XP Sprayer, Instructions-Parts
Ratio Check Kit, Instructions-Parts
Ball Valves, Check Valves, and Swivels,
Instructions-Parts
High Pressure Hose and Accessories Bro-
chure
Warnings
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 symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and
warnings not covered in this section may appear 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.
• 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 from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and
follow the Pressure Relief Procedure when equipment is not in use.
• 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.
3A0590G3
Warnings
WARNING
WARNINGWARNINGWARNING
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 spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• 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.
• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
THERMAL EXPANSION HAZARD
Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure due to
the thermal expansion. Over-pressurization can result in equipment rupture and serious injury.
• Open a valve to relieve the fluid expansion during heating.
• Replace hoses proactively at regular intervals based on your operating conditions.
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 the Pressure Relief Procedure 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.
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 MSDSs 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 chemically impermeable gloves when spraying, dispensing, or cleaning equipment.
43A0590G
Warnings
WARNING
WARNINGWARNINGWARNING
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical
reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or
property damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier
for compatibility.
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, hearing loss, inhalation of
toxic fumes, and burns. This equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
3A0590G5
Important Two-Component Material Information
Important Two-Component Material Information
Isocyanate Conditions
Spraying or dispensing 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
Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings and
material MSDS.
Keep Components A and B
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 pump wetcup or reservoir (if installed)
filled with Graco Throat Seal Liquid (TSL
206995. The lubricant creates a barrier between the
ISO and the atmosphere.
•Use moisture-proof hoses specifically designed for
ISO.
•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 lubricate threaded parts with TSL or grease
when reassembling.
™
), Part
Separate
Foam Resins with 245 fa
Blowing Agents
Some foam blowing agents will froth at temperatures
Cross-contamination can result in cured material in
fluid lines which could cause serious injury or
damage equipment. To prevent cross-contamination
of the equipment’s wetted parts, never interchange
component A (isocyanate) and component B (resin)
parts.
63A0590G
above 90°F (33°C) when not under pressure, especially
if agitated. To reduce frothing, minimize preheating in a
circulation system.
Changing Materials
•Changing material types used in your sprayer
requires special attention to avoid equipment damage and downtime.
•Always clean the fluid inlet strainers after flushing.
•When changing between epoxies and urethanes or
polyureas, disassemble and clean all fluid components and changes hose sets.
•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.
Important Two-Component Material Information
A and B Component Designations
Material suppliers and markets refer to plural component materials differently. The table below summarizes the different designations for the components used in various machines.
MarketEquipmentDesignations
Foam and Polyurea
Urethane Pour
Epoxy and Urethane
Protective Coatings
Epoxy, Silicone, Ure-
thanes, and other mate-
rials
All Reactors, HFR
and VRM
Hydra-Cat
™
Mix
, XM™, XP, and
PR70
PR70 and PR
™
®
, Xtreme-
™
Letter
Color
™
,
Component Names
Major or Minor Component
(when not 1:1 mix)
Letter
Color
Component Names
Major or Minor Component
(when not 1:1 mix)
Letter
Color
Component Names
Major or Minor Component
(when not 1:1 mix)
Machine Left
Side
AB
RedBlue
ISO, Hardener,
Catalyst
Low Volume
Side
AB
BlueGreen
Resin, Base
High Volume
Side
AB
RedBlue
Polyol, Resin,
Base
High Volume
Side
Machine Right
Side
Polyol, Resin,
Base
High Volume
Side
Hardener, Cata-
lyst
Low Volume
Side
ISO, Hardener,
Catalyst
Low Volume
Side
3A0590G7
Component Identification
Component Identification
D
P
S
G, H
B
A
E
F
R
C
J, M★
J, M★
Key:
AResin (High Volume) Inlet (A material)
BHardener (Low Volume) Inlet (B material)
CSolvent Inlet Valve, 1/4 npt(m)
DManifold
EDual Shutoff Handle
FHardener Restrictor Adjustment
GHardener Center Inject Tube (not shown; inside outlet H)
HMix Manifold Outlet, 1/2 npt(f) with 3/8 npt(m) adapter
JStatic Mix Housing
KFluid Whip Hose
LAirless Spray Gun
MStatic Mixing Element (not shown; inside J)
NFluid Mix Hose
PAccessory Ports (see Accessory Ports, page 26)
RB Side Flush Inlet Check Valve
SA Side Check Valve Cartridge (B side not shown)
TA Side Solvent Inlet Valve (Quickset Manifold)
UA Side Solvent Check Valve (Quickset Manifold)
N ★
J, M★
★ Not included with mix manifold. See Parts, starting
on page 22.
K ★
Quickset Manifold
FIG. 1: Typical Installation
L ★
ti19003a
T
U
ti18954a
83A0590G
Overview
n
Overview
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 an adjustable restrictor for
balancing the system back pressure and flow.
See FIG. 2 to view flow of “A” and “B” material inside the
Mix Manifold.
“A” Inlet Ball Valve
F
The resin and hardener enter the mix manifold through the
manifold inlet ports and spring loaded carbide ball checks.
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 resin and hardener material mix after
they have left the mix manifold block (B).
When the manifold is mounted remote from the proportioner, adjust the “B” side restrictor (F) to balance the system back pressure and flow.
On the standard mix manifold, mixed material is flushed out
by sending a flush solvent through the B side center tube.
On the quickset mix manifold, solvent is also flushed across
the A side fluid check valve.
“B” Side of Mix Manifold“A” Side of Mix Manifold
“B” Inlet Ball Valve
“A” side solvent
flush inlet
across check
ball added on
Quickset model.
Carbide
Solvent Fluid Inlet
(on “B” side)
“B” side flow
after check
valve
Check Valve
(on each side)
H
r_258987_3a0420_3a
Mixed MaterialA Side MaterialB Side Material
FIG. 2: Cross-Section Side Views of A and B Flow
F
“B” side solvent
flush inlet after
restrictor (Used o
both models)
H
r_258987_3a0420_2a
3A0590G9
Installation
Installation
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.
See illustration in F
IG. 1 on page 8.
Fluid Inlets
The A and B fluid inlets (A and B) are equipped with 1/2
npt(f) ball valves. Connect 1/2 in., 3/8 in., or 1/4 in.
npsm(f) fluid hoses with adapter nipples as needed. See
brochure 339361 for high pressure hose and fitting part
numbers.
NOTE: If the manifold is remote, the hoses must be
properly sized and balanced. See Volume Balancing
the Mix Manifold on page 15 for more remote setup
information.
Solvent Inlet
Connect the solvent supply line (D) from the solvent
pump to the 1/4 npt(m) solvent inlet valve (C), or inlet
tee on the Quickset model.
NOTE: 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 the outlet to two primary static mixer tubes (J),
with mixer elements (M), to the mix hose (N), cleanup
mixer (J), whip hose (K), and spray gun (L).
NOTICE
To prevent creating a flare on the mixer tube, do not
use a union swivel end on the mix tube inlet.
Add mixed material hose as necessary between the mix
hose and cleanup mixer.
NOTICE
Never split the flow to multiple guns until the two fluids are mixed after the mix manifold assembly.
Mounting
Remote Mix Manifold
The mix manifold can be removed from the proportioner
and mounted closer to the gun. This reduces the volume
of mixed material and flush solvent for quick setting
materials (less than 10 minute pot life). See Volum e Balancing the Mix Manifold on page 15 for more
remote setup information.
Use Remote Mix Manifold Carriage 262522 for in-line
hose mount locations. The carriage protects the manifold and valves from accidental operation which could
cause a plugged line.
Bare Manifold
To mount the bare manifold, drill two holes in the mounting surface, and secure with the two 1/4-20 screws (28).
9/32 diameter
1.1 in. (27.94 mm)
103A0590G
Grounding
Grounding
Your system must be grounded. Read warnings in
your sprayer manual. Check your local electrical
code.
•Pump: use ground wire and clamp as instructed in
your sprayer 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.
•Spray gun:ground through connection to a properly grounded fluid hose and pump.
•Fluid supply container: follow local code.
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
Flushing, page 13.
Ratio Check
Perform the ratio check procedure after any changes to
the proportioning system. Use Ratio Check Kit 24F375
to check the ratio at the mix manifold. See manual
3A0421 for instructions and parts.
NOTICE
To prevent an inaccurate ratio check when feed
pumps are used in your system, the feed pressure
cannot be more than a maximum of 25% of the proportioner outlet pressure while dispensing. High
feed pressure can float the proportioner pump
check balls, resulting in an inaccurate ratio check.
•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 firmly to the side of a grounded metal pail, then
trigger the gun.
3A0590G11
Operation
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 the trigger lock.
ti1949a
2. Turn off the sprayer.
3. Close the bleed-type master air valve.
4. Open the dual shutoff handle (E).
8. Hold a metal part of the gun firmly to a grounded
metal pail. Trigger the gun to relieve pressure.
ti1953a
9. Engage the trigger lock.
ti1949a
10. Open all fluid drain valves in the system, having a
waste container ready to catch drainage. Leave
drain valves open until you are ready to spray again.
5. Shut off fluid heaters, if used on your sprayer.
6. Shut off feed pumps, if used.
7. Disengage the trigger lock.
ti1950a
11. If you suspect the spray tip or hose is clogged or
that pressure has not been fully relieved after following the steps above, VERY SLOWLY loosen tip
guard retaining nut or hose end coupling to relieve
pressure gradually, then loosen completely. Clear
hose or tip obstruction.
Trigger Lock
Always engage the trigger lock when you stop spraying
to prevent the gun from being triggered accidentally by
hand or if dropped or bumped.
123A0590G
Operation
Flushing
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.
•Use a solvent that dissolves the material you are
mixing.
4. Open the solvent inlet valve (C). For the quickset
manifold, close the A side flush valve (T).
T
C
ti18994a
C
5. Place the siphon tube in a grounded metal pail containing cleaning fluid.
6. Set pump to the lowest possible fluid pressure, and
start pump.
7. Trigger the gun into a grounded metal pail with lid.
Use a lid with a hole to dispense through to avoid
splashing. Trigger the gun until clean solvent dispenses.
•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.
•Always leave equipment filled with fluid to avoid
drying and scaling.
•Frequently remove, clean and replace the static
mixer elements
1. Follow Pressure Relief Procedure, page 12.
2. Remove the spray tip and soak in solvent.
3. Close the dual shutoff handle (E).
ti1953a
a. For the standard mix manifold, go to step 8.
b. For the quickset mix manifold, after briefly flush-
ing with the B side valve, close the B side flush
valve (C) and open the A side flush valve (T).
Repeat step 7 until clean.
C
T
ti18995a
8. Turn off the solvent pump air supply.
9. Hold the metal part of the gun firmly to a grounded
metal pail with lid in place. Trigger the gun until all
fluid pressure is relieved.
3A0590G13
Dispensing and Spraying
10. Engage the trigger lock.
ti1949a
11. Close solvent inlet valve (C).
12. Remove the gun from the hose. See gun manual to
further clean the gun.
Dispensing and Spraying
1. Close the solvent inlet valve (C) and A side solvent
valve (T) if equipped.
4. Disengage the 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.
ti1953a
2. Open the dual shutoff handle (E).
NOTICE
To prevent damage to the valve balls and seats,
always fully open or fully close the dual shutoff handle. Also increase the fluid pressure after opening
the ball valves to allow valves to last longer.
3. Turn on sprayer. See sprayer operation manual.
6. Proceed spraying.
143A0590G
Volume Balancing the Mix Manifold
Volume Balancing the Mix Manifold
If the mix manifold is mounted on the machine, you do
not need to adjust the restrictor (F). Leave open two
turns minimum.
When the manifold is remote, two things must be done
to reduce momentary ratio errors that can occur due to
the compressible nature of paint hoses.
•Adjust Restriction
•Select correct sized hoses
Adjust Restriction at the Mix
Manifold
The B side restrictor (F) in the mix manifold is only used
when the mix manifold is positioned remote from the
machine with a short mix hose to the spray gun.
The restrictor (F) controls “lead/lag” ratio errors of the A
and B flow into the static mixer tubes. These errors
occur momentarily when the gun opens. The error is
caused by differences in viscosity, volume, and hose
expansion between the proportioner outlets and the mix
point.
Adjust the restrictor (F) stem clockwise while spraying
until you see a slight rise in the B side pressure gauge.
The point where the pressure starts to rise is a good
adjustment setting.
restrictor stem
NOTE: Unless you are dispensing directly out of the
mix manifold and mixer, this an approximate adjustment.
For low viscosity fluids, an optional 40 mesh screen can
be installed in the mix manifold, in front of the restrictor.
This keeps the carbide tapered stem and seat from
plugging.
Hose Selection for Feeding A
Remote Mix Manifold
The mix manifold can be removed from the machine and
used closer to the spray gun to minimize the mixed
material in the hoses and reduce flush solvent with the
following restrictions.
•Only one mix manifold can be used on a proportioner.
•Splitting flow to two or more guns can only be done
after the two fluids are mixed.
NOTE: This applies to applications that are not 1:1
ratio, and don’t have near balanced viscosities.
Balance the hoses inside area sizes in relation to the
mix ratio by volume. This is most important when the
mix manifold gets close to the spray gun.
The proportioner will put out the two materials in the
exact ratio by volume. If the hose sizes are not balanced
to the ratio, one hose will always come up to pressure
first. This ratio error at the mix point can occur anytime
that there is a change in pressure. Balance the hose
sizes by effective area, not by inside diameter.
Area = (3.1416 * radius
NOTE: For balancing purposes, it is always
assumed that the A side is the high volume side.
Table 1: Volume Ratio of “A” to “B” Hose
Mix Ratio
1:11/2 x 1/21.0:1
1.5:1, 2:11/2 x 3/81.78:1
2:13/8 x 1/42.25:1
2.5:13/8 x 1/42.25:1
3:1
4:11/2 x 1/44.0:1
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.
2
) or see Table 1.
Hose Selection
“A” x “B”
3/8 x 3/8
Volume Ratio
For high viscosity 1:1 applications, the entire restrictor
assembly and seat can be removed and replaced by a
high pressure 3/4 npt plug.
3A0590G15
Volume Balancing the Mix Manifold
Use Table 2 and the examples provided to approximate
how much pressure drop you can expect for every 50 ft
(15.2 m) of hose at 1 gpm flow in that particular hose for
a 1000 cps viscosity material. Adjust for your applications flow rate and viscosity.
Table 2: Hose Selection by Pressure Drop
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)
1/8559101018
3/1611044201
1/4349464
3/869013
1/22184
5/8891.62
3/4430.78
#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?
NOTE: Typical flow rates are usually 0.4-0.8 gpm
(1.5-3 l/mn) per gun depending on tip size and viscosity.
Reference Formula
Pressure drop = 0.0273 QVL/D
(Bar)
Key:
Q = Vis poise (centipoise/100)
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?
4
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.
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
NOTE: Avoid under sizing the high volume side.
Pressure drop during flow conditions will increase
momentary hose induced ratio errors. See Table 2.
163A0590G
Maintenance
Maintenance
Clean Static Mixers
See FIG. 1 on page 8. Typically, two static mixer housings are connected to the mix manifold outlet (H). These
housings use plastic mix elements, available in a package of 25 (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 12. Remove mixer
housings (J) from whip hose (K).
2. Place flats of mixer housing (J) in a grounded vise.
Push mix element (P) out of the inlet end.
3. If necessary, use a 1/2 in. drill bit to drill out old
material and the mix element from the inlet end,
down to the internal shoulder at the outlet end.
4. Use a brush to clean any debris in housing (J).
NOTE: The o-ring (18) is used as a retainer ring, not a
seal. It may be scratched or deformed from pushing the
screen (17) back in.
21
20
19
18
17
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 Accessories on page 26.
1. Loosen swivels (19) and remove shutoff handle (21)
and valves (20). See F
2. Remove “B” inlet union (19) from manifold block (1).
3. Pull “V” screen (17) and retainer o-ring (18) straight
up and out with a needle nose pliers.
4. Clean or replace screen (17).
5. Reinstall screen (17) and o-ring (18) with accessory
tool 15T630.
IG. 3.
FIG. 3: “B” Side Screen
6. Install “B” inlet union (19) from manifold block (1).
Clean Mix Manifold Outlet
1. Remove outlet fitting (5) to expose “B” center injection tube (4).
2. Clean any build-up on, around, or inside the tube
(4).
3. Reinstall outlet fitting (5).
4
5
3A0590G17
Troubleshooting
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.
ProblemCauseSolution
Little or no resin output.Fluid inlet is plugged.Clean inlet; remove obstruction.
Fluid container is empty.Refill.
Little or no hardener output.Fluid inlet is plugged.Clean inlet; remove obstruction.
Fluid container is empty.Refill.
Hardener screen (18) is plugged.Clean hardener screen. See Clean “B”
Side Screen, page 17.
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.
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.
Worn hardener restrictor.Adjust restrictor. See Adjust Restriction
Low pressure from sprayer. Check air supply pressure. Check inlet air
Cold material.Increase heat.
Too much pressure drop.Use larger hoses or more heat.
Not enough air supply. Gauge drops
while spraying.
Motor is icing.Use De-Ice Bleed Air on motor. Dry or
Dirty filter in pumps or spray gun.Clean filters.
Resin or hardener does not shut off.Damaged ball or seat or seal in valve
(20).
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 with compatible solvent. See Main-tenance, page 17. Replace as necessary.
Clean “B” Side Screen, page 17.
at the Mix Manifold, page 15.
Clean Static Mixers, page 17.
Clean spray gun and tip. See gun manual.
gauges while spraying.
Air hose is too small.
Compressor is too small.
cool air before use.
Wait for motor to thaw.
Replace or rebuild valve (2). See manual
306861.
hoses closer to volume mix ratio. See
Hose Selection for Feeding A Remote
Mix Manifold, page 15 and Maintenance, page 17.
183A0590G
Repair
Follow pressure relief procedure when you stop
spraying or dispensing; and before cleaning,
checking, servicing, or transporting equipment.
NOTICE
Be sure to label all fluid parts “resin” or hardener”
when disassembling them. Doing so prevents interchanging resin and hardener parts during reassembly and prevents contamination of the materials and
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.
Repair
5. Remove the seat (2e), ball (2d), spring (2c), and
o-ring (2b) from housing (2a).
2f
2e
2b
2d
2c
2a
Cartridge Assemblies
1. Follow Pressure Relief Procedure, page 12.
2. Use a wrench to remove the cartridge assemblies
(2) from the manifold.
3. Use a 90° allen wrench to pop the seat (2e) and
seal (2f) out of the housing, or tap them out from the
“A” and “B” inlet side.
NOTE: Seat retainer seal (2f) normally splits into two
pieces when it is fully torqued into the housing. The lip is
meant to retain the seat, spring, and ball during assembly. The seat retainer seal (2f) must always be replaced
once it is disassembled.
4. Use a soft bristle brush to clean the manifold passageways.
6. Inspect parts for damage and replace as necessary.
7. Assemble parts in reverse order from steps above.
Press the assembly against a flat clean surface until
seal (2f) snaps into place on the end of housing
(2a). The seal (2f) will hold the spring (2c), ball (2d),
seat (2e), and o-ring (2b) in place during assembly.
8. Apply lubricant to o-ring (2b) and end seal (2f).
9. Apply anaerobic sealant to external threads of cartridge.
10. Install cartridge assemblies in manifold and torque
to 125 ft-lbs (170 N•m).
NOTE: The high torque crushes the seal (2f) for a
reliable seal up to 7250 psi (50 MPa, 500 bar).
3A0590G19
Repair
Remove Restrictor
1. Note number of turns from open to closed position.
Remove restrictor housing (15) from manifold (1).
2. Place restrictor housing (15) in a vice and remove
nut (16).
16
15
1
r_258987_3a0590_4a
3. Unscrew stem (12) clockwise and remove from
restrictor housing (15).
16
12
13
14
15
Assemble Restrictor
1. Insert seat (10) with larger tapered end facing up in
manifold (1).
16
15
12
1
2. Apply blue thread lock to external threads to set
screw (11) and install in manifold.
3. Install o-rings (13, 14) and insert stem (12) into
restrictor housing (15). Turn stem (12) counter-clockwise until in open position.
13 (black)
14 (white)
11
10
r_255684_256980_312749_12a
r_258987_3a0590_5a
4. Remove and replace o-rings (13, 14).
5. Remove set screw (11) and seat (10) from manifold.
11
10
r_258987_3a0590_6a
4. Loosely install lock nut (16) on stem (12).
5. Tighten restrictor housing (15) into manifold (1).
6. Tighten stem (12) down until it bottoms on seat (10).
Then back stem out to previously noted position or
two full turns and lock in place with lock nut (16).
NOTE: For high volume or high viscosity “B” side
applications, the restrictor parts can be replaced by
a high pressure 3/4 npt plug.
203A0590G
Repair
3A0590G21
Parts
Parts
262807 Mix Manifold
6
8
2
19
21
20
22
20
22
19
1
Apply lubricant to o-rings and cartridge o-ring and end seal.
2
Apply taper thread pipe sealant to all non-swiveling threads
except cartridge (2) and needle (12).
3
Apply anaerobic medium thread locker to external threads.
4
Torque to 125 ft-lbs (70 N•m).
5
Turn stem fully into manifold. Then back out two turns and
lock in place.
6
Large end of inside taper faces out.
7
Push assembly hard against a flat surface to snap retainer
seal (2f) in place.
8
2
Shipped loose. Use when a mix manifold is replaced on a
Series A XP Plural-Component Sprayer.
Use to check ratio at mix manifold. See manual 3A0421
for instructions.
P1
P3
P5
FIG. 4: Accessory Ports
P2
P4
r_258987_3a0590_9a
263A0590G
Technical Data
Technical Data
Mix Manifolds
USMetric
Maximum A, B, and mix working pressure7250 psi 50 MPa, 500 bar
Maximum fluid temperature160° F71° C
Fluid inlet1/2 npt(f) ball valves
Fluid outlet1/2 npt(f) with 3/8 npt(m) adapter nipple
Solvent inlet valve
Maximum working pressure at solvent inlet
Wetted parts
Manifold block and internal parts302 and 303 stainless steel, PTFE, tungsten carbide, elec-
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.
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 INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2010, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
Graco reserves the right to make changes at any time without notice.
For patent information, see www.graco.com/patents.
Original instructions. This manual contains English. MM 3A0590
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
www.graco.com
Revised June 2013
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