Graco 309518P manual

Repair Xtreme Mix ™ Plural Component Pr opor tioner For spra ying tw o-compon ent protective coatings. Not appr o ved f or use in explosive atmospheres. Important Safety Instructions Read all warnings and instr uctions in this manual. Sav e these instructions See page 3 for model inf ormation, including maxi- mum working pressure and approv als .[...]

2 309518P Contents Xtreme Mix M odels . . . . . . . . . . . . . . . . . . . . . . . . . 3 Manual Con ventions . . . . . . . . . . . . . . . . . . . . . . . . 4 Related M anuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 W arnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pressure Relief Procedure . . . . . . .[...]

Xtreme Mix Models 309518P 3 Xtreme Mix Models WA R N I N G Do not install e quipment appr ov ed only f or non-haz- ardous location in a ha zardous area. Substi tution of components ma y impair intrinsic saf ety . See page 5. Appro ved for Non-hazar dous Location Xtreme Mix Pa r t N o . S e r i e s Pump Pa r t N o . Pump Description Maximum W orkin [...]

Manual Conventions 4 309518P Manu al Con ventions Note Components A and B IMPORT ANT! Material suppliers can v ar y in how the y ref er to plural component materials . Be aw are that in this manual: Component A ref ers to resin or major volume. Component B ref ers to catalyst (curin g agent) or minor vo l um e. Related Manuals Component Man uals Th[...]

Warnings 309518P 5 Wa r n i n g s The f ollowing general w ar nings are related to the saf e setup , use, gro unding, maintenance , and repair of this equip- ment. Additional mor e specific wa r nings ma y be f ound throughout the te xt of this manual where applicab le. Wa r n i n g FIRE AND EXPLOSION HAZARD Flammab le fumes , such as solven t and [...]

Warning 6 309518P EQUIPMENT MISUSE HAZARD Misuse can cause deat h or ser ious inju r y . • Do not e xceed the maximum working pressu re or tempera ture rating o f the low est rated system com- ponent. See T echnical Data in all equip ment manuals . • Use fluids and solv ents that are compati ble with equipment we tted par ts. See Te c h n i c a[...]

Pressure Relief Procedure 309518P 7 Pressure Relief Pr ocedure WA R N I N G F ollow Pressure Relief Procedure when you stop spra ying and be f ore clea ning, checking, ser v icing, or transporting equipment. Read warnings, page 5. 1. Engage tr igger lock. 2. Press Stop . 3. Close main air shut off v alve on air supply line and on unit. T urn off ai[...]

Proper Lifting of Unit 8 309518P Pr oper Lifting of Unit Either remo ve the cart handle or secure it to the ca r t bef ore lifting the unit. Connect a bridle s wing, hooking an end to each of th e Xtreme Mix air mot or rings. Hook the center ring on a hoist. See F IG . 1. Carefully lift the Xtreme Mix unit; mak e sure it balances ev enly . Gr oundi[...]

Shutdown 309518P 9 Shutdo wn F ollow t his procedure bef ore prolonged shutdo wn or ser vicing equipment. 2. F ollow Full System Flushing procedure in the Xtreme Mix Operat ion manual. 3. F ollow Pressure Relief Pr ocedure , page 7. Engage tr igger lock. 4. Befo re prol onged shut down: cap fluid outlets to keep solv ent in the lines. Fill pump A a[...]

Pump Test 10 309518P Pump T est F ollow t his procedure the first ti me system is operated (after flushin g and priming) and whene ver y ou need to check whether pum ps are on ratio. The f ollowing tab le shows the v olume dispensed during the pump test, ba sed on y our pump ratio . Dispense into a container with adequate gr aduations . Pump V olum[...]

Pump Test 309518P 11 6. Compare fl uid amounts in the conta iners; the y should be equal. Repea t test if fluids are not equ al. If problem still persists, see T roub leshooting , page 12. 5. Close sampling valv e B. B Close[...]

Troubleshooting 12 309518P T r oubleshooting WA R N I N G Read wa r nings, page 5. If an error code displa ys, see page 15. Pr oblem Cause Solution Displa y not lit. No electri c power . Air va lve not turned on. T ur n on main air v alve to system. Air supply pressure too low . Increase pressure to 50 psi (0.35 MP a, 3.5 bar) or greater . Air supp[...]

Troubleshooting 309518P 13 P ain t does not cure consistently . Ratio not set correctly . Check that correct ratio is set and set b y volume . See Xtreme Mix Operation man- ual. Material not mixing correctly . T e st pump . P age 10. Make sure mix er is clean; flush as needed. See Xtreme Mix Operation man- ual. Pump not operating correctly . Obser [...]

Troubleshooting 14 309518P Flow rate too low . Inadequate air su pply . Use larger CFM compre ssor . Air pressure to pumps too low . Increase pressure. Fluid A or B filters plugged. Clean filters. See pump manual. Spra y tip too small. Relie ve pressure. Install larger tip . Follow gun manual instructions. Mixer or hoses par tially plugg ed or too [...]

Alarms 309518P 15 Alarms * Indicates error wher e audible alarm soun ds once briefly . ** Indicates error where audi ble alarm sound pul ses. • An alarm condition will shutdown the equip- ment. • A chirping sound e v er y 60 seconds indicate s the unit is set f or recirculation mode . Code Alarm Active Pr o blem Cause Startup Error s 01 Sensor [...]

Repair 16 309518P Repair F ollow Shutdo wn proc edure, page 9, if ser v ice time ma y e x ceed pot lif e time, bef ore ser vicing fluid compo- nents , and bef ore transporting equipment to a service area. Replacing Air Filter Element There are 2 air filter s on the unit: the 5 micron air mani- f old filter (518) and 40 micron pump air filter (8). C[...]

Repair 309518P 17 User Interface Removing Co ver 1. Close main air shutoff v alve on air supply line and on unit. 2. Remove air manifold co ver (42). F IG . 3, pa ge 16. 3. Remo v e f our nuts (32) and open user inter f ace cov e r (4). F IG . 7–F IG . 8. 4. T o complete ly remov e cov er (4), disconnect grou nd wire (315), wires (416 and 406) fr[...]

Repair 18 309518P Replacing Display Cir cuit Board 1. Remov e User Interf ace cov er . See page 17. 2. Disconnect wires fro m displa y board (410). F IG . 11. 3. Remove two screws (411). 4. Remo v e setscrew (B) from knob (405) and re mov e knob assembly . 5. Remo v e and replace displa y board (410). 6. Reassemble. Ref e r to Electrical Schematic [...]

Repair 309518P 19 Recalibrate Circuit Boar d F ollow t his procedure whene ver the main circuit board, softwar e, or sensor is r eplaced, or when Alarm 8 occurs (ref er to page 15). 1. Note calibration value on pum p A sensor . Refer to F IG . 23, p age 27. 2. Open main air valv e to star t unit. 3. T urn knob to pump A . F IG . 12. Hold do wn Stop[...]

Repair 20 309518P Pneumati c Contr ol Alternator Repair T urbine Alternator Repair Kit 2236 88 is av ailable to replace turbine b earings. 1. Remov e User Interf ace cov er . See page 17. 2. Disconnect po wer supply wires (P). F IG . 13. 3. Disconnect tw o air lines (310) from alternator (304). F IG . 14. 4. Remove top nut (305) and loosen bottom n[...]

Repair 309518P 21 Replacing Solenoids F ollow t his procedure to replace a sin gle solenoid. 1. Remov e User Interf ace cov er . See page 17. 2. Disconnect tw o solenoid wires (V) from main board. F IG . 16. 3. Remove two screws (S). 4. Remo v e and repl ace solenoid ( 306b). 5. Reassemble. Solenoid wires are polar ized (red +, bl ack –). Ref er [...]

Repair 22 309518P Pump Air Manif old 1. Close main air shutoff v alve on air supply line and on unit. 2. Pull off reg ulator kn ob (R). F IG . 17. 3. Remove two screws (44). 4. Disconnect tw o hoses (515) from pump mot ors. 5. Replace parts as needed. See page 40. 6. Reassemble. F IG . 17 5 44 R 515[...]

Repair 309518P 23 Sampling V alve 1. F ollow Pressure Relief Pr ocedure , page 7. 2. Unscrew sampling v alve a ssembly (83) from meter- ing v alve (601). 3. Unscrew seat (83c). 4. Remove o-rings (83f), ball (83 d), seat (83g) , and gasket (83h). 5. Replace parts as needed and reassemble . WA R N I N G Read wa r nings, page 5. F IG . 18 601 83c 607 [...]

Repair 24 309518P Metering V alve/Manifold Assembl y Removing Assemb ly 1. F ollow Pressure Relief Pr ocedure , page 7. 2. Disconnect t op and bottom b lack air tu bes. 3. Unscre w fluid tube. 4. Remov e nuts (26), screws (27, 48) and lockw ashers (25). F IG . 19. 5. Remov e meter ing valv e manifold (6). Removing Metering V alve 1. Remove Metering[...]

Repair 309518P 25 F IG . 20 627 639* † * † 637 626 * † 638 628 630 † 645* † 644 † 645* † 646 647 621 621 622 * † 632 631 623 * † 633 † 635 624 * † 643 625 629 636 1. Apply pipe sealant to non-swiveling pipe threads . 2. Apply lubricant to th reads, o-rings, and seals. Apply medium anaerobic adhesive. Thread to bottom. T orque [...]

Repair 26 309518P Servicing Fluid Manifold 245833 F ollow t his procedure to replace pac kings. Ref erence numbers with * ar e included in repair kit 234100. 1. Remo ve metering valv e. See page 24. 2. Unscrew plug (661). 3. Remo v e and replace o-rings (662*, 66 3*, 665*), seat (664*), ball (66 6*), and spring (667*). 4. Reassemble. Servicing Flui[...]

Repair 309518P 27 Sensor Reference numbers with * ar e include d in repai r kit 246345. Ref erence numbers with † are included in repair kit 246344. 1. Close main air shutoff v alve on air supply line and unit. F IG . 22. 2. Unscre w sensor cap (701†) fr om nut (712 †). F IG . 23. 3. Disconnect cab le (705*). 4. Unscrew fitting (713*), locknu[...]

Electrical Schematic 28 309518P Electrical Schematic * 2 2        ", 7 2 3 7 ",7 ",2 ' ",' 3   2         *              ",                [...]

Electrical Schematic 309518P 29 2  !      ", 2 2 ' ", "2 ' ", 7 "  48  '.$   * 7     28         *      '.$           '.$     Po w e r Supply Barri er Board Po w e r Sup[...]

Pneumatic Schema tic 30 309518P Pneumatic Schematic F IG . 24 King Motor A King Motor B Pump A Pilot Pump B Pilot Gauge 90/110 psi 0.6/0.8 MP a, 6. 2/8 bar) Relief V alv e Air Regulator 110 psi (0.8 MP a, 8 bar) Relief Va l v e Gauge 3/8 in. Air Reg. Auto Dr ain 5 micron 100 psi (0.7 MP a, 7 bar) T o Manifold 3/8 in. tube 3/4 in. Air Filter A uto D[...]

Pneumatic/Sensor Connections 309518P 31 Pneumatic/Sensor Connections F IG . 25 B Key: A Pump A Air B Pump B Air C Pump A Pilot Air D Pump B Pilot Air E Air Supply F Metering V alve A - CLOSE G Metering V alve A - OPEN H Mete ring V alve B- CLOSE J Metering V alve B- OPEN K Sensor A Cable L Sensor B Cable A C D E F G H J K L[...]

Parts 32 309518P Pa r t s Xtreme Mix Pr opor tioner P ar ts shown here and page 34 and 36. Ref . 6 (side B) 45 (side A) 46 47 47 Ref . 62 42 1 2 63 66 68 64 *30 *33 Ref . 6 Ref . 3, 4, 5 *59 *60 65 43 7 11,12,13 *8 17,29,37, 38,40 Ref . 71 See DET AIL C See DET AIL A & D See DET AIL B (blu e) *16 (green) *78 86 86 DET AIL D Pa r t s f o r Model[...]

Parts 309518P 33 Xtreme Mix Pr opor tioner Pa r t N u m b e r T a b l e Ref er to page 3 f or additional model inf ormation. Appro ved for Non-hazar dous Location Xtreme Mix Pump (2) Metering Va l v e ( 6 ) Gun (15) Hose (20) Coupling (56) Relief V alve (79) T ube (45) T ube (46) 233863 249274 (45:1) 245824 XTR704 H53 850 15B729 113498 15A914 15A91[...]

Parts 34 309518P Ref. No. Part N o. Description Qty . 1 2459 97 CAR T 1 2 see table , page 33 PUMP; see manual 31 1762 f or par ts 2 3 2458 03 PNEUMA TIC CONTR OL; parts page 37 1 4 2458 04 USER INTERF AC E; par ts page 39 1 5 2458 02 PUMP AIR MANIFOLD; parts page 40 1 6 245824 see table , page 33 METERING V AL VE MANIFOLD; par ts page 41 1 248843 [...]

Parts 309518P 35 * Not included wi th Model 248 842. ** Included with Model 248842 only . ‡ Not av ailable for order from Gr aco. ★ Order length needed from distr ibutor . 83 245143 SAMPLING V AL VE; par ts page 41 2 84* 116746 FITTING; 1/8 npt x 1/ 4 in. (6.4 mm) tube; see page 41 2 85* 116750 TUBE, nylon; 5 in. (12.7 cm); parts page 41 2 86 1[...]

Parts 36 309518P 65 77 68 67 77 77 74 76 76 76 75 72 62 6 83, 84, 85 25 28* 26 27 5 36 3 100 4 31 32 44 48* 25 10* DET AIL C DET AIL B DET AIL A 73 72 25 25 26 26 48 48 79 TI2316A Pa r t s fo r Model 248842 98 99[...]

Parts 309518P 37 Pneumatic Contr ol 245803 Item 3, page 33 306 REF 316 313 304 317 312 Ref . 304 303 301 311 315 306 m s t f c j g h f n a p k b 309 e 313 314 305 310 307 304 c d a e b 306r f 302 320 321 TI2303A TO SOLENOIDS FROM TURBINE POWER TO PUMP POSITION SENSORS 310 MOTOR A MOTOR B A PUMP B PUMP[...]

Parts 38 309518P Pneumatic Contr ol 245803 IS = intrinsically safe ** Alternator bea ring repair kit 223688 availab l e. ‡ Not availab le for order from Graco . ★ Order length ne eded from distr ibutor . Ref. No. Part N o. Description Qty . 301 2 45705 CIRCUIT BOARD 1 301a 15C318 FUSE, circuit board 1 302‡ SCREW; 8-32 UNC 4 303‡ CO VER 1 30[...]

Parts 309518P 39 User Interface 245804 Item 4, page 33 ‡ Not av ailable for order from Graco . * Alarm Code Labels Item 409, English pro vided. T o order other langu ages: 404 401 411 407 406 413 412 405,419 409 403 410 Ref . 405 Ref . 407 Ref . 403 Bac k View 414, Ref. 407 Ref. 403 Ref. 416 416 Ref . 406 415 418 TI2307A, TI2308A 15A804 15A806 Re[...]

Parts 40 309518P Pump Air Manif old 245802 Item 5, page 33 Ref. No. P art No. Description Qty . 501 C59 752 V AL VE, 3-wa y 2 502 108307 ELBOW; 3/4 npt 2 503 101689 PRESSURE GA UGE 2 504 1 12166 SCREW; 1/4-20 UNC 4 505 1 5A820 MANIFOLD 1 506 1 5A821 PLA TE, direction 1 516 515 501 523 522 502 504 503 513 505 504 506 507 508 521 513 524 503 519 518 [...]

Parts 309518P 41 Metering V alve Manif old 245824 Item 6, page 34 Metering V alve Manif old 248843 Item 6, page 34 Sampling V alve 245143 Item 83, page 35 Ref. No. Part N o. Description Qty . 601 2 45846 METERING V AL VE; par ts page 42 2 606 2 45861 SHUTOFF V AL VE; see manual 306861 1 607a 245833 FLUID MANIFOLD; parts page 43 1 611 2 45860 SHUTOF[...]

Parts 42 309518P * P ar ts included in kit 234098. † P ar ts included in kit 234131. ‡ Not av ailable for order from Gr aco. ▲ Replacement W ar ning labels availab le at no cost. 627 639* † * † 637 626 * † 638 628 630 † 645* † 644 † 645* † 646 647 621 621 622 * † 634 * † 632 631 623 * † 633 † 635 624 * † 643 625 ▲ 62[...]

Parts 309518P 43 Fluid Manif old 245833 Item 607a, pa ge 41 * P ar ts included in kit 23410 0. ‡ Not availab l e f or order from Graco . 669 676 661 *662 *663 *665 *664 *665 *666 *667 675 674 665 670 668 671 TI2304A Ref. No. Part N o. Description Qty . 661 1 5A823 PLUG 2 662* 107098 O-RING, PTFE 2 663* 107313 O-RING, PTFE 2 664* SEA T 2 665* 1033[...]

Parts 44 309518P Sensor 245825 Item 7, page 33 * P ar ts included in kit 246345. † P ar ts included in kit 246344. ★ Order length ne eded from distr ibutor . 704† 703† 720† 710* 709* 702* 719* 713* 711* 716† 712† †714 715 †701 †707 †706 †708 705* 721* TI2301A 1 Ref. No. Part N o. Description Qty . 701† 196280 CAP 1 702* 15[...]

Technical Data 309518P 45 Te c h n i c a l D a t a Mix ratio range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0 :1-10:1 (i n 0.1 inc rements) Ratio tolerance range . . . . . . . . . . . . . . . . . . . . . . . . . . . . +/- 5% Flow rates Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 qt./min[...]

Technica l Data 46 309518P PC Communication s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-232 Dimensions Car t mo del (width x height x diam eter) . . . . . . . . . . . 33 in. wide x 64.53 in. high x 44. 5 in. deep (83.8 x 163.9 x 113 cm ) W eight (car t, witho ut hose an d gun) . . . . . . . . . . . . . 625 lbs. (285 kg) * Minimum[...]

Technical Data 309518P 47[...]

All written and visual data contained in this document reflects the latest product information available at the time of publica tion. Graco reserves the right to make changes a t any time without notice. Original instructions. This manual contains English. MM 309518 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea[...]