Graco Series A User manual

Instructions-Parts
Mix Manifold Kit 3A2801A
EN
For at-the-gun mixing of 2 component materials when used with a ProMix™ PD2K Proportioner.
For professional use only.
Important Safety Instructions
Read all warnings and instructions in this manual
and in your PD2K proportioner manual. Save these
instructions.
See page 2 for model part numbers,
maximum fluid working pressure, and
approvals.
PROVEN QUALITY. LEADING TECHNOLOGY.

Models
Part No. Series Description Maximum Fluid Working Pressure
24R991 A Low Pressure Mix Manifold 300 psi (2.1 MPa, 21 bar)
24R992 A High Pressure Mix Manifold 1500 psi (10.5 MPa, 105 bar)
24T273 A High Pressure Mix Manifold, for
acid-catalyzed materials
1500 psi (10.5 MPa, 105 bar)
23A2801A

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 symbol refers to procedure-specific
risks. When these symbols appear in the body of this manual or on warning labels, refer backtothese
Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout
the body of this manual where applicable.
WARNING
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.
•Grounda
ll equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless
they are antistatic or conductive.
•Stop operation immediately if static sparking occurs or you feel a shock, Do not use
equipment until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
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.
•Dono
t 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.
•Dono
t 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/dispensing and before
cleaning, checking, or servicing equipment.
•Tig
hten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
3A2801A 3

Warnings
WARNING
TOXIC FLUID OR FUMES
Toxic fluids or fumes can cause serious injury or death if splashed in the eyesoronskin,
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.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury,
including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective
equipment includes but is not limited to:
•Protectiv
e eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent
manufacturer.
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.
•Useflui
ds 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. Alterations or modifications may void agency approvals
and create safety hazards.
• Make sure all equipment is rated and approved for the environment in which youareusingit.
•Usee
quipment 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.
•Kee
p children and animals away from work area.
• Comply with all applicable safety regulations.
43A2801A

Installation
Installation
1. Connect the component A supply to the A side
fitting (19a) of the mix manifold.
2. Connect the component B supply to the B side
fitting (19b) of the mix manifold.
3. Connect the solvent supply to the solvent fitting
(20) of the mix manifold.
4. Connect the static mixer hose (106) to the gun
whip hose.
This equipment must be grounded to reduce
the risk of static sparking. Static sparking can
cause fumes to ignite or explode. Grounding
provides an escape wire for the electric current.
5. Connect the ground wire (105) to the ground
screw (23). Connect the other end of the ground
wire to a true earth ground.
Figure 1 Mix Manifold
Operation
1. Check that all hose connections are tight before
each use.
2. To spray, move the lever (16) to the
(SPRAY) position. Components A and B will
enter the mix manifold and be mixed by the mix
nozzle (10) and the static mixer tube (106).
3. To flush, move the lever (16) to the (FLUSH)
position. Solvent will flush the mix manifold,
static mixer, and gun.
4. To shut down, flush the mix manifold and relieve
pressure as described in the PD2K operation
manual. Always leave the mix manifold lever in
the (FLUSH) position when not in use.
Figure 2 Mix Manifold Set to Spray
Figure 3 Mix Manifold Set to Flush
3A2801A 5

Repair
Repair
Disassembly
1. Flush the mix manifold before servicing. See the
PD2K operation manual.
2. Relieve the pressure as described in the PD2K
operation manual. Disconnect the hoses, taking
note of which port (A or B) they are connected to.
3. Unscrew a plug (15) from the manifold body (1).
Remove and discard the seal (22) each time
aplugisre
moved. Inspect the seat (12) and
o-rings (13, 14). Replace if damaged.
4. Repeat for the other two plugs (15).
5. Unscrew the outlet fitting (11). Remove the o-ring
(9), bearing (8), mix nozzle (10), and stem ball
(6).
NOTE: When removing the A and B check valves
(19), notewhichisfromtheAsideandwhichis
from the Bside.
6. Unscrew the check valves (19, 20).
7. Unscrew the packing nut (5). Remove the valve
stem (4), backup washers (3), and o-ring (2).
8. Unscrew the nut (17). Remove the lever (16).
Figure 4 Mix Manifold Repair
63A2801A

Repair
Reassembly
NOTE: Lubricate all o-rings when reassembling.
Plug Seals Repair Kit 420011 is available. Parts
includedinthekitaremarkedwithanasterisk,for
example (12*). Order the kit separately.
Lever Seals Repair Kit 420012 is available. Parts
included in the kit are marked with a symbol, for
example (2◆). Order the kit separately.
Outlet Seals Repair Kit 420013 is available. Parts
included in thekitaremarkedwithasymbol,for
example (8†). Order the kit separately.
Ball Repair Kit 24T752 is available. Parts included in
the kit are marked with a symbol, for example (6‡).
Order the kit separately.
1. Install the backup washers (3◆) and o-ring (2◆)
on the valve stem (4). Insert the stem into the
body (1).
2. Screw the packing nut (5) into the body (1) so it
bottoms on the shoulder. Install the lever (16)
and nut (17) so the notch (N) in the lever faces
the B side, as shown.
Figure 5 Lever Orientation
3. Move the lever to the SPRAY position. Install the
stem ball (6) in the manifold body (1) so the small
hole on one side of the stem is facing the side
of the body marked SPRAY (A). The ball must
engage with the valve stem (4).
4. Install the bearing (8†) and o-ring (9†). Insert
the mix nozzle (10) into the stem ball (6) so it
bottoms on the shoulder. Loosely screw the
outlet fitting (11) into the body (1).
5. Apply thread adhesive to the check valves
(19, 20). Be sure to install the A and B check
valves (19) in the correct ports, as noted under
Disassembly.
6. Check that the lever (16) is in the SPRAY
position. This positions the ball stem (6) so the
smooth rounded surface is facing the solvent
port. Proper positioning is important to ensure
that the seal (22) conforms properly against the
ball.
7. Apply a small amount of fluid compatible grease
to the seat (12) and seal (22). Install them in the
solvent plug port, with the beveled side of the
seat (12) facing in, toward the ball (6).
8. Install the o-rings (13*, 14*) on the solvent plug
(15) and screw the plug into the solvent port
securely.
9. Move the lever (16) to the FLUSH position. This
positions the ball stem (6) so the smooth rounded
surface is facing the A and B ports. Repeat steps
7and8fortheAandBplugs.
Figure 6 Detail of Seal and Seat Assembly
10. When all three plugs (15) are installed, tighten
the outlet fitting (11).
11. Reconnect the hoses, A to A and B to B.
Reconnect the solvent hose.
12. Return the mix manifold to service.
3A2801A 7

Parts
Parts
Mix Manifold Kit Parts
Part No. 24R991 Low Pressure Mix Manifold Kit
Part No. 24R992 High Pressure Mix Manifold Kit
Part No. 24T273 High Pressure Mix Manifold Kit, for acid catalyzed materials
Ref.
No.
Part
No.
Description Qty
101 16W557 BRACKET, belt 1
102 16W558 BRACKET, gun/belt 1
103 16W559 RETAINER, bracket 1
104 16W560 NUT, retaining 1
105 16W562 WIRE, ground; 25 ft (7.6 m) 1
16W564 HOSE, static mixer; low
pressure; for 24R991; 3/8
npsm (fbe); 9.25 in. (235 mm)
long
1
106
16W563 HOSE, static mixer; high
pressure; for 24R992; 3/8
npsm x 1/4 npsm (fbe); 8.0 in.
(203 mm) long
1
16W556 MANIFOLD, mix; for 24R991
and 24R992
1107
16W616 MANIFOLD, mix; for 24T273 1
108 16W561 HANDLE, mix manifold 1
109 101550 SCREW, cap, socket head;
1/4–20 x 0.5 in. (13 mm)
1
83A2801A

Parts
Mix Manifold Parts
Part No. 16W556 Mix Manifold (used on 24R991 and 24R992 Kits)
Part No. 16W616 Mix Manifold (used on 24T273 Kit for acid-catalyzed materials)
Ref.
No.
Part
No.
Description Qty
1——— BODY, manifold 1
2◆ ——— O-RING; PTFE 1
3◆ ——— WASHER, backup; acetal 2
4 178745 STEM, valve, ball 1
5165964 NUT, packing 1
6‡ ——— BALL, stem 1
7‡ ——— PLUG, ball valve 1
Ref.
No.
Part
No.
Description Qty
8†‡ ——— BEARING, guide; acetal 1
9†‡ 111457 O-RING; PTFE 1
10‡ ——— NOZZLE, mix 1
11 16W554 FITTING, outlet; 3/8 npsm(m) 1
12*‡ ——— SEAT, ball; PEEK 3
13*‡ 112319 O-RING; chemically resistant 3
14*‡ 121399 O-RING; chemically resistant 6
16W551 PLUG; for 16W556 315
24T874 PLUG; for 16W616 3
16 24T838 LEVER 1
17 102310 NUT, hex; 10–32 1
18 ——— HANDLE, lever 1
16W462 VALVE, check; 1/4 npsm; for
16W556
219
16W461 VALVE, check; 1/4 npsm; for
16W616
2
20 16W463 VALVE, check; 3/8 npsm 1
22*‡ ——— SEAL, ball; PPS 3
23 112506 SCREW, ground; 4–40 x 0.25
in. (6 mm)
1
* These parts are included in Plug Seals Repair Kit
420011, which must be ordered separately.
◆T
hese parts are included in Lever Seals Repair Kit
420012, which must be ordered separately.
† These parts are included in Outlet Seals Repair Kit
420013, which must be ordered separately.
‡ These parts are included in Ball Repair Kit 24T752,
which must be ordered separately.
Parts labeled — — — are not available separately.
3A2801A 9

Accessories
Accessories
Part No. Description
24N641 1/8 in. (3 mm) ID Fluid Whip Hose; nylon; 6 ft (1.8 m); for high and low pressure applications.
3200 psi (22 MPa, 220 bar) Maximum Fluid Working Pressure.
24N305 1/4 in. (6 mm) ID Fluid Whip Hose; nylon; 6 ft (1.8 m); for low pressure applications only. 225
psi (1.6 MPa, 16 bar) Maximum Fluid Working Pressure.
24N348 1/4 in. (6 mm) ID Fluid Whip Hose; ptfe; 6 ft (1.8 m); for high pressure applications only. 3000
psi (20.7 MPa, 207 bar) Maximum Fluid Working Pressure.
24T753 Acid Catalyst Conversion Kit. To convert a 16W556 standard mix manifold to a 16W616 mix
manifold for use with acid-catalyzed materials.
24T873 Fluid Outlet Quick Disconnect Kit. Replaces the manifold’s fluid outlet fitting to allow
quick-disconnect of the static mixer hose.
24U059 5/16 in. (8 mm) ID Grounded Air Whip Hose, for use with electrostatic guns; 1/4 npsm(f) x
1/4 npsm (f) left–hand thread; 6 ft (1.8 m). 100 psi (0.7 MPa, 7 bar) Maximum Air Working
Pressure.
16F537 5/16 in. (8 mm) ID Air Whip Hose, for use with conventional air spray guns; 1/4 npsm(f); 6 ft
(1.8 m). 200 psi (1.4 MPa, 14 bar) Maximum Air Working Pressure.
24S004 Air Line Quick Disconnect, for use with electrostatic guns.
10 3A2801A

Technical Data
Technical Data
Mix Manifold U.S. Metric
Maximum fluid working
pressure:
24R991 Low Pressure
Mix Manifold
300 psi 2.1 MPa, 21 bar
24R992 High Pressure
Mix Manifold
1500 psi 10.5 MPa, 105 bar
24T273 High Pressure
Mix Manifold, for
acid-catalyzed materials
1500 psi 10.5 MPa, 105 bar
Mixing ratio range: 0.1:1 — 50:1, ±1%
Fluid outlet size (static
mixer):
3/8 npt(f)
Weight (approximate): 1.25 lb 0.57 kg
Wetted parts:
16W556 Mix Manifold 302, 303, 316, and 17–4PH SST,
perfluoroelastomer; PEEK, PTFE, CV-75
16W616 Mix Manifold, for
acid-catalyzed materials
302, 316, and 17–4PH SST,
perfluoroelastomer; PEEK, PTFE, CV-75
3A2801A 11

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, 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: [phone] or Toll Free: 1-800-328-0211 Fax: [phone]
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.
For patent information, see www.graco.com/patents.
Original Instructions. This manual contains English. MM 3A2801
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2013, Graco Inc. All Graco manufacturing locations are registeredtoISO9001.
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