Hitachi 309521J User's Manual
Contents
1. 26 Metering Valve 245846 27 Fluid Manifold 245833 28 Sensor245825 cee deo ace ante weeds 4 29 Technical Data 30 Graco Standard Warranty 32 Graco Information 32 309521J Manual Conventions Warning WARNING MIN 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 indi cated hazard warnings pages 5 6 Caution Manual Conventions A CAUTION A caution alerts you to possible equipment damage or destruction if you do not follow instructions Related Manuals Note NA note indicates additional helpful information Refer to the following manuals for detailed component information Component Manuals This manual available in following languages Manual Description Manual Language Manual Language 309535 Xtreme Mix Operation 309521 English 309540 German 309518 Xtreme Mix Repair 309538 French 309546 Swedish 311762 Xtreme Displacement Pump 309539 Spanish 309604 Japanese 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 Ki2. See page 21 for part no and description Parts 606 A side 611 B side 309521J Metering Valve 245846 Ref No 621 622 623 624 625 626 627 628 629A 630 631 632 t 633 634 Part No 598140 15B545 15A834 15A835 15A833 180233 245850 111040 309521J Description ELBOW 1 8 npt m x 5 32 4 mm tube VALVE CAP PISTON CYLINDER PISTON ROD TIE ROD PACKING NUT INLET HOUSING WARNING LABEL FLUID NEEDLE LOCKNUT nylon 5 16 UNC 3B O RING nitrile O RING nitrile O RING nitrile Qty 2 M hmm N Ref No 635 109141 636 637 t 638 t 189901 6391 643 t 644f 15A830 645 t 107079 102040 646 15A832 647 102637 t i A Part No Description SPRING LOCKNUT 1 4 UNC V PACKING UHMWPE GLAND male V PACKING leather O RING buna n SEAT O RING PTFE SEAT HOUSING SCREW 3 8 UNC 2A Parts included in kit 234098 Parts included in kit 234131 Not available for order from Graco Replacement Warning labels available at no cost Parts Qty BR AN O0 DON 27 Fluid Manifold 245833 Item 607 page 26 Ref No 661 662 663 664 665 666 667 668 28 Part No 15A823 107098 107313 103341 117333 Description PLUG O RING PTFE O RING PTFE SEAT O RING PTFE BALL metallic SPRING PLUG 3 8 npt Qty BN N 02 ND D ND N Ref No Part No 669 15A825 670 192977 67
3. NEA unan g ic i 61 Y ploug jog I oaaz i AJA LOG Bullajo V uonisogd Jolld V dwng Y plougjos I OdA cL g 1010W Bury V 10101 Bury I SERE SE ESR ERE RSS RES NEN S1 Prom BEKI D jsneyxg 7 Buo pe X 2 L aV Alddng aiy 309521J 18 FiG 10 Pneumatic Schematic 309521J 19 Parts Parts Xtreme Mix Proportioner 918 919 920 20 309521J Xtreme Mix Proportioner Part Numbers Parts Approved for Hazardous Location Class 1 Div 1 Group D Xtreme Mix Pump 2 Plate 10 233871 249274 45 1 246332 233872 249275 56 1 246334 233873 249276 68 1 246336 233874 249277 80 1 246338 233875 249278 45 1 246332 233876 249279 56 1 246334 233877 249280 68 1 246336 233878 249281 80 1 246338 234024 none 246338 Includes Ref No Part No Description Qty 2 PUMP see table above see pump 2 manual for parts 3 245803 PNEUMATIC CONTROL page 22 1 4 245804 USER INTERFACE page 24 1 5 245802 PUMP AIR MANIFOLD 1 6 245824 METERING VALVE MANIFOLD 1 page 26 7 245825 SENSOR page 29 2 9 246149 KIT includes 901 917 1 10 PLATE see table above 1 918 245143 SAMPLING VALVE parts page 26 2 919 116746 FITTING 1 8 npt x 1 4 6 4 mm 2 tube see page 26 920 116750 TUBE nylon 5 in 12 7 cm see 2 30
4. Key A Pump A Air 3 Pneumatic Control B Pump B Air 6 Metering Valve Manifold C Pump A Pilot Air 501 Pneumatic Valve D Pump B Pilot Air 901 Air Filter E Air Supply 902 Ground Wire Assembly F Metering Valve A CLOSE a G Metering Valve A OPEN N Ground manifold to true earth ground H Metering Valve B CLOSE A Ground by connecting ground wire from control box 3 to J Metering Valve B OPEN manifold 6 K Sensor A Cable L Sensor B Cable A Ground by connecting ground wire from pumps 2 to manifold 6 2 Pump FIG 3 10 309521J Assemble Grounding Standard Setup FIG 1 and FIG 3 WARNING VAN CE Read warnings page 5 and follow instructions below 2 1 Connect 12 gauge ground wire provided by installer from pneumatic control box 3 ground screw 312 page 22 to metering valve manifold 6 Refer to FIG 3 1 Mount pneumatic control assembly 3 to mounting plate 10 FiG 1 Connect an air line A and B between each pneu matic valve 501 and pump air motor inlet FIG 3 36 914 mm hoses provided Installer may pro Vide different lengths 2 Connect ground wire from each pump 2 to meter 3 Connect air supply from air manifold s 5 micron air ing valve manifold 6 3 Connect ground wire assembly 902 to fluid mani filter 518 to control box air inlet not shown fold 6 Connect clamp end to a true earth ground N the alternator requires 12 15 scfm of air to
5. e For professional use only e Use equipment only for its intended purpose Call your Graco distributor for information e Read manuals warnings tags and labels before operating equipment Follow instructions e Check equipment daily Repair or replace worn or damaged parts immediately Do not alter or modify equipment Use only Graco parts and accessories e Do not exceed the maximum working pressure or temperature rating of the lowest rated system com ponent See Technical Data in all equipment manuals e 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 e Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces e Do not kink or overbend hoses or use hoses to pull equipment e To lift equipment follow instruction page 15 e 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 e Do not touch hot fluid or equipment e Allow equipment to cool completely before touching it e Wear gloves if fluid temperature exceeds 110 F 43 C Da 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 swal lowed e Read Material Safety Data Sheet MSDS to
6. 112166 SCREW 1 4 20 UNC 4 SL 505 15A820 MANIFOLD 1 Cs 9 i EX gs S 506 15A821 PLATE direction 1 SEER IX ove 507 117332 REGULATOR 1 508 100840 ELBOW 1 4 npt 1 510 15A819 MANIFOLD BLOCK 1 511 160032 NIPPLE 3 4 npt 1 512 117346 SHUTOFF VALVE vented 1 513 117364 O RING nitrile 3 514 108849 SCREW 1 4 20 UNC 2 515 15B554 HOSE 3 4 npt 4 ft 1 2 m 2 516 100549 ELBOW 90 3 4 npt 2 517 165198 NIPPLE 1 4 x 3 8 npt 1 518 119644 FILTER 3 8 npt 5 micron 1 519 114316 ELBOW swivel 3 8 npt 1 520 114151 ELBOW swivel 1 8 npt x 5 32 4 2 mm tube 521 100721 PLUG 1 4 18 nptf 3 522 512912 MUFFLER 1 2 npt 2 523 100896 BUSHING 3 4 x 1 2 npt 2 524 113498 SAFETY RELIEF VALVE 110 psi 1 0 8 MPa 8 bar 525 117443 STANDOFF aluminum 8 32 UNC 526 240900 HOSE 3 4 npt 2 5 ft 0 76 m 527 158962 ELBOW 1 8 m x 1 4 f 528 113911 GUAGE 1 8 air NM TI2295B AN 100 psi 0 7 MPa 7 bar setting 309521J 25 Metering Valve Manifold 245824 Item 6 page 21 Ref No Part No Description 601 245846 METERING VALVE page 27 606 245861 SHUTOFF VALVE see manual 306861 607 245833 FLUID MANIFOLD page 28 611 245860 SHUTOFF VALVE see manual 306861 Sampling Valve 245143 Item 918 Ref No Part No Description 918a 245110 KNOB 918b 197681 HOUSING 918c 197332 SEAT 918d 107536 BALL carbide 918e 110082 RETAINING RING 918f 111457 O RING PTFE 918h 187060 GASKET 26 Qty po
7. 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 r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information TO
8. remote fluid manifold only Flow rates and or viscosity differences between compo nent materials can create different pressure drops from the proportioner to the manifold causing unequal back pressure This will effect mix ratio accuracy 14 Assemble To calculate pressure loss Pressure Loss 0 000273 x Q x VL D4 Q Flow GPM V Viscosity in centipoise L Length of pipe in feet D Pipe diameter to the 4th power Example If you need to pump 1 gpm of high solids paint 40 seconds in a Zahn 2 cup 100 cp 100 ft in a sys tem using 1 4 pipe Pressure Loss 0 000273 x 1 gpm x 100 cp x 100 ft 364 ID 018 D factor Pressure Loss 152 psi Reduce pressure loss by using Large diameter pipe or tubing Constant tubing or pipe size Long runs without bends Long radius elbows You can balance differences in component back pres sure by adjusting hose diameter and length D 018 for 1 4 pipe 06 for 3 8 pipe 15 for 1 2 pipe Using the previous example 000273 x 1 x 100 x 100 2 73 Pressure drop 1 4 pipe 152 psi 3 8 pipe 46 psi 1 2 pipe 18 psi 309521J Proper Lifting A WARNING Follow instructions below to avoid dropping or swing ing unit or being struck by the cart handle which can cause serious injury or damage to equipment Either remove the cart handle or secure it to the cart before lifting the unit Connect a bridle swing hooking an end to each of
9. the Xtreme Mix air motor rings Hook the center ring on a hoist See FIG 9 Carefully lift the Xtreme Mix unit make sure it balances evenly Operation and Repair For operating instructions including data collection see Xtreme Mix Operation manual 309521J aS RU Ec TESTET Proper Lifting For troubleshooting alarm information and repair instructions see Xtreme Mix Repair manual 15 Electrical Schematic Main Circuit Board 245705 Key BL Black BR Brown BL GBlack with green BL RBlack with red 16 ElectricalSchematic Je 1 15VDC rg 2 COM Far 3 Jumper 15V 95 H Solenoids La mw E g Metering Valve A Metering a Bt 3 Metering Valve B _ Valves 7 L ER 2 T 2 ee Air Motors n BL 3 Pump B 1 Hr J4 Sensor 243678 8 7 5 Sensor 4 243678 3 2 1 J2 Case Gnd Clip i a 3 EET 4 BE G6 a 7 p JA 1 J1 4 2 2 3 3 3 4 4 4 5 5 6 6 6 BL WBlack with white S Shield G Green W White GNDGround R Red 309521J Power Supply Barrier Board Air Input Front Panel Alarm Alarm COM COM Port Alarm 15A849
10. 11 674 111307 675 116343 676 159239 Description PIPE outlet PIPE center HOUSING LOCKWASHER GROUND SCREW M5 x 0 8 NIPPLE 3 8 x 1 2 npt A Parts included in kit 234100 Not available for order from Graco Parts Qty MN N 309521J Sensor 245825 Item 7 page 21 Ref No Part No 7011 196280 702 15A818 703t 243500 7044 115925 705 117331 7061 115917 7074 110004 708T 196289 709 116024 710 101855 711 112546 309521J Description CAP COVER BOARD SPACER CABLE SENSOR O RING PTFE CAP TAB TERMINAL SCREW 4 24 UNC SCREW 4 40 taptite Ref No 7121 713 7141 715 7167 719 7201 721 D N uu Part No 15A817 117569 154741 245831 104765 117586 C20272 117582 Description NUT 1 8 npt FITTING 3 8 npt x 5 16 conduit O RING buna n BRACKET PLUG 18 27 ptf LOCKNUT 3 8 18 npt O RING fluoroelastomer CONDUIT 5 ft 1 5 m Parts included in kit 246345 T Parts included in kit 246344 Order length needed from distributor A Calibration label Parts Qty X Na a ap a 29 Technical Data Technical Data Mix ratio range 0 0 1 10 1 in 0 1 increments Ratio tolerance range 5 Flow rates Minimum rb a nan pLa 1 qt min 0 95 liter min MaxiMUM a amp ane ea DOE Rees 3 gal min 11 4 liter min Fluid viscosi
11. 952 1J page 26 Approved for Non hazardous Location Xtreme Mix Pump 2 Plate 10 233879 249274 45 1 246333 233880 249275 56 1 246335 233881 249276 68 1 246337 233882 249277 80 1 246339 233883 249278 45 1 246333 233884 249279 56 1 246335 233885 249280 68 1 246337 233886 249281 80 1 246339 234025 none 246339 EN Refer to page 4 for additional model information Kit 246149 Item 9 Ref No 901 902 903 904 905 906 907 908 909 910 911 912 913 914 915 916 917 Part No 117628 244524 15A847 15A814 104092 511352 054753 113498 116643 100015 100016 103196 100004 100133 100131 054139 C12508 Description AIR FILTER 3 4 npt GROUND WIRE with clamp MAGNET HOLDER MAGNET STRIP SCREW 10 24 UNC STATIC MIXER not shown TUBING nylon black 0 156 4 mm 10 ft 3 m not shown SAFETY RELIEF VALVE 110 psi 0 8 MPa 8 bar SAFETY RELIEF VALVE 90 psi 621 kPa 6 2 bar NUT 1 4 20 UNC LOCKWASHER SCREW 8 32 UNC SCREW 3 8 UNC LOCKWASHER NUT 3 8 16 UNC TUBING nylon 0 5 13 mm 3 ft 0 9 m not shown TUBING nylon 0 375 9 5 mm 3 ft 0 9 m not shown Order length needed from distributor Qty ANN mb 00005 21 Parts 313 316 Pneumatic Control 245803 Item 3 page 21 313 306r TO SOLENOIDS FROM TURBINE POWE
12. Installation Parts GRACO Xtreme Mix OEM Plural Component Mixer OEM Unit i 309521J Important Safety Instructions Read all warnings and instructions in this manual 24 Save these instructions See page 4 for model information including maxi mum working pressure and approvals PROVEN QUALITY LEADING TECHNOLOGY Graco Inc P O Box 1441 Minneapolis MN 55440 1441 Copyright 2005 Graco Inc is registered to I S EN ISO 9001 Contents Manual Conventions 3 Related Manuals 3 Xtreme Mix OEM Models 4 Warning 30e nes de eee LANANG 5 Pressure Relief Procedure 7 Assembl es nus al ment j r aa NA 8 Pumps and Sensors 9 Control Box 5228 funeste rue Lee os 9 Grounding 11 Air Controls fer tee oe hae LAS bee Ras 11 User Interface a ee a kak aedes 12 Fluid Manifold 12 Proper Lifting 15 Operation and Repair 15 Electrical Schematic 16 Pneumatic Schematic 18 Parts 1 BANK BNG a a ee nee 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
13. 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 reserves the right to make changes at any time without notice This manual contains English MM 309521 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 www graco com 309521J 1 2008
14. R Ref 304 TO PUMP POSITON SENSOR 314 MOTOR A MOTOR B A PUMP REF 310 309521J 22 Parts Pneumatic Control 245803 Ret Ref No ipti No Part No Description Qty o Parto eeenpllon SN sol 245705 CIRCUIT BOARD RR a 301a 15C318 FUSE circuit board 1 P iuba PAP 3024 SCREW 8 32 UNC 306qt 112512 WIRE FERRULE orange not 8 3031 COVER 1 shown 304 245854 ALTERNATOR MODULE includes 1 306r 117369 CONNECTOR 12 position 1 items 304a 304e 306s 150278 ADAPTER 1 4 x 1 8 npt 1 304a 193154 GASKET 304b 15A853 e WIRE HARNESS 304c 111225 TUBE FITTING 90 306t 117480 e SAFETY RELIEF VALVE 26 psi 179 kPa 1 8 bar 307 15A800 GASKET neoprene i N BR N sn 4 304d 114380 SCREW M5 x 25 3094 SCREW M5 x 10 2 304e 249254 TURBINE ALTERNATOR 310 590385 TUBE poly flo 3 8 OD 1 ft 3m x 3054 LOCKNUT 8 32 UNC 3114 NUT KEPS 410 24 1 3064 SOLENOID MODULE IS includes 312 104029 GROUNDING STUD 1 items 306a 306t 313 15A849 WIRE HARNESS alarm 1 306a 15A822 e MANIFOLD 1 314 117442 CONNECTOR 18 position 1 306b 117356 e VALVE 12 VDC IS 4 315 15B090 GROUNDING WIRE door 1 306c 114263 qu 1 8 npt x 5 32 4mm 6 316 15B056 LABEL air connections 1 9099 NIPELE UADD gt ine i ER terminal SUO PICO AIRES TRUST got 118129 SPACER 8 32 UNC x 5 127 mm 1 306f 115841 ELBOW swivel 1 4 npt x 3 8 3 i 9 5 mm tube 306g 160701 e ELBOW street 1 8 npt m x f 306h 108190
15. RS232 Connector R Ww HHHHH Display Board 245706 309521J Electrical Schematic Comport Pin Front View Start Stop GND Switch 15A851 Stop 1 2 2 19 5 2 1 GND 3 Key Switch momentary Key Switch 15A852 17 Pneumatic Schematic Pneumatic Schematic ONEA 491194 eq 8 1 eq4 62 ISd 92 UOJOIW OZ jddng Jamog euiqunj id dn Jojejnbay JOH AY v e oe JI J0 2UJ9 Y YAN adA p jq voe 190 BAA Ieg t E o bed 2908 129 Z BAN i i 2 0 isd 001 onjeA Aem g EB i UOJOIW G i ureiq om abner lod g dun o1 MEZ F pa b O TENA px UNS arie aqn B E x i i PIOJILUEW OL OA ZL i I b I LOS I l onjeA Aem g pro W 8LG Jolld v dung OL uoiisog ONEN i Kg ak i T jeyou eq 8 i Y lougjo I ed 8 0 gt Joyejnboy sly piouejog sd i AGA 7 ves isd Okt s ane 81184 O eq 8 2 9 ean abne9 i 80 9 0 Sd OL L 06
16. TFE leather Metering Valves carbon steel zinc plating carbide polyethylene leather Manifold ocra xe een ee Pace e carbon steel zinc plating carbide 302 stainless steel MIXGE sn Seems boat a KALIPUNAN ias stainless steel Spray QUI Scart KANA enr hr bn abies See gun manual PC Communications RS 232 Minimum flow rate is dependent on the material being sprayed and mixing capability Test your material for spe cific flow rate 30 309521J Technical Data 309521J 31 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 tampe
17. e GAUGE 306jt GASKET neoprene 306kt GASKET neoprene IS intrinsically safe Alternator bearing repair kit 223688 available Not available for order from Graco Order length needed from distributor n 309521J 23 User Interface 245804 Item 4 page 21 Ref i 414 407 415 Ref TH La 403 i Ref AN Ref 406 AG Back View 412 Ref No Part No Description 401 COVER 403 15A851 WIRE HARNESS start stop 404 15A801 GASKET 405 15C335 KNOB 406 15A850 WIRE HARNESS data port 407 15A852 WIRE HARNESS key switch 409 LABEL alarm code 410 245706 CIRCUIT BOARD 4114 SCREW 4 40 412 15A856 DISPLAY PANEL 4134 NUT 4 40 24 15A804 407 403 Qty 1 1 1 1 1 1 1 1 2 1 4 Parts Ref 407 410 411 Ref 403 Ref No Part No Description Qty 414 MOUNT 415 STRAP 416 15A854 WIRE HARNESS display 4184 419 107232 SET SCREW WASHER a BA WW Not available for order from Graco Alarm Code Labels Item 409 English provided To order other languages Part No Languages 15B843 Chinese Finnish Portuguese Greek Swedish Italian 15B844 English Spanish French German Korean Japanese 309521J Parts Pump Air Manifold 245802 Item 5 page 21 520 Ref No Part No Description Qty 501 C59752 VALVE 3 way 2 502 108307 ELBOW 3 4 npt 2 502 503 101689 PRESSURE GAUGE 2 504
18. func before starting unit Air Controls N Do not use air supply hose smaller than 3 4 19 mm ID Smaller hose could restrict air flow and cause alternator solenoids or Mac valves to mal function Check air supply gauge at pump changeover air pressure should not drop 309521J tion correctly e Do not use 3 8 9 5 mm ID air supply tubing longer than 24 610 mm from air filter to control box air inlet e Do not restrict control box exhaust air Increased back pressure can cause a drop in alternator power output resulting in delayed valve action and processor shutdown and reboot Connect tubing C and D from solenoids to each pneumatic valve 501 Mount air supply filter 901 to cart stand and con nect air supply E to air manifold 5 air inlet 11 User Interface FIG 4 and FIG 5 1 Connect display board 410 communication cable 416 to J1 on main circuit board 301 2 Connect data cable 406 7 pin connector to J2 A WARNING Mw The user interface must be grounded Read warnings page 5 3 Connect ground wire 315 to ground stud on back of cover with nut 311 4 Secure cover 4 to mounting plate 10 with lock washers 911 and nuts 910 FIG 1 311 406 FIG 4 Cover back view Assemble 301 Fic 5 Control Box Fluid Manifold A CAUTION Do not assemble
19. it provided do not 561 220 lengthen 68 1 PES 4 Wire two sensors 7 to control box 18 pin connec 80 1 145 tor 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 1 Secure magnet holders 903 to the pump 2 motor displacement rods with screws 905 FIG 1 5 Connect 18 pin connector to main control board connector F FIG 2 2 Install a short magnet strip then a long one 904 on each magnet holder 903 Secure with tape sup plied 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 Fic 2 Control Box 309521J 9 Assemble 2 501 al 9 pod 9 9 9 e p gt j JUR T I 902 6 m i q
20. jection 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 A 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 e Do not blow back fluid this is not an air spray system e Follow Pressure Relief Procedure page 7 when you stop spraying and before cleaning checking or servicing equipment e Use lowest possible pressure when flushing priming or troubleshooting e Never spray without tip guard and trigger guard installed Engage trigger lock when not spraying e Tighten all fluid connections before operating the equipment e Check hoses tubes and couplings daily Replace worn or damaged parts immediately High pres sure 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 e Use equipment only in well ventilated area Eliminate all ignition sources such as pilot lights cigarettes and plastic drop cloths potential static arc e Do not plug or unplug power cords or turn lights on or off when flammable fumes are present e Keep the work area free of debris including solvent rags and gasoline e Grou
21. know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines LT y 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 e Protective eyewear e Gloves clothing and respirator as recommended by the fluid and solvent manufacturer e 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 309521J Pressure Relief Procedure Pressure Relief Procedure 6 Hold a metal part of the gun firmly to a grounded WARNING metal pail Trigger gun to relieve pressure 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 iol 8 Place waste container under sampling valves then open valves A and B slowly to relieve pressure G between pump and metering valves pp creme AD Close 3 Close main air shutoff valve on air supply line and on
22. nd equipment and conductive objects See Grounding page 11 e Hold gun firmly to side of grounded pail when triggering into pail e Use only grounded hoses e 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 e 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 e Keep a fire extinguisher in the work area uly 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 regu lations e Connect only to grounded power source e Turn off and disconnect power at the main switch before disconnecting any cables and before servic ing equipment ER 309521J 5 Xtreme Mix OEM Models Nem Tus Moving parts hazard Moving parts can pinch or amputate fingers and other body parts Pressurized equipment can start acci dentally and cause serious injury e Keep clear of moving parts e Do not operate equipment with protective guards or covers removed e 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
23. ring 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
24. static mixer directly to fluid manifold Install static mixer after first 50 ft 15 m of hose to ensure material is completely mixed Spraying unmixed material could necessitate rework of part sprayed See Setup in Xtreme Mix Operation manual 12 Install Sampling Valves 244683 Install sampling valves 918 into the metering valves 601 Install barb fitting 919 and tubing 920 into each sampling valve FIG 7 309521J Assemble Cart mounted 1 Secure metering valve assembly 6 to cart stand with screws 913 washer 914 and nuts 915 FIG 1 page 8 2 Connect fluid lines provided by installer between 218 pumps and metering valves 3 Cut air line tubing included to length needed to 919 920 connect between metering valves 601 and sole Th noid outlets FIG 3 page 10 and FiG 6 A side 606 B side 611 Bottom of Valve A Bottom of Valve B FIG 7 POSING VALVES AIR MOTOR PILOT VALVES Pilot Valve A side Pilot Valve B side BD CLOSE Top of Valve B Top of Valve A FIG 6 Control Box bottom Remote Fluid Manifold To install remote fluid manifold order part no 15A898 All other parts referred to in the following procedure are parts you remove from the stan dard manifold and reuse or parts the installer must supply 1 Remove metering valves 601 and shutoff valves 606 611 from fluid manifold 607 FIG 7 2 Install me
25. t 309568 Remote Manifold Kit 309521J 3 Xtreme Mix OEM Models A WARNING VO Do not install equipment approved only for non haz ardous location in a hazardous area Substitution of components may impair intrinsic safety See page 5 Xtreme Mix OEM Models Approved for Hazardous Location Class I Div 1 Group D Xtreme Maximum Working Mix Pump Pump Pressure Part No Series Part No Description psi MPa bar Approvals 233871 A 249274 45 1 King 4500 31 310 lt gt Ed 233872 A 249275 56 1 King 5600 38 6 386 M ah 2G 233873 A 249276 68 1 King 6800 46 9 469 FMst 3600 8 4610 for 233874 A 249277 80 1 King 7250 50 500 uu ne Be 233875 A 249278 45 1 Quiet King 4500 31 310 T3 Hazardous locations 233876 A 249279 56 1 Quiet King 5600 38 6 386 CE Sn ma 233877 A 249280 68 1 Quiet King 6800 46 9 469 OE 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 USNC 233881 A 249276 68 1 King 6800 46 9 469 a inte DE 233882 A 249277 80 1 King 7250 50 500 233883 A 249278 45 1 Quiet King 4500 31 310 CE 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 309521J Xtreme Mix OEM Models Skin In
26. tering valves 601 and shutoff valves 606 611 onto fluid metering manifold 15A898 Fia CAUTION 8 Do not assemble static mixer directly to fluid manifold Install static mixer after first 50 ft 15 m of hose to ensure material is completely mixed Spraying unmixed material could necessitate rework of part sprayed See Setup in Xtreme Mix Operation manual e Maximum length of tubing is 36 914 mm Locate fluid manifold as close as possible 3 Secure fluid metering manifold 15A898 on the cart stand with 2 screws 913 washers 914 and nuts 915 309521J 13 4 Screw ball valves 606 611 purchased separately into fluid mix manifold 607 5 Select appropriate fittings and fluid hose sizes and lengths to connect between fluid metering manifold 15A898 and mix manifold 607 Balance pressure drops in the 2 lines as instructed below to assure an accurate mix ratio 6 Connect fluid lines provided by installer between pumps and metering valves 601 7 Connect mixed material hose to fluid mix manifold 607 outlet E 8 Cut air line tubing included to length needed to connect between metering valves 601 and sole noid outlets FIG 3 page 10 and FIG 6 page 13 9 Cut air line tubing included F G H J FIG 3 page 10 to length needed to connect between metering valves 601 and solenoid outlets 10 Connect ground wires Balancing Back Pressure QW This procedure is for the
27. ty range 200 20 000 cps heavier viscosities can be mixed with use of optional heaters heated hoses and hardware Fluid filtration 60 mesh 238 micron standard Maximum fluid working pressure ABN ziniserkeeterieisRag ETERA kage nee 4500 psi 31 MPa 310 bar DOM ae na NATA UE 5600 psi 38 6 MPa 386 bar 68 3 ejer ir tid tated cea ete AR ER ce beh hae ee 6800 psi 46 9 MPa 469 bar 310 Far MORD 7250 psi 50 MPa 500 bar Air supply pressure range 50 110 psi 345 800 kPa 3 5 8 bar Maximum air consumption at 100 psi 0 7 MPa 7 bar in cfm m3 min A51 EP Soa 110 3 1 BOs oed sieur RM pista Beets aks 125 3 5 GSH usus due als vu a eR SR RC Ea EROS 155 4 4 BO laan netu a Delta Ed uev PAR Cbr 180 5 1 Ambient temperature range Operating ii e bad sia eae nu 32 130 F 0 54 C SIOrdge vs peaux ues BE DOR ead 30 160 F 1 71 C Environmental Conditions Rating Indoor outdoor use Altitude up to 4000 meters Maximum relative humidity to 9996 up to 54 C Pollution degree 11 Installation category 2 Sound pressure 98 dBA at 100 psi 0 7 MPa 7 bar Wetted parts Suction tubes aluminum PUMpS 2 cu Yam Te reel Es eee ANG carbon steel alloy steel 303 440 amp 17 4ph grades stain less steel zinc and nickel plating ductile iron tungsten carbide P
28. unit Turn off air regulator 4 Close fluid sampling and shutoff valves A and B 309521J 7 Assemble Assemble FIG 1 8 309521J Assemble Pumps and Sensors Control Box 1 M t trol t ti late 10 FIG 1 AL If using feed pumps do not allow feed pressure sul ba AES to Mouna plate EX Fl to exceed 25 of spray pressure a Slide gasket 307 over back of pneumatic con trol box 3 against lip Insert box through e For accurate ratios pump lowers must be pa mounting plate 10 same size e If installing 234024 or 234025 the pump size b Secure box 3 to plate 10 with 8 32 UNC has not been set in the software To set pump screws 912 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 hazard ous area 2 Secure mounting plate 10 to cart stand Install fas teners provided by installer through six 0 3 7 62 mm mounting plate holes Mount box 3 vertically for optimum alternator and component life Calibration values are on pump A and B sen sors 3 Connect conduit 721 from two sensors 7 to pneu Pump Size Values matic control box 3 Pump Size Value cc cycle K Conduit must be used Approximately 62 1575 45 1 250 mm of cable and condu
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