

TI5046A

7. Engage trigger lock.

8. Place waste container under sampling valves, then open valves A and B slowly to relieve pressure between pump and metering valve.

Open

PSI Bar MPa

5. Disengage trigger lock.

9. Close sampling valves A and B.

Close Close

309518P 7

Proper Lifting of Unit

WARNING

Follow instructions below to avoid dropping or swinging unit or being struck by the cart handle, which can cause serious injury or damage to equipment.

Either remove the cart handle or secure it to the cart before lifting the unit. Connect a bridle swing, hooking an end to each of the Xtreme Mix air motor rings. Hook the center ring on a hoist. See F Xtreme Mix unit; make sure it balances evenly.

IG. 1. Carefully lift the

Grounding

WARNING

Read warnings, page 5.

If the Xtreme Mix ground wire clamp (G) is disconnected during repair, be sure to reconnect it to a true earth ground before starting operation.

FIG. 1

IG. 2

8 309518P

Shutdown

Follow this procedure before prolonged shutdown or servicing equipment.

If your system includes heaters and heated hose, make sure they are turned off and cool before flushing.

1. Follow Pressure Relief Procedure, page 7. Engage

trigger lock, turn off air regulator, and close main air shutoff valve. Remove spray tip.

PSI Bar MPa

2. Follow Full System Flushing procedure in the

Xtreme Mix Operation manual.

TI5193

Maintenance

Metering Valve

• Fill metering valves A and B packing nuts (627) with throat seal liquid (TSL) and tighten 1/4 turn after nut contacts packings; about 145-155 in/lbs (16-18 N•m). Check packing nut tightness after first hour of operation, again after 24 hours, then check as needed (when TSL discolors or seeps over packing nut). Also check tightness whenever unit is transported.

• Recommend that you replace metering valve packings every other time that pump packings are replaced.

627

3. Follow Pressure Relief Procedure, page 7.

Engage trigger lock.

4. Before prolonged shutdown: cap fluid outlets to keep solvent in the lines. Fill pump A and B packing nuts with throat seal liquid (TSL); follow instructions in pump manual.

Pump

See pump manual.

Turbine Alternator

Replace bearings every 2000 hours. See page 20.

Air Filters

Check daily. Drain and clean as necessary. See page

16.

309518P 9

Pump Test

Follow this procedure the first time system is operated (after flushing and priming) and whenever you need to check whether pumps are on ratio.

The following table shows the volume dispensed during the pump test, based on your pump ratio. Dispense into a container with adequate graduations.

Pump Volume Dispensed

45:1 750 cc 56:1 660 cc 68:1 540 cc 80:1 435 cc

1. Turn knob to pump test . Turn off air regulator. Open main air shutoff valve. Adjust air pressure to 50 psi (0.35 MPa, 3.5 bar).

c. Press Start . Pump A light comes on.

d. Slowly open and adjust sampling valve A to

achieve desired flow. The pump stops automatically when dispense is complete. Pump A light turns off, Pump B light comes on.

PSI Bar MPa

Open

PSI Bar MPa

2. Dispense fluid A: a. Close fluid shutoff valves and sampling valves A

and B.

b. Place a clean 1 quart (1000 cc) container under

sampling valve A.

a. a. b.

3. Close sampling valve A.

4. Dispense fluid B as follows: a. Place a clean 1 quart (1000 cc) container under

sampling valve B.

b. Slowly open and adjust sampling valve B to

achieve desired flow. The pump stops automatically when dispense is complete. Pump B light turns off.

Open

10 309518P

5. Close sampling valve B.

6. Compare fluid amounts in the containers; they should be equal. Repeat test if fluids are not equal. If problem still persists, see Troubleshooting, page

12.

Pump Test

309518P 11

Troubleshooting

WARNING

If an error code displays, see page 15.

Read warnings, page 5.

Problem Cause Solution

Display not lit. No electric power.

Pumps do not run.

Pump test volume is not correct. Air pressure to pumps too low Increase pressure to 50 psi (0.35 MPa,

Air valve not turned on. Turn on main air valve to system. Air supply pressure too low. Increase pressure to 50 psi (0.35 MPa,

3.5 bar) or greater.

Air supply filters plugged. Clean filter bowls; replace filter elements.

Page 16. Turbine air regulator set too low. Adjust to proper setting. Turbine alternator failure. Repair or replace turbine. Page 20. Power supply not connected to main

board. Main board not connected to display

board.

Display board failure. Replace display board. Page 18.

Knob set to cycle counter Air pressure to pumps too low Increase pressure to 50 psi (0.35 MPa,

Air pilot lines are obstructed Check pilot lines for kinks or pinches. Solenoid valve stuck. Actuate solenoid manually, if it does not

Air pilot valve(s) to motor stuck. Replace valve(s). Page 22. Metering valve(s) not opening. Service or replace valve(s). Page 24.

Sensors not functioning properly. Check position of sensors. See page 27.

Pump cavitating excessively. Check for air in lines caused by loose fit-

Check power connections to main board.

See Electrical Schematic, page 28.

Check electrical connections between

display and main board. See Electrical

Schematic, page 28.

Set knob to desired setting.

3.5 bar) or greater.

operate, replace solenoid. Page 21.

3.5 bar) or greater.

Check board calibration and recalibrate if

necessary. See page 19.

Replace sensors. Page 27.

ting or use of agitator.

Material too viscous. Use heater.

12 309518P

Troubleshooting

Problem Cause Solution

Paint does not cure consistently. Ratio not set correctly. Check that correct ratio is set and set by

volume. See Xtreme Mix Operation manual.

Material not mixing correctly. Test pump. Page 10.

Make sure mixer is clean; flush as needed. See Xtreme Mix Operation manual.

Pump not operating correctly. Observe whether pumps are loading and

checking correctly, if not, clean and repair pump. See pump manual.

Poor spray pattern. Fluid pressure too low. Increase pump pressure.

Spray tip dirty or worn. Relieve pressure. Clean or replace tip.

Follow gun manual instructions. Fluid A or B filters plugged. Clean filters. See pump manual. Mixer or hoses partially plugged or too

restrictive.

System runs erratically. Air filter(s) clogged. Replace elements. Clean. Replace element(s). See page 16.

Air supply hoses undersized. Replace hoses with appropriate size. Air compressor undersized. Use larger air compressor. Air supply pressure tank undersized. Use larger pressure tank.

Air supply relief valve opens. Turbine air regulator set too high. Lower setting to 23-25 psi (172-241 kPa,

Turbine alternator makes high-pitched whining noise.

Display shows 88888 or unit reboots unexpectedly.

Xtreme Mix does not start when start button is pressed.

Fluid valves leaking. Loose or worn packings. Tighten packing nut. If leak continues,

Turbine bearings worn. (Setting turbine air regulator too high, wears bearings.)

Turbine is not supplying enough power to board.

Faulty start switch or wire harness. Check start switch and wiring harness

Faulty stop switch or wiring harness. Check stop switch and wiring harness

Bad I/O port on main board. Replace board. Page 17.

Inspect parts for cured material. Clean or

replace, or use larger hoses and mixer.

1.7-2.4 bar).

Replace bearings. Page 20.

Increase turbine regulator setting to

23-25 psi (172-241 kPa, 1.7-2.4 bar).

Check turbine and electrical control

exhaust air for restrictions.

Replace turbine bearings. Page 20.

continuity; switch is normally open circuit.

See Electrical Schematic, page 28.

continuity; stop switch is normally closed

circuit. See Electrical Schematic, page

28.

replace packings. Page 24.

309518P 13

Troubleshooting

Problem Cause Solution

Flow rate too low. Inadequate air supply. Use larger CFM compressor.

Air pressure to pumps too low. Increase pressure. Fluid A or B filters plugged. Clean filters. See pump manual. Spray tip too small. Relieve pressure. Install larger tip. Follow

gun manual instructions.

Mixer or hoses partially plugged or too restrictive.

Inspect parts for cured material. Clean or replace, or use larger hoses and mixer.

Pump stops after 12 cycles.

Xtreme Mix makes chirping noise every 60 seconds.

Knob is set to

independently.

Knob is set to

independently.

Run pump A or B

Material too heavy to siphon or gravity feed.

Turn knob to spray

if spraying mate-

rial.

Turn knob to spray

if spraying mate-

rial.

Change material feed/supply method.

14 309518P

Alarms

• An alarm condition will shutdown the equipment.

• A chirping sound every 60 seconds indicates

* Indicates error where audible alarm sounds once briefly.

** Indicates error where audible alarm sound pulses.

the unit is set for recirculation mode.

Code Alarm Active Problem Cause

Startup Errors

01 Sensor Error A* Always No signal from pump A sensor. Loose cable, failed sensor or cable.

Page 27.

02 Sensor Error B* Always No signal from pump B sensor. Loose cable, failed sensor or cable.

Page 27.

03 Controller Error* Always Loss of communication between main

and display boards.

Operating Errors

04 Pump Runaway A** Spray 05 Pump Runaway B**

06 Pump Error A** Spray 07 Pump Error B**

08 Sensor Code Error Always Software boot, sensor values reverted to

09 Metering Error A** Spray A dose too great. Metering valve A leak. Page 24.

Te st

Batch

Te st

Batch

Pump running too fast.

This alarm is not active when pumps are run independently.

Pump does not stall after top change over.

Pump cavitating excessively.

default.

Loose cable, failed board. Page 17.

Empty fluid reservoir(s).

Clogged fluid filter.

Hose rupture after mix manifold.

Sampling valve open too far.

Excessive cavitation. Foot valve leak.

Air in lines caused by loose fitting or use of agitator.

Empty fluid reservoir(s). Sensor value data corrupt; board

needs replacement and /or recalibration. Page 17-19.

Empty B fluid reservoir.

10 Metering Error B** Spray B dose too great. Metering valve B leak. Page 24.

Empty A fluid reservoir. 11 Sensor Reading Low A* Always Pump stroke travels beyond sensor 12 Sensor Reading Low B*

13 Sensor Reading High A* Always Pump stroke travels beyond sensor 14 Sensor Reading High B*

range at bottom change over.

range at top change over.

Sensor or bracket loose. Page 27.

Sensor magnet dirty.

Sensor or bracket loose. Page 27.

Sensor magnet dirty.

Testing Error

15 Piston packing/ball A* Test Pump does not completely stall in up 16 Piston packing/ball B* 17 Inlet Ball A* Test Pump does not completely stall in down18 Inlet Ball B* 19 Metering Valve A* Test Pump does not completely stall in both 20 Metering Valve B*

309518P 15

stroke.

up and down strokes.

Piston packing or ball check failure.

Foot valve ball check failure.

Throat packing or metering valve fail-

ure. Page 24.

+ 33 hidden pages