Graco 312749G User Manual

Page 1

Instructions - Parts

XM Mix Manifold Kits

For mixing two component reactive materials with XM plural-component sprayers. Not for use on mechanical proportioners. Approved for use in explosive atmospheres.

For professional use only.

312749G

Part No. 255684

Mix Manifold

Part No. 256980

Remote Mix Manifold Conversion Kit with protective guard

7250 psi (50 MPa, 500 bar) Maximum Working Pressure 160°F (71°C) Maximum Fluid Temperature

Important Safety Instructions

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

Mix Manifold and Remote Mix Manifold

Conversion Kit

II 2G c T5

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Related Manuals

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Isocyanate Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Material Self-Ignition . . . . . . . . . . . . . . . . . . . . . . . . 5

Moisture Sensitivity of Isocyanates . . . . . . . . . . . . 5

Keep Components A and B Separate . . . . . . . . . . 6

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . . 6

Component Identification . . . . . . . . . . . . . . . . . . . . 7

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Fluid Inlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Remote Mounted Manifolds . . . . . . . . . . . . . . . . 9

Remote Circulation Control Valves . . . . . . . . . . . 9

Solvent Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Fluid Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Flush Before Using Equipment . . . . . . . . . . . . . . 11

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Pressure Relief Procedure . . . . . . . . . . . . . . . . 12

Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Dispensing and Spraying . . . . . . . . . . . . . . . . . 14

Volume Balancing the Mix Manifold . . . . . . . . . 15

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Remove Restrictor . . . . . . . . . . . . . . . . . . . . . . 19

Assemble Restrictor . . . . . . . . . . . . . . . . . . . . . 20

Assemble Cartridge Assembly . . . . . . . . . . . . . 20

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Clean Static Mixers . . . . . . . . . . . . . . . . . . . . . . 21

Clean “B” Side Screen . . . . . . . . . . . . . . . . . . . 21

Clean Mix Manifold Outlet . . . . . . . . . . . . . . . . . 21

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

255684 Mix Manifold . . . . . . . . . . . . . . . . . . . . . 22

Repair Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Accessory Ports . . . . . . . . . . . . . . . . . . . . . . . . 28

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 30

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 30

Related Manuals

Manuals are available at www.graco.com.

Component Manuals in U.S. English

Manual Description

312359 XM Operation

313289 XM Repair

313292 XM OEM, Instructions-Parts

313342 Dosing Valve, Instructions-Parts

313343

306861

310797 Mix Manifold Kits, Instructions-Parts

307892 Back Pressure Valve Instructions-Parts

High Flow Severe Duty Shutoff Check Valve, Instructions-Parts

Ball Valves, Check Valves, and Swivels, Instructions-Parts

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Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.

WARNING

WARNINGWARNINGWARNING

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.

• When flammable liquid is sprayed or used for flushing or cleaning, keep sprayer at least 20 feet (6 meters) away from explosive vapors.

• 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 all equipment in the 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 working fire extinguisher in the work area.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. 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. For complete information about your material, request MSDS forms from distributor or retailer.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment.

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

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety 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.

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Page 4

Warnings

WARNING

WARNINGWARNINGWARNING

PRESSURIZED EQUIPMENT HAZARD

Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury.

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

• Tighten all fluid connections before operating the equipment.

• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment.

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

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

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.

• Always wear impervious gloves when spraying or cleaning equipment.

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

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Page 5

Isocyanate Hazard

Spraying materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates.

Read material manufacturer’s warnings and material MSDS to know specific hazards and precautions related to isocyanates.

Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not available, a supplied-air respirator is required for everyone in the work area.

To prevent contact with isocyanates, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons, and goggles, is also required for everyone in the work area.

Material Self-Ignition

Moisture Sensitivity of Isocyanates

Isocyanates (ISO) are catalysts used in two component foam and polyurea coatings. ISO will react with moisture (such as humidity) to form small, hard, abrasive crystals, which become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts.

NOTE:

The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature.

To prevent exposing ISO to moisture:

• 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 lube pump reservoir filled with Graco Throat Seal Liquid (TSL), Part 206995. The lubricant creates a barrier between the ISO and the atmosphere.

Some materials may become self-igniting if applied too thick. Read material manufacturer’s warnings and material MSDS.

• Use moisture-proof hoses specifically designed for ISO, such as those supplied with your system.

• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.

• Never use solvent on one side if it has been contaminated from the other side.

• Always park pumps when you shutdown.

• Always lubricate threaded parts with Part 217374 ISO pump oil or grease when reassembling.

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Page 6

Keep Components A and B Separate

NOTICE

To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (isocyanate) and component B (resin) parts. The gun is shipped with the A side on the left. The fluid manifold, fluid housing, side seal assembly, check valve cartridge, and mix chamber are marked on the A side.

Changing Materials

• 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.

• Most materials use ISO on the A side, but some use ISO on the B side.

• Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the B (resin) side.

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Component Identification

P, R

FIG. 1: Typical Installation

Key:

A Resin (High Volume) Supply Hose (A material) B Hardener (Low Volume) Supply Hose (B material) C Resin Adapter Nipple D Hardener Adapter Nipple E Resin Shutoff Handle (blue; A material) F Solvent Inlet Valve, 1/4 npt(m) G Grounded Solvent Hose H Hardener Shutoff Handle (green; B material) J Hardener Restrictor Adjustment K Hardener Screen (inside) L Integrator Hose

M Solvent Check Valve P Hardener Injector (not shown; inside outlet R) R Mix Manifold Outlet, 1/2 npt(f) with 3/8 npt(m) adapter S Static Mixer Housing T Fluid Whip Hose U Airless Spray Gun V Static Mixer Adapter W Static Mixing Element

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Overview

XM plural-component sprayers can mix most two component epoxy and urethane protective coatings. When using quick-setting materials (less than 10 minute pot life) a remote mix manifold must be used.

The left side of the mix manifold is intended for the major volume material, or the higher viscosity material if using a 1:1 volume mix. This side is referred to throughout the manual as the resin side or “A” side.

The right side is referred to as the Hardener side or “B” side. The “B” side incorporates a 40 mesh strainer and an adjustable restrictor for balancing the system back pressure and flow.

See F

. 2 to view flow of A and B material inside the

XM Mix Manifold.

Resin Hardener

The resin and hardener enter the manifold through the manifold inlet ports. The “A” material flows through the manifold to the material outlet port. The injector tube creates a hollow stream of “A” material for the “B” material to fill once the hardener exits the injector tube. The mixed resin and hardener material enters the mix manifold outlet (R) before the mixed material enters the integrator fluid hose. Adjust the restrictor housing to balance the system back pressure and flow.

NOTE: Always use the integration hose, supplied with your XM plural-component sprayer, after the mix manifold.

NOTE: Please follow these recommendations for setup:

• Use at least a 3/8 in. (10 mm) x 25 ft. (7 m) integrator hose.

• Install at least 24-elements of static mixer after the integration hose and before the spray gun whip hose.

Hardener

Resin

Mixed Material

. 2: Cutaway View

8 312749G

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Installation

This manifold is designed for use on proportioning pumps with independent drive motors. Use of this manifold on a mechanically linked sprayer without using mechanically linked on/off A and B valves may cause hazardous fluid pressures that can rupture equipment.

Installation

Machine Mounted Restrictor Valve

When the mix manifold is used remotely a restrictor valve (222200) is added to the B side outlet of the proportioner. This configuration requires that the machine outlet restrictor be used to set the bar graph on the Ratio Mode screen.

Remote Circulation Control

For assistance in setting up a plural component sprayer, contact your Graco distributor, to ensure that you select the proper type and size equipment for your system.

Fluid Inlets

The A and B fluid inlets are equipped with 1/2 npsm unions in 1/2 in. npt(f) ports. Connect 1/2 in., 3/8 in, or 1/4 in. npsm(f) fluid hoses using the two adapter nipples (provided).

Remote Mounted Manifolds

Machine Outlet Check Valves

The XM sprayer must have outlet check valves (CV) in order to accurately measure pump outlet flow. These check valves are provided in the mix manifold when it is mounted on the sprayer.

When the mix manifold is removed and used remotely, you must add outlet check valves on the machine. Use shutoff check valves 255278 as the outlet check valves as provided in conversion kit 256980. The valves act as severe duty check valves when the check valve handle is open. They act as manual shutoff valves when the handle is closed.

Valves

Shutoff check valves (CV) may also be face-mounted on the remote mix manifold to circulate heated material before spraying.

r_255684_256980_312749_4

. 4: Remote Mix Manifold Options on Carriage

. 3: Machine Outlet Check Valves

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Page 10

Grounding

Solvent Inlet

Connect the solvent supply line (G) from the solvent pump to the 1/4 npt(m) solvent inlet valve (F). Use a Graco approved grounded hose rated to withstand the maximum fluid working pressure of the solvent pump. The hose core must be chemically compatible with the solvent being used such as nylon or PTFE.

Fluid Outlet

Connect a 3/8 in. ID x 25 ft. (minimum) integrator hose (L) to the fluid outlet (R). Then connect the static mixers (S) and whip hose (T) to the 3/8 npt(f) integrator hose (L). Two static mixers are often used, in series.

Mounting

To mount the bare manifold, drill four holes in the mounting surface, and secure with four 5/16-18 x 1/2 in. (50 mm) screws. See the following illustration for details and dimensions.

6.38 in. (162.05 mm)

• Mix manifold and solvent flush system: use only a Graco approved grounded solvent hose. Not all heated hoses are grounded, and the mix manifold primary ground is through the solvent hose. Ensure that the solvent pump is properly grounded, as instructed in your solvent pump manual. Ensure there is electrical continuity from the spray tip to the grounded solvent hose.

• Air compressor: Follow manufacturer’s recommendations.

• Spray gun/dispense valve: ground through connection to a properly grounded fluid hose and pump.

• Fluid supply container: follow local code.

• Object being sprayed: follow local code.

• Solvent pails used when flushing: follow local code. Use only conductive metal pails, placed on a grounded surface. Do not place the pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.

• To maintain grounding continuity when flushing or relieving pressure: hold metal part of the spray gun/dispense valve firmly to the side of a grounded metal pail, then trigger the gun/valve.

1.44 in. (36.57 mm)

11/32 diameter

Grounding

Your system must be grounded. Read warnings in your sprayer manual. Check your local electrical code.

• Pump: use a ground wire and clamp as instructed in your sprayer operation manual.

• Air and fluid hoses: use only electrically conductive hoses with a maximum of 500 ft (150 m) combined hose length to ensure grounding continuity. Check electrical resistance of hoses. If total resistance to ground exceeds 29 megohms, replace hose immediately.

Flush Before Using Equipment

The equipment was tested with lightweight oil, which is left in the fluid passages to protect parts. To avoid contaminating your fluid with oil, flush the equipment with a compatible solvent before using the equipment. See Flush, page 12.

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Page 11

Operation

Pressure Relief Procedure

Follow pressure relief procedure when you stop spraying or dispensing; and before cleaning, checking, servicing, or transporting equipment.

Relieve A and B Fluid Pressure

1. Engage trigger lock.

ti1949a

2. Press Stop to turn off sprayer.

3. Close all air motor supply valves or any source of fluid pressure.

7. Disengage trigger lock.

1.440 in.

(36.58 mm)

8 X 5/16-18 UNC 2B

ti1950a

8. Hold a metal part of the gun firmly to a grounded metal pail with a splash guard in place. Trigger gun to relieve pressure in material hoses.

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9. Engage trigger lock.

4. Open A and B circulation valves if equipped. See F

. 3 and FIG. 4 on page 9.

5. If fluid heaters are used, shut them off using the controls on the heater control box.

6. Shut off feed pumps, if used.

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10. Flush mixed material hoses, mixer, and gun. See Flush on page 12.

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Page 12

Operation

Flush

3. Close blue (E) A material and green (H) B material supply valves.

Read warnings and grounding instructions in your sprayer manual. If your system uses heaters, shut off the main power to the heaters and heated hose control before flushing.

NOTICE

To prevent fluid from setting up in the dispensing equipment, flush the system frequently. Be sure there is an adequate amount of solvent in the solvent supply before spraying.

NOTE:

• Ensure flushing fluid is compatible with dispense fluid and the equipment wetted parts.

• Solvent may channel through viscous fluids and leave a coating of mixed fluid on the inner tube of your hose. Be sure all fluid is thoroughly flushed from the hose after each use.

• Remove spray tip for more thorough cleaning of the whip hose and static mixers.

NOTE:

The valve handles point at each other in the closed position.

4. Open solvent inlet valve (F).

5. Turn on solvent flush pump.

• Use a solvent that dissolves the material you are mixing.

• Always leave equipment filled with fluid to avoid drying and scaling.

1. Relieve pressure; see page 11.

2. Engage trigger lock. Remove spray tip.

4)!

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6. Disengage spray gun trigger lock.

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7. Trigger gun into a grounded metal pail with lid. Use a lid with a hole to dispense through to avoid splashing. Be careful to keep fingers away from front of gun. Flush out mixed material until clean solvent dispenses.

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8. Turn off solvent pump air supply.

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Operation

9. Hold the metal part of the gun firmly to a grounded metal pail with lid in place. Trigger gun until all fluid pressure is relieved.

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10. Engage trigger lock.

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11. Close solvent inlet valve (F).

Dispensing and Spraying

1. Close solvent inlet valve (F).

2. Open blue (E) A material and green (H) B material valves.

3. Ensure sprayer is in “Spray Mode” and push start.

4. Disengage spray gun trigger lock.

ti1950a

5. Hold the metal part of the gun firmly to a grounded metal pail with a lid to avoid splashing. Trigger the gun until mixed coating material is evident and purge solvent is gone.

6. Proceed spraying.

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Page 14

Operation

Volume Balancing the Mix Manifold

When the mix manifold is remote mounted ratio errors can occur between the sprayer and the mix manifold; even when the sprayer output ratio is accurate.

The following can occur when the hoses are not volume balanced to the mix ratio:

• Hoses fill to high pressure while metering on ratio.

• Only the “A” material hose comes up to spray pressure.

• Off ratio at the mix point until hose pressures equalize.

Lead/Lag Imbalance

When resin and hardener volume requirements (ratio) and/or viscosities are different an imbalance can occur each time the gun is triggered. This occurs because the fluids can rush out of the manifold near a 1:1 ratio before the sprayer starts.

Remote Mounted Mix Manifold

Set Machine Restriction

With the restriction stem on the remote mix manifold open counter clockwise, adjust the restriction stem (222200) on the outlet of the proportioner to optimize the B side dosing control window. The goal is to create constant flow on the A side and frequent dosing or near constant flow on the B side. See the XM operation manual for instructions.

Set Mix Manifold Restriction

1. Adjust the restriction stem clockwise until the bar graph on the Ratio Mode screen starts moving to the left. The “B” dosing valve (blue) light will get brighter and the “B” dosing valve will open further.

2. Turn the restriction valve counter clockwise a half turn, and then lock the adjustment by tightening the nut.

Adjust Restriction on Early Xtreme Mix Sprayers

To avoid this imbalance:

• Add restriction on the hardener (low volume) side to balance the flow at the mix manifold.

• If the mix manifold is remote, pressurize hoses to spray pressure before starting spray mode when mix manifold is remote.

• If the mix manifold is remote, size the fluid delivery hose volume to nearly match the mix ratio. See Table 1.

Adjust B Mix Manifold Restriction on XM Sprayers While Spraying

Machine Mounted Mix Manifold

Adjust the restriction stem on the mix manifold to optimize the B side dosing control window. The goal is to create a constant flow on the A side and frequent dosing or a near constant flow on the B side. See the XM operation manual for instructions.

To check if the system is balanced watch the “B” dosing valves. The valve should be open (up) most of the time when the gun is triggered. If the “B” valve is giving only short “on” shots, adjust the restrictor in further. “B” fluid should flow most of the time, making only short “off” corrections.

Hose Selection For Feeding A Remote Mix Manifold

Hoses should be sized to match the hose volume ratio to the mix ratio. The hose size should also allow for minimum pressure drop on the major volume side to meet your flow requirements.

Use Table 1 to match mix ratio, hose selection, and volume ratio. Use Table 2 on page 15 to reference amount of pressure drop for 50 ft lengths of different hose sizes.

Size remote mix manifold hoses to:

• Minimize pressure drop on the high volume and often higher viscosity resin side to achieve higher flow and pressure at the gun while spraying.

• Allow both A and B material hoses to come up to spray pressure together when A and B fluids are metered into the hoses on ratio.

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Page 15

Operation

• Balance the inherent stall pressure between the resin “A” and hardener “B” sides when the gun closes and also when triggered. This reduces the lead/lag error at the mix point when the spray gun is triggered.

Table 1: Volume Ratio of “A” to “B” Hose

Hose

Mix Ratio

Selection

“A” x “B”

Hose Volume

Ratio

1:1 1/2 x 1/2 1.0:1

3/8 x 3/8

2:1 1/2 x 3/8 1.78:1

3/8 x 1/4 2.25:1

3:1 3/8 x 1/4 2.25:1

4:1 to 6:1 1/2 x 1/4 4.0:1

6:1 to 10:1 1/2 x 3/16 7:1

Table 2: Hose Selection by Pressure Drop

Example: At a 4:1 mix ratio, a 1/2 in. ID resin hose and

a 1/4 in. ID hardener hose matches the 4:1 volume ratio.

Pressure Drop per 15.24

meter section per 1000

cps at 1 liter/min.

Hose ID

(in.)

Pressure drop per 50 ft

section per 1000 cps at 1

gal/min.

(psi)

1/8 55910 1018

3/16 11044 201

1/4 3494 64

3/8 690 13

1/2 218 4

5/8 89 1.62

3/4 43 0.78

#1 Example: What is the pressure loss of a 2000 cps material through 150 ft of 3/8 in. ID hose at 0.75 gpm?

690 psi (from chart) x 2 (viscosity factor 2 x 1000 cps) x 3 (3 x 50 ft hoses) x 0.75 (% of gpm) = 3105 psi loss

That is a lot of pressure loss before the spray gun. Let’s try 1/2 in. hose. See example #2.

Reference Formula

Pressure drop = 0.0273 QVL/D

(Bar)

Key:

Q = Vis poise. V= Gallons per minute L= Length (ft) D=Inside diameter (in.)

#2 Example: What is the pressure loss of a 2000 cps material through 150 ft of 1/2 in. ID hose at 0.75 gpm?

218 psi (from chart) x 2 (viscosity factor 2 x 1000 cps) x 3 (3 x 50 ft hoses) x 0.75 (% of gpm) = 981 psi loss

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Page 16

Operation

Optional Recirculation

Ports are provided on the “A” and “B” sides for recirculating the material hoses back to the machine supplies.

To add remote recirculation, install shutoff check valves 255278 on front of mix manifold assembly. This is a high quality carbide ball and seat valve designed to close and be leak free when in spray mode.

Use adjustable restrictor valves 222200 to control the flow rate back into the supply.

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. 5: Remote Mix Manifold Recirculation

NOTE:

When recirculation valves are moved remote downstream of the dosing valves, the machine can no longer automatically check that the recirculation valves are closed and leak free when going into Spray Mode.

If the recirculation valves leak while you are spraying, you will be off ratio with no indication. See XM sprayer operation manual 312359 for more information.

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Page 17

Troubleshooting

1. Relieve the pressure before you check or service any system equipment.

2. Check all possible causes and solutions in the troubleshooting chart before disassembling the manifold.

Problem Cause Solution

Little or no resin output. Fluid inlet is plugged. Clean inlet; remove obstruction. See

Clean Mix Manifold Outlet, page 20.

Fluid container is empty. Refill.

Little or no hardener output. Fluid inlet is plugged. Clean inlet; remove obstruction. See

Clean Mix Manifold Outlet, page 20.

Fluid container is empty. Refill.

Hardener screen (28) is plugged. (Only applies if it is installed.)

Mixed fluid will not flush out. Fluid is hardened in static mixers or whip

hose.

Solvent supply container is empty. Refill.

Solvent is not compatible with fluid. Change to compatible solvent.

Hardener pressure higher than normal. Hardener is cold. Correct heat problem. See fluid heater

Restrictor or screen plugging up. Open restrictor or clean screen. See

Hardener pressure lower than normal. Resin is cold. Flow rate is low. Correct heat problem. See fluid heater

Worn hardener restrictor. Adjust restrictor. See Adjust B Mix Mani-

Spray pattern developing tails. Static mixer and/or whip hose plugging

up.

Low pressure from sprayer. Check air supply pressure. Check inlet air

Cold material. Increase heat. See XM Plural-Compo-

Too much pressure drop. Use larger hoses or more heat.

Resin or hardener does not shut off. Damaged ball or seat or seal in valve

(11).

Off ratio condition after increasing spray pressure in spray mode with a remote mix manifold.

Hoses not volume balanced. Volume balance A and B remote material

Clean hardener screen. See Clean Mix Manifold Outlet, page 20.

Clean with compatible solvent. See Main- tenance, page 20. Replace as necessary.

section of XM Plural-Component Sprayer Repair manual 313289.

Clean Mix Manifold Outlet, page 20.

section of XM Plural-Component Sprayer Repair manual 313289.

fold Restriction on XM Sprayers While Spraying, page 14.

Replace restrictor.

Clean Static Mixers, page 20.

Clean spray gun and tip. See gun manual.

gauges while spraying.

nent Sprayer Operation manual 312359.

Replace or rebuild valve (11). See repair section of High Flow Severe Duty Shutoff Check Valve manual 313343.

hoses closer to volume mix ratio. See Volume Balancing the Mix Manifold, page 14.

312749G 17

Page 18

Repair

Follow Pressure Relief Procedure when you stop spraying and before cleaning, checking, servicing, or transporting equipment. Read warnings in your sprayer manual.

Remove Restrictor

1. Note number of turns from open to closed position. Remove restrictor housing (19) from manifold (1).

2. Place restrictor housing (19) in a vice and remove nut (20).

NOTICE

• Be sure to label all fluid parts “resin” or “hardener” when disassembling them. Doing so prevents interchanging resin and hardener parts during reassembly, which will contaminate the materials and the fluid path through the equipment.

• Color-coded chemically resistant tape may be used to label the parts. Use blue for resin and green for hardener.

1. Relieve the pressure, see page 11.

2. Clean “B” side screen. See page 20.

3. Remove cap nut (CN) and handle (CH) from cartridge assembly (11). Use wrench to remove cartridge assemblies from manifold (1). See manual 313343 for repair instructions.

r_255684_256980_312749_9a

FIG. 7

3. Unscrew stem (18) clockwise and remove from restrictor housing (19).

. 8

r_255684_256980_312749_10a

4. Remove and inspect o-rings (16, 17). Replace as

necessary.

5. Remove set screw (15) and seat (14) from manifold

r_255684_256980_312749_18a

. 6

(1).

4. Clean all parts thoroughly in a compatible solvent. Use a soft bristle brush to clean the manifold passageways.

. 9

18 312749G

r_255684_256980_312749_11a

Page 19

Assemble Restrictor

Repair

1. Insert seat (14) with larger tapered end facing up in manifold (1).

16 (black) 17 (white)

r_255684_256980_312749_12a

. 10

4. Loosely install lock nut (20) on stem (18).

5. Tighten restrictor housing (19) into manifold (1).

6. Tighten stem (18) down until it bottoms on seat (14). Then back stem out to previously noted position or two full turns and lock in place with lock nut (20).

Assemble Cartridge Assembly

1. Apply blue thread lock to external threads of cartridges (11) and install in manifold with stem backed out fully counter-clockwise. Place wrench on cartridge flats and torque to 125 ft-lbs (170 N•m). See F

. 6 on page 18.

2. Install handle (CH) and cap nut (CN) on cartridge so that the handles point toward each other when closed.

2. Apply blue thread lock to external threads of set screw (15) and install in manifold.

3. Install o-rings (16, 17) on stem (18) and insert stem into restrictor housing (19). Turn stem (18) counter-clockwise until in open position.

16 (black)

17 (white)

r_255684_256980_312749_13a

. 12

. 11

312749G 19

Page 20

Maintenance

Clean Static Mixers

See FIG. 1, page 7. Typically, two static mixer housings (S, Part No. 262478) are connected to the static mixer adapter (V) on the integrator hose (L). These housings use plastic mix elements, available in a package of 25 (W, Part No. 248927).

NOTICE

Never use a swivel union on the mixer inlets. The union will compress the tube and make it impossible to remove the mix element.

To clean the housing and replace the mix element:

1. Relieve pressure, see page 11. Remove mixer housings (S) from integrator hose (L) and from whip hose (T).

2. Place flats of mixer housing (S) in a grounded vise. Push mix element (W) out of the inlet end.

3. If necessary, use a 1/2 in. drill bit to drill out old material and clean the mix element from the inlet end, down to the internal shoulder at the outlet end.

2. Pull “V” screen (28) and retainer o-ring (29) straight up and out with a needle nose pliers.

3. Clean or replace screen (28).

4. Reinstall screen (28) and white plastic o-ring (29) with tool 15T630 (included in repair kit 256238).

NOTE:

The o-ring (29) is used as a retainer ring, not a seal. It may be scratched or deformed from pushing the screen (28) back in.

5. Install “B” inlet union (31) on manifold block (1).

Clean Mix Manifold Outlet

1. Remove outlet fitting (33) to expose “B” center injection tube (9).

4. Use a brush to clean any debris in housing (S).

5. Insert new mix element, wide end first.

Clean “B” Side Screen

NOTE:

The following instructions apply only when using the strainer accessory for low viscosity fluids. See Acces- sories on page 26.

1. Remove “B” inlet union (31) from manifold block (1).

2. Clean any build-up on, around, or inside the tube (9).

3. Reinstall outlet fitting (33).

20 312749G

Page 21

Parts

255684 Mix Manifold

Parts

Detail A

11j

11a

FLOW DIRECTION

11b

11c

11d

29◆

28◆

11e

11g

11f

11h

11, see Detail A

FLOW DIRECTION

r_255684_256980_312749_15a-1

SOLVENT DIRECTION

Apply lithium grease.

Apple anaerobic pipe thread sealant.

Apply blue thread lock to external threads.

Torque to 125 ft-lbs. (170 N•m).

Plastic assembly tool for (28), (29), and (11d) included in repair kit 256238.

U-cup open lips face spring.

After tightening valves (11) into housing (1), orient handles (23, 24) to face each other when closed.

Large end of inside taper faces out.

◆

Accessory only.

r_255684_256980_312749_6

312749G 21

Page 22

Parts

255684 Mix Manifold

Qty

Ref. Part Description

1 15M229 BLOCK, manifold 1 2† 117558 SPRING, compression 1 3† 101947 BALL, solvent check 1 4 15E367 ELBOW, street, lapped 1 5 214037 VALVE, ball; see manual 306861 1 9 15R378 TUBE, injector, hardener 1 10 15R067 PIPE, outlet, mixer manifold 1 11* 255747 CARTRIDGE, valve, shutoff

check; includes 11a-11j 11a† 15A968 SEAT, foot valve, carbide 1 11b† 116166 BALL, carbide 1 11c† 15M530 SPRING 1 11d† 15M529 SEAL, u-cup UHMWPE 1 11e† 15M189 SPACER, backup, seal 1 11f† 15K347 STEM 1 11g† 121138 PACKING, o-ring; PTFE, white 1 11h 15K199 HOUSING, top, check valve 1 11j† 15K692 SEAL, seat retainer 1

13 117623 NUT, cap; 3/8-16 2 14 183951 SEAT, valve, carbide 1 15 15R382 SCREW, set, hollow, 3/4-16 1 16† 113137 PACKING, o-ring, black solvent

resist

17† 110004 PACKING, o-ring, white, PTFE 1 18 235205 STEM, valve, carbide 1 19 15M969 HOUSING, restrictor 1 20 110005 NUT, jam, hex; 5/16-24 unf 1 21 100721 PLUG, pipe; 1/4 npt(f) 2 22 101754 PLUG, pipe; 3/8 npt(f) 1 23 15R380 HANDLE, green 1 24 247789 HANDLE, blue 1 31 156684 UNION, adapter; 1/2 npt 2 32✿ 158491 NIPPLE; 1/2 npt, see page 23 2 33✿ 159239 NIPPLE, pipe; 1/2 x 3/8 npt, see

page 23

34 100361 PLUG, pipe; 1/2 in. - 14 npt 2 35 156823 UNION, swivel; 2 x 1/4-18 npt 1 45✿ 162449 NIPPLE, 1/2 x 1/4 npt, see page 232

118✿ 126786 WRENCH, restrictor 1

†

Provided in mix manifold repair kit 256238.

* See manual 313343 for repair instructions.

✿

Not shown.

22 312749G

Page 23

Parts

256980 Remote Mix Manifold Conversion Kit

(with outlet check/shut off valves and machine mounted restrictor valve)

Shutoff check valves must be used when using the mix manifold remote on an XM sprayer. Includes everything needed to move the existing mix manifold remote, except the A and B fluid hoses which should be chosen according to the guidelines starting on page 14.

NOTE: Extra hose nipples are included to accommodate 1/2 in. or 3/8 in. “A” hose and 1/2 in., 3/8 in., or 1/4 in. “B” hose.

102

108

103

111

109

101

110

112

r_255684_256980_312749_8

119

113

115

Mix manifold 255684 is not included (purchase

Mix manifold 255684 is not included (purchase separately). See page 21 for parts.

separately). See page 21 for parts.

Face down.

“B” outlet to hose.

33 or 116

WLE

312749G 23

114

or 117

Page 24

Parts

256980 Remote Mix Manifold Kit Parts

Qty

Ref. Part No. Description

13 117623 NUT, cap 3/8-16 unc 2 23 15R380 HANDLE, green 1 24 15J916 HANDLE, blue 1 31 156684 UNION, adapter 2 32★ 158491 NIPPLE, 1/2 npt 3 33★ 159239 NIPPLE, pipe; 1/2 x 3/8 npt 5 45★ 162449 NIPPLE; 1/2 x 1/4 npt 2 101 262522 CARRIAGE, remote manifold 1 102 15R529 BLOCK, fluid distribution 2 103* 255278 VALVE shutoff/check;

(includes 11, see page 22) 108† 121139 PACKING, o-ring 2 109 121295 SCREW, cap, sch 8 110 111801 SCREW, cap, hex hd; 5/16-18 4 111 100361 PLUG, pipe 2 112 551387 GAUGE, pressure, fluid 1 113 162505 UNION; 3/8 male x 1/2 female 1 114 222200 VALVE, restrictor 1 115 155699 ELBOW, street; 3/8-18 npt 1 116 156849 NIPPLE, pipe; 2 x 3/8-18 npt 1 117 164672 ADAPTER; 3/8-18 npt x 1/4-18

npsm 118✿ 126786 WRENCH, restrictor 1 119 16N367 COUPLING, 1/2 x 3.5 in. 1

113

115

114

33 or 116 or 117

★

Use to adapt to any combination of one 1/2 in., two 3/8 in., and one 1/4 in. hoses.

†

Provided in mix manifold repair kit 256238.

* See manual 313343 for repair instructions.

✿

Not shown.

24F284 Remote Manifold Restrictor Kit

Qty

Ref. Part No. Description

32★ 158491 NIPPLE, 1/2 npt 1 33★ 159239 NIPPLE, pipe; 1/2 x 3/8 npt 1 113 162505 UNION; 3/8 male x 1/2 female 1 114 222200 VALVE, restrictor 1 115 155699 ELBOW, street; 3/8-18 npt 1 116 156849 NIPPLE, pipe; 2 x 3/8-18 npt 1 118✿ 126786 WRENCH, restrictor 1

24 312749G

Page 25

Repair Kit

256238, XM Mix Manifold without Circulation Repair Kit

See parts lists on pages 22 and 23.

Qty

Ref. Part Description

2 117558 SPRING, compression 1 3 101947 BALL, solvent check 1 11a 15A968 SEAT, foot valve, carbide 1 11b 116166 BALL, carbide 1 11c 15M530 SPRING 1 11d 15M529 SEAL, u-cup UHMWPE 1 11e 15M189 SPACER, backup, seal 1 11f 15K347 STEM 1 11g 121138 PACKING, o-ring; PTFE, white 1 11j 15K692 SEAL, seat retainer 1 16 113137 PACKING, o-ring, black solvent

resist 17 110004 PACKING, o-ring, white, PTFE 1 108 121139 PACKING, o-ring 2 120✿ 15T630 TOOL, u-cup and manifold 1 121✿ 113500 ADHESIVE, anaerobic 1

Repair Kit

✿

Not shown.

312749G 25

Page 26

Accessories

255747, Shutoff Check Valve Cartridge Assembly

See manual 313343 for parts.

255278, Complete High Flow Sever Duty Shutoff Check Valve

Includes housing, screws, and o-ring for recirculation or machine with outlet valves. See manual 313343 for parts.

10,000 psi Fluid Pressure Gauge (2.5 in.)

114434 - 1/4 npt(m) back mount pressure gauge can be used in port (AB) as gun pressure gauge. Includes 316 stainless steel wetted.

551387 - 1/4 npt bottom mount version.

262522, Remote Mix Manifold Carriage (101)

The carriage holds and protects the mix manifold assembly. This requires four 5/16-18 x 1/2 in. screws.

262478, 7250 psi Static Mixer Housing

Accessory Ports

See FIG. 13.

(AA) Inlet Side - 1/2 in. npt(f)

These ports are located before “A” and “B” shutoff check valves. Use these ports for inlet gauges or recirculation. They also are equipped to manifold face mount 255278 circulation valves.

(AB) “A” Side After Shutoff - 1/4 in. npt(f)

These ports are located after “A” and “B” shutoff check valves. Use these ports as an outlet pressure gauge or as a second flush inlet for materials that require dual, separate flushing for complete flush material isolation.

(AC) “B” Side After Shutoff, Before Restrictor - 1/4 in. npt(f)

This port can be used as an alternate flush coming in before the restrictor on the “B” side.

3/8 npt(m) holds 1/2 in. 12 element stick from 25 pack

248927.

248927, Plastic Mix Elements

25 pack of 1/2 in. x 12 elements plastic sticks.

511352, Mixer

Stainless 3/8 npt(m) pipe with 12 element stainless welded stick; 7250 psi (50 MPa, 500 bar).

15B729, Adapter Mixer Inlet

3/8 npt m x f; 7250 psi (50 MPa, 500 bar).

162024, Adapter Between Mix Tubes

3/8 npt f x f; 7250 psi (50 MPa, 500 bar).

B-side Screen

For low viscosity fluids only.

185416 STAINER; 40m 121410 PACKING, screen retainer

. 13: Accessory Ports

26 312749G

Page 27

Technical Data

Maximum working pressure 7250 psi (50 MPa, 500 bar) Maximum fluid temperature 160° F (71° C) Fluid inlet 1/2 in. npsm union with nipple adapters for 1/2 in., 3/8 in., or 1/4 in. hoses Fluid outlet size 1/2 npt(f) with 3/8 npt(m) adapter nipple Solvent inlet valve 1/4 npt(m) Wetted parts

Manifold block and internal parts:

bide, electroless nickel plated steel, zinc plated steel, UHMWPE

Flush valves and fittings:

steel, acetal, PTFE

440 stainless steel, plated carbon steel, hardened alloy

302 and 303 stainless steel, PTFE, tungsten car-

312749G 27

Page 28

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

For the latest information about Graco products, visit www.graco.com.

For patent information, see www.graco.com/patents.

TO PLACE AN ORDER,

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 INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

contact your Graco distributor or call to identify the nearest distributor.

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

Original instructions. This manual contains English. MM 312749

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revised April 2014