Graco 312753E User Manual

Operation - Maintenance

312753E

L-Head

For dispensing controlled ratio shots of resin and isocyanate.

3000 psi (20.6 MPa, 206 bar) Maximum Working Pressure

Important Safety Instructions

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

See page 2 for model information.

Models

Contents

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

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

Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . . . 5

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

Keep Components A and B Separate . . . . . . . . . . 5

Foam Resins with 245 fa Blowing Agents . . . . . . . 5

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . . 5

Component Identification . . . . . . . . . . . . . . . . . . . . 6

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Hydraulic & Chemical Hose Installation . . . . . . . 7

Bleeding Air from Hydraulic Fluid Lines . . . . . . . 8

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

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . 9

Nozzle Grip Assembly Removal and Cleaning . 10

Nozzle Grip Assembly Installation . . . . . . . . . . . 11

Cleanout Plunger Proximity

Switch Replacement . . . . . . . . . . . . . . . . . 12

Material Plunger Proximity

Switch Replacement . . . . . . . . . . . . . . . . . 14

Cleanout Plunger Stroke Adjustment . . . . . . . . 17

Pour Nozzle Maintenance . . . . . . . . . . . . . . . . . 19

Pour Nozzle Removal and Installation . . . . . . . . 20

Step Seal and Scraper Seal Replacement . . . . 20

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Models 5/8, 6/10, 10/14 . . . . . . . . . . . . . . . . . . . 24

Models 13/20 and 16/25 . . . . . . . . . . . . . . . . . . 26

Orifice Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Additional Tools and Accessories . . . . . . . . . . . 29

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 32

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 32

Models

Maximum Working

Model

20.20.5/8 ✔ 5 8 2 3000 (20.6, 206)

20.20.6/10 ✔ 6 10 2 3000 (20.6, 206)

20.20A.6/10 6 10 2 3000 (20.6, 206)

20.20.10/14 ✔ 10 14 2 3000 (20.6, 206)

20.20.13/20 ✔ 13 20 2 3000 (20.6, 206)

20.20.16/25 ✔ 16 25 2 3000 (20.6, 206)

Approved

Impingement

Chamber ID (mm)

Exiting

Chamber ID (mm)

Number of

Streams

Pressure

psi (MPa, bar)

2 312753E

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

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

SKIN INJECTION HAZARD

High-pressure fluid from dispense valve, 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 dispense valve at anyone or at any part of the body.

• Do not put your hand over the end of the dispense nozzle.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

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

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 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.

312753E 3

Warnings

WARNING

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.

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.

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.

4 312753E

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.

• 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.

• 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 ISO pump oil or grease when reassembling.

Keep Components A and B Separate

Material Self-ignition

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

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.

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.

NOTICE

To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (isocyanate) and component B (resin) parts.

Foam Resins with 245 fa Blowing Agents

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

Changing Materials

• 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

FIG. 1: L-Head

Key:

AEye Bolt B Cleanout Plunger Open Fitting C Resin Close Fitting D Resin Open Fitting E Resin Nozzle Grip Assembly F Pour Nozzle G MixHead Body

H Cleanout Plunger Proximity Switch J Cleanout Cylinder Housing K Iso Close Fitting L Iso Open Fitting M Iso Nozzle Grip Assembly N Material Plunger Close Fitting P Material Plunger Open Fitting Q Cleanout Plunger Close Fitting

6 312753E

Installation

When hoisting the MixHead from an overhead position, always lift by the top eyebolt.

Handle the MixHead with care. The internal moving parts are precisely machined for proper alignment. Any disturbance of this alignment may result in MixHead failure.

Hydraulic & Chemical Hose Installation

Do not come into contact with Isocyanate. See Isocyanate Hazard on page 5.

NOTICE

The person performing the installation must understand the operation of the MixHead hydraulic power source and chemical flow system.

Before disconnecting a chemical fitting or nozzle grip assembly, turn off the proportioner, bleed the chemical pressure to ZERO, and allow the fluid to cool.

Install Hydraulic Hose

The fittings are identified on the MixHead body and the hoses are color-coded to aid in identification and proper installation.

When connecting the hoses, do not allow any dirt or foreign matter to enter the lines.

See FIG. 1 on page 6.

After mounting the MixHead, install the hydraulic and chemical hoses as follows:

1. Install the hydraulic hoses for the cleanout plunger to the fittings on the MixHead as follows:

a. Install the “close” hose to the Cleanout Plunger

Close Fitting (Q).

b. Install the “open” hose to the Cleanout Plunger

Open Fitting (B).

2. Install the hydraulic hoses for the material plunger to the hydraulic fittings on the MixHead as follows:

a. Install the “close” hose to the Material Plunger

Close Fitting (N).

Before Disconnecting Hydraulic Fitting or Proximity Switch

• Turn off the hydraulic pump

• Depressurize the hydraulic system

• Allow the fluid to cool

b. Install the “open” hose to the Material Plunger

Open Fitting (P).

Follow hydraulic fluid lines air purging procedure carefully to avoid skin injection hazard.

Before Disconnecting a Chemical Fitting or Nozzle Grip Assembly

• Turn off the proportioner

• Bleed the chemical pressure to ZERO

• Allow the fluid to cool

312753E 7

3. Purge all air from the hydraulic fluid lines using the procedure in the Bleeding Air from Hydraulic Fluid Lines section on page 8.

4. Manually cycle the cleanout plunger back and forth to check for proper operation. Check for hydraulic leaks and retighten fittings as required. Make sure the proximity switch is securely tightened and making contact, and then return the cleanout plunger to the “retract” position.

Installation

5. Manually cycle the material plunger back and forth to check for proper operation. Check for hydraulic leaks and retighten fittings as required. Make sure the proximity switch is securely tightened and making contact, and then return the material plunger to the closed/recirculation position.

NOTICE

Before connecting the chemical hoses, make sure the hydraulic hoses are properly connected and the cleanout plunger and material plunger have been tested for proper operation. Failure to do so may result in chemical cross-contamination of the MixHead and proportioning system.

6. Install the chemical hoses to the fittings on the MixHead as follows:

a. Install the isocyanate “close” hose to the Iso

Close Fitting (K).

b. Install the isocyanate “open” hose to the Iso

Open Fitting (L).

c. Install the resin “close” hose to the Resin Close

Fitting (C).

4. Use a bucket to catch the hydraulic fluid, and lay down a drop cloth to catch spilled hydraulic fluid.

The hydraulic fluid motor must be off and the manual unloading valve must be completely open before proceeding to the next step to avoid high pressure spraying of hydraulic fluid.

5. At the “close” port of the material plunger (N), loosen the hydraulic hose very slowly, allow all pressurized air to escape, then tighten the hose.

6. Move the cleanout plunger to the “extend” position. At the “close” port of the cleanout plunger (Q), loosen the hydraulic hose very slowly, allow all pressurized air to escape, then tighten the hose.

7. Move the cleanout plunger to the “retract” position. At the “open” port of the cleanout plunger (B), loosen the hydraulic hose very slowly, allow all pressurized air to escape, and then tighten the hose.

Install Chemical Hose

d. Install the resin “open” hose to the Resin Open

Fitting (D).

7. Recirculate both chemical lines until the pressures stabilize.

8. Pressurize the MixHead and check for chemical leaks.

Bleeding Air from Hydraulic Fluid Lines

1. Start the hydraulic fluid motor to build pressure in the hydraulic lines.

2. Turn off the hydraulic fluid motor.

3. Open the manual unloading valve all the way.

An assistant is required for the following steps.

8. With the cleanout plunger in the “retract” position, open the material plunger by manually energizing the hydraulic directional valve.

9. Have an assistant bleed out any air at the “open” port of the material plunger (P).

10. Hold the material plunger in the open/pour position until the “open” port has been completely bled of air and the hydraulic hose has been securely tightened, then return the material plunger to the closed position.

8 312753E

Maintenance

All maintenance must be done with pressure relieved and the power switched off and locked out, unless otherwise noted.

Maintenance Schedule

Service Action Frequency Reference

Maintenance

Apply cleanout plunger lubrication Flush mesamoll into the

cleanout bore

Inspect for hydraulic and chemical leaks

Inspect proximity switch wires for open exposure

Inspect pour nozzle bore Clean as needed Weekly See page 20

Inspect adjustment stem, injection nozzle, and nozzle grip for blockage and erosion

Replace seals as needed Daily See page 7

Replace cord set/switch as needed

Replace parts as needed Weekly See page 10

Daily See page 20

Weekly See pages 12, 14

312753E 9

Maintenance

Nozzle Grip Assembly Removal and Cleaning

The nozzle grip assembly must be removed, disassembled and cleaned whenever disconnecting the chemical hoses, replacing the internal o-rings, and/or changing the injection nozzle and adjustment stem. It is advisable to maintain a supply of spare nozzle grips, adjustment stems, hex o-ring seats, locknuts, and the necessary screws and o-rings.

See Parts List on page 25.

Nozzle Grip Assembly for models 5/8, 6/10, 10/14 shown

Tools Required

See Additional Tools and Accessories on page 29.

• Nozzle ejector

• 5/32 in. hex key

• M3 hex key for M6 set screws

• 1 in. open-end wrench

• Torque wrench with M6 hex for M8 SHC screws

Nozzle Grip Removal

1. Bleed all chemical pressures to zero.

2. Remove one of the M8 socket head cap screws (13) from the nozzle grip assembly and reinsert it at least two full turns.

This screw is a safety stop for the nozzle grip should any pressure be left in the system.

Key:

FA Roll Pin (pressed into nozzle grip, not shown) FB Slot for roll pin

IG. 2:

3. Unscrew the other three M8 screws (13) from the nozzle grip. Try pulling and pushing the assembly in and out of its bore to ensure that no pressure exists.

a. If it will not come out, turn the two M6 set

screws (14) contained in the nozzle grip clockwise to separate it.

b. If the nozzle grip assembly will not come out

with the set screws fully extended into the MixHead body, replace the M6 set screws (14) with longer M6 cap screws, and continue to move the nozzle grip assembly out of the MixHead body with the cap screws until the nozzle grip assembly can be removed by hand.

NOTICE

Whenever a chemical hose is disconnected, immediately remove its associated nozzle grip assembly and flush all chemical from the assembly and the MixHead bore. Exposure to atmospheric moisture will cause the remaining chemical in the nozzle grip assembly to harden, making removal from the MixHead difficult.

10 312753E

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