Hitachi MIX 309521J User Manual

Installation - Parts

™

Xtreme Mix

Plural Component Mixer, OEM Unit

Important Safety Instructions

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

See page 4 for model information, including maximum working pressure and approvals.

OEM

309521J

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441

Contents

Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 3

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Xtreme Mix OEM Models . . . . . . . . . . . . . . . . . . . . . 4

Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Pumps and Sensors . . . . . . . . . . . . . . . . . . . . . . 9

Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Fluid Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Proper Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Operation and Repair . . . . . . . . . . . . . . . . . . . . . . 15

Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . 16

Pneumatic Schematic . . . . . . . . . . . . . . . . . . . . . . 18

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Xtreme Mix Proportioner . . . . . . . . . . . . . . . . . . 20

Pneumatic Control 245803 . . . . . . . . . . . . . . . . 22

User Interface 245804 . . . . . . . . . . . . . . . . . . . . 24

Pump Air Manifold 245802 . . . . . . . . . . . . . . . . 25

Metering Valve Manifold 245824 . . . . . . . . . . . . 26

Sampling Valve 245143 . . . . . . . . . . . . . . . . . . . 26

Metering Valve 245846 . . . . . . . . . . . . . . . . . . . 27

Fluid Manifold 245833 . . . . . . . . . . . . . . . . . . . . 28

Sensor 245825 . . . . . . . . . . . . . . . . . . . . . . . . . 29

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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

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

2 309521J

Manual Conventions

Warning Caution

Manual Conventions

WARNING

A warning alerts you to possible serious injury or death if you do not follow instructions.

Symbols, such as fire and explosion (shown), alert you to a specific hazard and direct you to read the indicated hazard warnings (pages 5-6).

CAUTION

A caution alerts you to possible equipment damage or destruction if you do not follow instructions.

Note

A note indicates additional helpful information.

Related Manuals

Refer to the following manuals for detailed component information.

Component Manuals This manual available in following languages:

Manual Description

309535 Xtreme Mix Operation 309518 Xtreme Mix Repair 311762 Xtreme Displacement Pump 309347 King Air Motor

or 309348 King Quiet Air Motor

312145 XTR Spray Gun 309524 VISCON HP Heater 309525 Heated Hose Kit 308981 Husky 716 Diaphragm Pump 309615 Heater Bracket Kit 309568 Remote Manifold Kit

Manual Language Manual Language

309521 English 309540 German 309538 French 309546 Swedish 309539 Spanish 309604 Japanese

309521J 3

Xtreme Mix OEM Models

WARNING

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

Approved for Hazardous Location

Class I, Div 1, Group D

Xtreme Mix OEM Models

Xtreme

Mix

Part No. Series

Pump

Part No.

Pump

Description

Maximum Working

Pressure

psi (MPa, bar) Approvals

233871 A 249274 45:1 King 4500 (31, 310) 233872 A 249275 56:1 King 5600 (38.6, 386) 233873 A 249276 68:1 King 6800 (46.9, 469) 233874 A 249277 80:1 King 7250 (50, 500) 233875 A 249278 45:1 Quiet King 4500 (31, 310) 233876 A 249279 56:1 Quiet King 5600 (38.6, 386) 233877 A 249280 68:1 Quiet King 6800 (46.9, 469) 233878 A 249281 80:1 Quiet King 7250 (50, 500) 234024 A none

Approved for Non-hazardous Location

233879 A 249274 45:1 King 4500 (31, 310) 233880 A 249275 56:1 King 5600 (38.6, 386) 233881 A 249276 68:1 King 6800 (46.9, 469) 233882 A 249277 80:1 King 7250 (50, 500) 233883 A 249278 45:1 Quiet King 4500 (31, 310) 233884 A 249279 56:1 Quiet King 5600 (38.6, 386) 233885 A 249280 68:1 Quiet King 6800 (46.9, 469) 233886 A 249281 80:1 Quiet King 7250 (50, 500) 234025 A none

Conforms to

FM std 3600 & 3610 for

use in Class I Div 1

Group D

T3 Hazardous locations

Conforms to UL std 61010A-1

CSA std C22.2 No 1010.1-92

CAN/CSA

22.2 No. 157-92

& No. 1010.1-92

ll 2 G

4 309521J

Xtreme Mix OEM Models

Warning

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 the gun at anyone or at any part of the body.

• Do not put your hand or fingers over the gun fluid nozzle.

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

• Do not “blow back” fluid; this is not an air spray system.

• Follow Pressure Relief Procedure, page 7, when you stop spraying and before cleaning, checking,

or servicing equipment.

• Use lowest possible pressure when flushing, priming, or troubleshooting.

• Never spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• Tighten all fluid connections before operating the equipment.

• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. High pressure hose cannot be recoupled; replace the entire hose.

Fire and Explosion Hazard

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 and plastic drop cloths (potential static arc).

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

• Keep the work area free of debris, including solvent, rags, and gasoline.

• Ground equipment and conductive objects. See Grounding, page 11.

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

• Use only grounded hoses.

• If there is static sparking or you feel an electric shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

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

• Keep a fire extinguisher in the work area.

Electric Shock Hazard

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

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

• Connect only to grounded power source.

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

309521J 5

Xtreme Mix OEM Models

Warning

Moving parts hazard

Moving parts can pinch or amputate fingers and other body parts. Pressurized equipment can start accidentally and cause serious injury.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Before checking or servicing equipment, follow Pressure Relief Procedure, page 7. Disconnect

power or air supply.

• Do not move or lift pressurized equipment.

Equipment Misuse Hazard

Misuse can cause serious injury or death.

• For professional use only.

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

• Read manuals, warnings, tags, and labels before operating equipment. Follow instructions.

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

• Do not alter or modify equipment. Use only Graco parts and accessories.

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

ponent. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all

equipment manuals. Read fluid and solvent manufacturer’s warnings.

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

• Do not kink or overbend hoses or use hoses to pull equipment.

• To lift equipment, follow instruction, page 15.

• Comply with all applicable approval requirements and safety regulations.

Burn Hazard

This equipment is used with heated fluid, which can cause equipment surfaces to become very hot. To avoid severe burns:

• Do not touch hot fluid or equipment.

• Allow equipment to cool completely before touching it.

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

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 Material Safety Data Sheet (MSDS) to know the specific hazards of the fluids you are using.

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

Personal Protective Equipment

You must wear proper 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; and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Gloves, clothing, and respirator as recommended by the fluid and solvent manufacturer

• Hearing protection

Recoil Hazard

The gun can recoil when triggered at a very high pressure. If unprepared, this could force your hand back or cause you to fall and injure yourself. Be sure you have firm footing and hold the gun securely.

6 309521J

Pressure Relief Procedure

WARNING

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

1. Engage trigger lock.

2. Press Stop .

SUPPLY AIR PRESSURE

PLURAL COMPONENT PROPORTIONER

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

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

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

7. Engage trigger lock.

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

Open

PSI Bar MPa

9. Close sampling valves A and B.

Close Close

5. Disengage trigger lock.

309521J 7

Assemble

913913

910

911

Assemble

901

904

905

914

915

721

307

912

903

902

FIG. 1

8 309521J

Assemble

Pumps and Sensors

• If using feed pumps, do not allow feed pressure to exceed 25% of spray pressure.

• For accurate ratios, pump lowers must be same size.

• If installing 234024 or 234025, the pump size has not been set in the software. To set pump A and B size and A and B sensor calibration factors, you need Xtreme Mix Data Download software, part no. 246322 for proportioners located in a non-hazardous area, or part no. 246397 for proportioners located in a hazardous area.

Calibration values are on pump A and B sensors.

Pump Size Values

Pump Size Value

(cc/cycle)

45:1 250 56:1 220 68:1 180 80:1 145

1. Secure magnet holders (903) to the pump (2) motor displacement rods with screws (905). F

2. Install a short magnet strip then a long one (904) on each magnet holder (903). Secure with tape supplied.

3. Secure pumps (2) on mounting brackets with two 3/8 x 1-1/4” screws (913), lockwashers (914), and nuts (915).

4. Secure sensors (7) on pumps and pump mounting brackets with two screws (913), lockwashers (914), and nuts (915).

IG. 1.

Control Box

1. Mount control box (3) to mounting plate (10). FIG. 1.

a. Slide gasket (307) over back of pneumatic con-

trol box (3), against lip. Insert box through mounting plate (10).

b. Secure box (3) to plate (10) with 8-32 UNC

screws (912).

Mount box (3) vertically for optimum alternator and component life.

2. Secure mounting plate (10) to cart/stand. Install fasteners (provided by installer) through six 0.3” (7.62 mm) mounting plate holes.

3. Connect conduit (721) from two sensors (7) to pneumatic control box (3).

Conduit must be used. Approximately 62” (1575 mm) of cable and conduit provided; do not lengthen.

4. Wire two sensors (7) to control box 18-pin connector. Connect sensor A, then sensor B wires in pairs sequentially – black/green, black/red, black/white – to pins 2-13. See Electrical Schematic, page 16.

5. Connect 18-pin connector to main control board connector (F). F

IG. 2.

10 9 8 7 6 5 4 3

IG. 2 Control Box

309521J 9

Assemble

501

Key:

A Pump A Air B Pump B Air C Pump A Pilot Air D Pump B Pilot Air E Air Supply F Metering Valve A - CLOSE G Metering Valve A - OPEN H Metering Valve B- CLOSE J Metering Valve B- OPEN K Sensor A Cable L Sensor B Cable 2Pump

FIG. 3

902

901

3 Pneumatic Control 6 Metering Valve Manifold 501 Pneumatic Valve 901 Air Filter 902 Ground Wire Assembly

Ground manifold to true earth ground.

Ground by connecting ground wire from control box (3) to manifold (6).

Ground by connecting ground wire from pumps (2) to manifold (6).

10 309521J

+ 22 hidden pages