Graco 309535L User Manual

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Page 1

Operation

™

Xtreme Mix

Plural Component Mixer with stand. For professional use only. 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.

United States Patent Number: 6,896,152 Chinese Patent Number: ZL02823545.2 Korean Patent Number: 10-0967987 European Patent Numbers: 126418, 145567, 1762138

309535L

ENG

Page 2

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

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)

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Page 4

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 supplier s 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.

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Page 5

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.

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Page 6

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.

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Page 7

Warning

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Page 8

Overview

Usage

The Xtreme Mix can mix most two-component epoxy and urethane paints. Only Model 248842 is for use with “quick-setting” paints (those with a pot life of less than 15 minutes). Other models cannot be used with such paints without modification. Contact your distributor for information.

The Xtreme Mix is operated with the User Interface, Air Controls and Fluid Controls, described below and on page 9. Refer to F

IG. 1 and FIG. 2.

User Interface

The User Interface has 6 main interfaces.

1. Knob to select functions:

Icon Function

Spray: proportion and spray material

Run pump A: operate pump A independent

of pump B (priming, flushing) for 12 cycles Run pump B: operate pump B independent

of pump A (priming, flushing) for 12 cycles Batch Dispense: dispense proportioned

amounts of A and B Pump Test: dispense predetermined

amount of A and B to verify pump operation and metering

Cycle Counter: totalize A and B pump cycles

3. Stop button to terminate functions

4. Key switch to change ratio or reset pump cycle

counter

5. Display (five-digits) to view:

•Ratio

• Alarm codes

• Pump cycles

The display includes an alarm code label in English. See page 2 to order additional languages.

6. Data port allows for connection to a PC serial port

to download cycle count, operation, ratio setting, and error alarm data.

WARNING

The PC must be in a non-hazardous location and a safety barrier must be installed between the PC and Xtreme Mix unit. See Xtreme Mix software manual.

PSI Bar MPa

PSI Bar

When run independently, A and B light indicators (L) will show which pump is running.

MPa

IG. 1

2. Start button to initiate functions

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Page 9

Overview

Air Controls

A. Main air shutoff valve (bleed-type) to shutoff all

air to Xtreme Mix (including controller power)

B. Supply air pressure gauge to monitor air pressure

to Xtreme Mix

A minimum air pressure supply of 50 psi (0.35 MPa, 3.5 bar) must be maintained for the Xtreme Mix to operate properly.

C. Pump air pressure regulator with gauge to adjust

and monitor pump air pressure

Push in regulator knob to lock setting. Be careful when pulling knob out to change setting as knob is removable. To reinstall, push knob to snap into place.

PSI Bar MPa

Solenoid Module

There are 4 solenoids inside the controller.

FIG. 3

Solenoid ON/OFF for:

1 Metering valve A 2 Metering valve B 3 Pilot valve A - turns pump A ON/OFF 4 Pilot valve B - turns pump B ON/OFF

IG. 2

Fluid Controls

PSI Bar MPa

D. Sampling valves A and B to batch dispense or test

pumps

E. Shutoff valves A and B to shutoff fluid A or B from

entering the fluid manifold

There are 2 metering valves, one for fluid A (F1) and one for fluid B (F2). The metering valves are turned on and off by solenoids 1 and 2.

A Side

B Side

IG. 4

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Page 10

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.

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2. Press Stop .

SUPPLY AIR PRESSURE

PLURAL COMPONENT PROPORTIONER

6. Hold a metal part of the gun firmly to a grounded

metal pail. Trigger gun to relieve pressure.

7. Engage trigger lock.

ti1949a

8. Place waste container under sampling valves, then

open valves A and B slowly to relieve pressure between pump and metering valves.

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.

PSI Bar MPa

5. Disengage trigger lock.

ti1950a

Open

9. Close sampling valve A and B.

Open

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Page 11

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. 5. Carefully lift the

1. Grounding: Connect Xtreme Mix ground wire clamp

(G) to a true earth ground.

ti2218a

2. Model 248842 Only: This model uses a remote mix

manifold, which is connected to the unit by at least 50 ft. (15 m) of individual fluid hoses. Refer to manuals 310794 and 310797 for typical setups.

All Other Models: The 50 ft. (15 m) fluid hose (W), static mixer (X), whip hose (Y), and gun (Z) come assembled. Note the order of connection.

CAUTION

Do not assemble static mixer (X) directly to fluid manifold. Install static mixer after first 50 ft. (15 m) of hose to ensure material is completely mixed. Spraying unmixed material could necessitate rework of part sprayed.

ti2319a

IG. 5

Setup

WX Z Y

WARNING

Do not install equipment approved only for non-hazardous location in a hazardous area. Substitution of components may impair intrinsic safety. Read warnings, page 5. Ground equipment as instructed below.

If connecting PC for data download, PC must be in non-hazardous location and a safety barrier must be installed. See Xtreme Mix software documentation.

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Page 12

Setup

3. Connect the fluid hose (W) to the fluid manifold out-

let (J). Do not install gun spray tip yet.

4. Tighten all fittings on unit.

5. Fill pumps A and B packing nuts with throat seal liq-

uid (TSL) and torque to 25-30 ft-lb (34-41 N•m). Follow instructions in pump manual.

6. Fill metering valves A and B packing nuts (H) 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.

7. Connect air supply line to 3/4 npt(f) air filter inlet (F).

Air supply requirement: 110 psi (0.8 MPa, 8 bar) maximum, 50 psi (0.35 MPa, 3.5 bar) minimum

Flow volume required: 60 scfm minimum; 250 scfm maximum

Model 248842 is designed to use Air Supply Kit

248827.

TI2218A

8. Turn off air regulator. Open main air shutoff valve.

When starting up, display will show “88888”, then software revision, then current ratio.

PSI Bar MPa

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Page 13

Setup

9. Setup ratio.

a. Turn knob to spray .

b. Current ratio displays.

c. Turn key to +, hold for 1 second, then turn back

to neutral (vertical) to increase ratio by 0.1. Turning key to + increases ratio by increments of 0.1 until key is turned back to neutral (vice versa when key is turned to –).

To decrease ratio, follow same pattern as increasing, only turn key to –.

+–

2.0:1

10.Flush and prime system. See pages 14 and 18. Run

Pump Test, page 20 to check ratio accuracy.

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Page 14

Flushing

There are times when you only want to flush the fluid manifold, such as:

• breaks in spraying

• overnight shutdown

• end of potlife

In this manual, that procedure is referred to as Fluid Manifold Flushing. You can flush the fluid manifold by connecting either a:

• solvent pump to the fluid manifold or

• hose and solvent siphon tube to pump A

Other times, you need to flush the entire system:

• first time material is loaded into equipment*

• color change

•servicing

• shutting down equipment for more than 24 hours

• putting equipment into storage

* Some Full System Flushing steps are not necessary for

initial flushing, as no material has been loaded into the system yet.

Fluid Manifold Flushing

Model 248842 Only: Follow the flushing procedure

in the Remote Manifold manual 310797.

Using Solvent Pump

1. Press Stop to turn off proportioner. Follow Pres-

sure Relief Procedure, page 10. Engage trigger

lock. Remove spray tip.

ti1949a

2. Close sampling valves and fluid shutoff valves A and

TI1948A

To flush the entire system, you first follow the Fluid Manifold Flushing procedure, at right, then the Full System Flushing procedure, page 16.

WARNING

Read warnings, pages 5-6.

• If your system includes heaters and heated hose, turn them off and allow to cool before flushing. Do not turn on heaters until fluid

lines are clear of solvent.

• Use the lowest possible pressure when flushing to avoid splashing.

• Before color change or shutdown for storage, flush at a higher flow rate and for a longer time.

• To only flush fluid manifold, see following procedure.

• A circulation setting is available. Consult your distributor. Refer to page 25.

3. Connect a shutoff valve (V) to the fluid manifold inlet

on the A side as shown below (valve shown closed). Connect solvent pump line to the shutoff valve. Turn on solvent pump and open solvent shutoff valve.

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Page 15

Flushing

4. Adjust regulator to desired pressure; use lowest

pressure possible.

5. Disengage trigger lock and trigger gun into a

grounded pail. Flush out mixed material until clean solvent dispenses. Engage trigger lock.

ti1950a

ti1953a

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6. Shut off solvent pump and close solvent shutoff

valve.

Using Solvent Siphon Tube

1. Press Stop to turn off pumps. Follow Pressure

Relief Procedure, page 10. Engage trigger lock.

Remove spray tip.

ti1949a

TI1948A

2. Connect fluid hose with solvent siphone tube to

pump A 3-way ball valve. Put solvent siphon tube into a grounded solvent pail.

7. Follow Pressure Relief Procedure, page 10.

Engage trigger lock.

ti1953a ti1949a

3. Turn pump A 3-way ball valve to open suction tube

line, as shown below. Arrow on handle shows direction of flow.

Suction Tube Line

4. Open main air shutoff valve. Open shutoff valve A.

Close sampling valves A and B.

PSI Bar MPa

Open

PSI Bar MPa

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Page 16

Flushing

5. Turn knob to pump A . Press Start . Slowly

turn up air regulator until pump A starts.

PSI Bar MPa

2. Place beakers under fluid sampling valves. Open

main air shutoff valve. Open fluid sampling valves A and B.

PSI Bar MPa

Open

PSI Bar MPa

6. Disengage trigger lock and trigger gun into a

grounded pail until clean solvent dispenses.

ti1950a

ti1953a

7. Engage trigger lock. Press Stop to turn off pro-

portioner.

8. Follow Pressure Relief Procedure, page 10.

Full System Flushing

1. Follow Pressure Relief Procedure, page 10.

Engage trigger lock. Turn off air regulator and close main air shutoff valve. Remove spray tip and soak in solvent.

PSI Bar MPa

3. Turn up air regulator. Pump A and B reservoirs

empty, salvaging the material in separate, clean containers.

4. Add solvent to A and B reservoirs.

5. Close sampling valves. Set air regulator to 50 psi

(345 kPa, 3.4 bar).

6. Turn knob to pump A . Press Start .

PSI Bar MPa

When run independently (set to or ), the

A B

pump runs for 12 cycles, then stops. Press Start and Stop as needed to clean.

PSI Bar MPa

ti1949a

7. Open sampling valve A. Pump material through

TI1948A

sampling valve A until clean, then press Stop .

If the pump does not start when you open the sampling valve, increase the air pressure by 10 psi (69 kPa, 0.7 bar) increments; to avoid splashing, do not exceed 70 psi (483 kPa, 4.8 bar). If the pump still does not start, the solvent may have caused

16 309535L

your packings to swell and it is recommended you use Tuff Stack

™

Packing Kit 244900.

Page 17

8. Repeat steps 5 and 7, using pump B setting

and sampling valve B, then press Stop .

PSI Bar MPa

Flushing

12.Trigger gun into grounded pail. Run pump until clean

solvent dispenses, then press Stop .

ti1953a

9. Remove fluid filter and soak in solvent. Replace filter

cap.

10.Close sampling valves A and B.

11.Turn knob back to pump A . Press Start .

PSI Bar MPa

13.Repeat steps 11 and 12, using pump B setting,

then press Stop .

PSI Bar MPa

14.Follow Pressure Relief Procedure, page 10, and

remove gun from hose. See gun manual to further clean gun.

15.Clean hoppers as needed. Empty out solvent.

Some materials require additional cleaning. You may need to recirculate solvent through the system or disassemble the hopper, 3-way valve, and strainer to clean them.

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Page 18

Priming

WARNING

Wear gloves if fluid temperature exceeds 110° F (43° C).

Do not install the gun spray tip yet. Use the lowest possible pressure to prime to avoid splashing.

1. Fill A and B reservoirs (R) with proper materials.

ti2318a

3. Turn off air regulator. Close fluid shutoff valves A and

PSI Bar MPa

4. Place a container under each sampling valve. Open

sampling valve A slowly.

Open

2. Turn both 3-way ball valves to open reservoir lines

as shown below. Arrow on handle shows direction of flow.

ti2320a

When run independently (set to or ), the

A B

pump runs for 12 cycles, then stops. Press Start and Stop as needed to prime.

Monitor containers to avoid overflowing.

5. Turn knob to pump A . Press Start . Turn up

air regulator slowly until pump A starts.

PSI Bar MPa

18 309535L

Page 19

Priming

6. When side A is primed, turn off air regulator. Close

sampling valve A. Open sampling valve B slowly.

PSI Bar MPa

Open

7. Turn knob to pump B . Press Start . Turn up

air regulator slowly until pump B starts.

PSI Bar MPa

8. When side B is primed, Stop and close sam-

pling valve B.

309535L 19

Page 20

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 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

For accurate ratios, pump lowers must be same size on both sides.

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

3. Close sampling valve A.

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.

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

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Page 21

Pump Test

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 persists, see Troubleshooting in Xtreme Mix Repair Manual.

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Page 22

Spraying

WARNING

Wear gloves if fluid temperature exceeds 110° F (43° C).

1. If heaters are used, turn them on. Operate heaters

as instructed in their manuals.

2. Close sampling valves A and B. Open shutoff valves

A and B.

Open

ti2249a

5. Engage trigger lock. Press Stop .

PSI Bar MPa

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6. Follow Pressure Relief Procedure, page 10.

7. Engage trigger lock. Install tip on gun.

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3. Turn knob to spray . Press Start .

PSI Bar MPa

4. Trigger gun into a pail and slowly increase air regula-

tor pressure until pump is running and clean material is dispensed.

PSI Bar MPa

ti1953a

8. Adjust air regulator to the necessary spraying pres-

sure and apply the coating. Refer to Mix and Integration Tests, page 23.

9. Follow Fluid Manifold Flushing, page 14, or Shut-

down, page 25, when you are done spraying or

before potlife expires.

Mixed material potlife or working time decreases with increased temperature.

22 309535L

Page 23

Mix and Integration Tests

Use the following tests to check for proper mix and integration.

Butterfly Test

WARNING

Follow Pressure Relief Procedure, page 10, before removing spray tip. Read warnings, page 5.

At low pressure, normal flow rate, and without a spray tip installed, dispense a 1/2” (12.7 mm) bead of material onto foil until multiple changeovers of each pump have occurred. Place a second sheet of foil over the first then peel it back and look for unmixed material (appears marble-like).

Curing Test

Spray a single continuous pattern on foil at typical pressure setting, flow rate, and tip size until multiple changeovers of each pump have occurred. Trigger and de-trigger at typical intervals for the application. Do not overlap or cross over your spray pattern.

Check curing at various time intervals, listed on the material data sheet. For example, check for dry to touch by running your finger along the test pattern’s entire length at the time listed on the data sheet.

Appearance Test

Spray material onto metal substrate. Look for variations in color, gloss, or texture that may indicate improperly catalyzed material.

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Page 24

Batch Dispense or Ratio Check

Batch dispense is always 1 liter of total volume, regardless of ratio setting.

Follow this procedure to dispense a batch (into one container) or verify a ratio setting (use separate container for fluid A and B). Dispense into a container with graduations no greater that 5% of each component.

1. Turn knob to batch dispense . Turn off air regula-

tor. Open main air shutoff valve. Adjust air pressure to 50 psi (0.35 MPa, 3.5 bar).

PSI Bar MPa

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

3. Close sampling valve A.

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.

c. Press Start . Pump A light comes on.

4. Dispense fluid B as follows: a. Batch dispense: move the 1 quart (1000 cc)

container under sampling valve B.

Ratio check: place 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

5. Batch dispense: stir material until mixed.

24 309535L

Ratio check: compare A and B fluid dispense.

Page 25

Pump Cycle Counter

To display total A and B pump cycles since the last reset, turn knob to cycle counter .

To reset the cycle counter to 0, turn the key to – (or 0) while knob is set to cycle counter .

Reset

–

SETUP KEY

DATA PORT

VALVE

Circulation Setting

Fluid can be circulated up to the mix manifold. You can only circulate one fluid component at a time. Additional fluid hardware is required; consult your distributor.

To set the Xtreme Mix to circulate:

5. Depending on the ratio selected, the following will occur:

• 1.0:1 - Air motor pilot valve A and metering

valve A open to run pump A.

• 0.0:1 - Air motor pilot valve B and metering

valve B open to run pump B.

To terminate circulation, press Stop .

To begin circulating again, press Start .

To begin spraying, reset to desired ratio and adjust

pump to spray pressure.

Shutdown

Follow this procedure before prolonged shutdown or servicing equipment.

1. Follow Pressure Relief Procedure, page 10.

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

1. Decrease the pump air pressure supply to the mini-

mum required to maintain the desired circulation volume.

2. Turn knob to spray .

3. To circulate fluid A, set ratio to 1.0:0, which is the

lowest ratio setting

To circulate fluid B, set ratio to 0.0:1, which is the second lowest ratio setting

See page 13 for instructions on setting ratio.

4. Press Start .

PSI Bar MPa

ti1949a

2. Follow Flushing, page 14.

3. Follow Pressure Relief Procedure, page 10.

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.

TI1948A

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Page 26

Alarms

* Indicates error where audible alarm sounds once briefly.

** Indicates error where audible alarm sound pulses.

• An alarm condition will shutdown equipment.

• A chirping sound every 60 seconds indicates the unit is set for circulation (page 25).

• See Xtreme Mix Repair manual for troubleshooting and repair.

Code Alarm Active Problem Cause

Startup Errors

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

10 Metering Error B** Spray B dose too great Metering valve B leak

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

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

Empty B fluid reservoir

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

Sensor magnet dirty

Sensor or bracket loose

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*

26 309535L

stroke

up and down strokes

Piston packing or ball check failure

Foot valve ball check failure

Throat packing or metering valve fail-

ure

Page 27

Performance Charts

45:1 King Pump

Pressure

psi (MPa, bar)

5000

(34, 345)

4500

(31, 310)

4000

(28, 276)

3500

(24, 241)

Performance Charts

100 psi (7 MPa, 7 bar)

3000

(21, 207)

2500

(17, 172)

2000

(14, 138)

1500

(10, 103)

1000

(7, 69)

500

(3.4, 34)

70 psi (483 kPa, 4.8bar)

40 psi (276 kPa, 2.8bar)

0123 45

100 psi (7 MPa, 7 bar), 1:1 ratio

70 psi (483 kPa, 4.8bar), 1:1 ratio

40 psi (276 kPa, 2.8 bar),1:1 ratio

(3.8) (11.4) (15.1) (18.9)(7.6)

4:1 ratio 10:1 ratio

Fluid Flow

GPM (liter/min.)

309535L 27

Page 28

Performance Charts

56:1 King Pump

Pressure

psi (MPa, bar)

6000

(41, 414)

5500

(38, 379)

5000

(34, 345)

4500

(31, 310)

4000

(28, 276)

3500

(24, 241)

3000

(21, 207)

2500

(17, 172)

2000

(14, 138)

1500

(10, 103)

1000

(7, 69)

500

(3.4, 34)

0123 45

100 psi (7 MPa, 7 bar), 1:1 ratio

70 psi (483 kPa, 4.8bar), 1:1 ratio

40 psi (276 kPa, 2.8 bar),1:1 ratio

100 psi (7 MPa, 7 bar)

70 psi (483 kPa, 4.8bar)

40 psi (276 kPa, 2.8bar)

(3.8) (11.4) (15.1) (18.9)

(3.8)

Fluid Flow

4:1 ratio 10:1 ratio

GPM (liter/min.)

28 309535L

Page 29

68:1 King Pump

Pressure

psi (MPa, bar)

7000

(48, 483)

6500

(45, 448)

6000

(41, 414)

5500

(38, 379)

5000

(34, 345)

4500

(31, 310)

4000

(28, 276)

3500

(24, 241)

3000

(21, 207)

2500

(17, 172)

2000

(14, 138)

1500

(10, 103)

1000

(7, 69)

500

(3.4, 34)

0123 45

100 psi (7 MPa, 7 bar), 1:1 ratio

70 psi (483 kPa, 4.8bar), 1:1 ratio

40 psi (276 kPa, 2.8 bar),1:1 ratio

100 psi (7 MPa, 7 bar)

70 psi (483 kPa, 4.8bar)

40 psi (276 kPa, 2.8bar)

(3.8) (11.4) (15.1) (18.9)(7.6)

4:1 ratio 10:1 ratio

Performance Charts

Fluid Flow

GPM (liter/min.)

309535L 29

Page 30

Performance Charts

80:1 King Pump

Pressure

psi (MPa, bar)

6000

(41, 414)

5500

(38, 379)

5000

(34, 345)

4500

(31, 310)

4000

(28, 276)

3500

(24, 241)

3000

(21, 207)

2500

(17, 172)

2000

(14, 138)

1500

(10, 103)

1000

(7, 69)

500

(3.4, 34)

0123 45

70 psi (483 kPa, 4.8bar), 1:1 ratio

40 psi (276 kPa, 2.8 bar),1:1 ratio

70 psi (483 kPa, 4.8bar)

40 psi (276 kPa, 2.8bar)

(3.8) (11.4) (15.1) (18.9)(7.6)

4:1 ratio 10:1 ratio

Fluid Flow

GPM (liter/min.)

30 309535L

Page 31

Technical Data

Mix ratio range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0:1-10:1 (in 0.1 increments)

Ratio tolerance range . . . . . . . . . . . . . . . . . . . . . . . . . . . . +/- 5%

Flow rates

Minimum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 qt./min. (0.95 liter/min.)*

Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 gal./min. (11.4 liter/min.)

Fluid viscosity range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200-20,000 cps (heavier viscosities can be mixed with use

of optional heaters, heated hoses, and hardware)

Fluid filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 mesh, (238 micron) standard on pump outlets (filter

assembly not included on models 248831, 248832, 248833, and 248834)

Air inlet

Model 248842. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

All Other Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model 248842 Fluid inlet. . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npsm union in 1” npt(f) ball valve

Maximum fluid working pressure

45:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4500 psi (31 MPa, 310 bar)

56:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5600 psi (38.6 MPa, 386 bar)

68:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6800 psi (46.9 MPa, 469 bar)

68:1 Model 248842 only . . . . . . . . . . . . . . . . . . . . . . . 5000 psi (34.5 MPa, 345 bar)

80:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7250 psi (50 MPa, 500 bar)

Air supply pressure range . . . . . . . . . . . . . . . . . . . . . . . . . 50-110 psi (345-800 kPa, 3.5-8 bar)

Model 248842: Maximum fluid feed pressure. . . . . . . . . . 500 psi (3.5 MPa, 35 bar)

Maximum air consumption at 100 psi (0.7 MPa, 7 bar) in cfm (m

45:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 (3.1)

56:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 (3.5)

68:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 (4.4)

80:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 (5.1)

Ambient temperature range

Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-130° F (0-54° C)

Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-160° F (–1-71° C)

Environmental Conditions Rating . . . . . . . . . . . . . . . . . . . Indoor/outdoor use

Sound pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 dBA at 100 psi (0.7 MPa, 7 bar)

Wetted parts

Suction tubes (if used) . . . . . . . . . . . . . . . . . . . . . . . . aluminum

Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . carbon steel, alloy steel, 303, 440 & 17-4ph grades stain-

Metering Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . carbon steel, zinc plating, carbide, polyethylene, leather

Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . carbon steel, zinc plating, carbide, 302 stainless steel

Mixer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . stainless steel

Spray gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See gun manual

PC Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-232

Dimensions

Cart model (width x height x diameter) . . . . . . . . . . . 33” wide x 64.53” high x 44.5” deep

Weight (cart, without hose and gun). . . . . . . . . . . . . . 625 lbs. (285 kg)

* Minimum flow rate is dependent on the material being sprayed and mixing capability. Test your material for specific flow rate.

3/4 npt(m) 3/4 npt(f)

/min.)

Altitude up to 4000 meters Maximum relative humidity to 99% up to 54° C Pollution degree (11) Installation category (2)

less steel, zinc and nickel plating, ductile iron, tungsten carbide, PTFE, leather

(83.8 x 163.9 x 113 cm)

309535L 31

Page 32

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to

the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.

Phone: 612-623-6921 or Toll Free: 1-800-328-0211, Fax: 612-378-3505

All written and visual data contained in this document reflects the latest product information available at the time of publication.

Graco reserves the right to make changes at any time without notice.

Original Instructions. This manual contains English. MM 309535

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441

www.graco.com

Revised 01/2011

Graco 309535L User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Related Documentation

Xtreme Mix Models

Manual Conventions

Warnings

Overview

Pressure Relief Procedure

Proper Lifting of Unit

Setup

Flushing

Priming

Pump Test

Spraying

Mix and Integration Tests

Batch Dispense or Ratio Check

Pump Cycle Counter

Circulation Setting

Shutdown

Alarms

Performance Charts

Technical Data

Graco Standard Warranty

Graco Information