Graco 233855 Instruction Manual

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2005, Graco Inc. is registered to I.S. EN ISO 9001
309535 rev.G
Operation
Xtreme Mix™
Plural Component Mixer with stand
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 3 for model information, including maxi-
mum working pressure and approvals.
United States, Patent No. 6,896,152

Contents
2309535G
Contents
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Related Documentation . . . . . . . . . . . . . . . . . . . . . 2
Xtreme Mix Models . . . . . . . . . . . . . . . . . . . . . . . . . 3
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 10
Proper Lifting of Unit . . . . . . . . . . . . . . . . . . . . . . . 11
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Pump Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Mix and Integration Tests . . . . . . . . . . . . . . . . . . . 23
Batch Dispense or Ratio Check . . . . . . . . . . . . . . 24
Pump Cycle Counter . . . . . . . . . . . . . . . . . . . . . . . 25
Circulation Setting . . . . . . . . . . . . . . . . . . . . . . . . . 25
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 27
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 32
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 32
Related Documentation
Component Manuals This manual available in following languages:
Alarm Code Labels:
Manual Description
309518 Xtreme Mix Repair
309329 Xtreme Displacement Pump Operation
309340 Xtreme Displacement Pump Repair
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
310797 Remote Mix Manifold
310794 Remote Mix Proportioning Systems
310863 Feed and Flush Kits
309827 Air Supply Kits
Manual Language Manual Language
309535 English 309598 Italian
309536 French 309599 Finnish
309537 Brazilian Por-
tuguese
309600 Swedish
309545 Spanish 309601 Chinese
309596 German 309602 Korean
309597 Greek 309603 Japanese
310754 Dutch 3107565 Danish
310755 Norwegian
Part No. Languages
15B843 Chinese, Finnish, Portuguese, Greek, Swedish,
Italian
15B844 English, Spanish, French, German, Korean,
Japanese

Xtreme Mix Models
309535G 3
Xtreme Mix Models
WARNING
Do not install equipment approved only for non-hazardous location in a hazardous area. Substitution of compo-
nents may impair intrinsic safety. See page 5.
Approved for Hazardous Location
Class I, Div 1, Group D
Xtreme
Mix
Part No. Series
Pump
Part No.
Pump
Description
Maximum Working
Pressure
psi (MPa, bar) Approvals
233855 A 249274 45:1 King 4500 (31, 310)
233856 A 249275 56:1 King 5600 (38.6, 386)
233857 A 249276 68:1 King 6800 (46.9, 469)
233858 A 249277 80:1 King 7250 (50, 500)
233859 A 249278 45:1 Quiet King 4500 (31, 310)
233860 A 249279 56:1 Quiet King 5600 (38.6, 386)
233861 A 249280 68:1 Quiet King 6800 (46.9, 469)
233862 A 249281 80:1 Quiet King 7250 (50, 500)
248831 A 249285 80:1 King 7250 (50, 500)
248832 A 249284 68:1 King 6800 (46.9, 469)
248833 A 249283 56:1 King 5600 (38.6, 386)
248834 A 249282 45:1 King 4500 (31, 310)
Approved for Non-hazardous Location
233863 A 249274 45:1 King 4500 (31, 310)
233864 A 249275 56:1 King 5600 (38.6, 386)
233865 A 249276 68:1 King 6800 (46.9, 469)
233866 A 249277 80:1 King 7250 (50, 500)
233867 A 249278 45:1 Quiet King 4500 (31, 310)
233868 A 249279 56:1 Quiet King 5600 (38.6, 386)
233869 A 249280 68:1 Quiet King 6800 (46.9, 469)
233870 A 249281 80:1 Quiet King 7250 (50, 500)
*248842 A 249276 68:1 King
Remote Mix
5000 (34.5, 345)
*Model 248842 is designed for remote feed pumps and a remote mix manifold. It does not include hoppers, mix
manifold, hose, or spray gun. Refer to manual 310794 for application layout.
Model 248842 is limited to 5000 psi (34.5 MPa, 345 bar) for use in “quick set” packages where heated hoses,
whip hoses, and spray accessories are limited to 5000 psi (34.5 MPa, 345 bar). If all your downstream compo-
nents are rated for 7000 psi (48 MPa, 483 bar), you can replace the standard relief valve with relief valve
113498.
Conforms to
F
M std 3600 & 3610 for
use in Class I Div 1
Group D
T
3 Hazardous locations
ll 2 G
CAN/CSA
22.2 No. 157-92
& No. 1010.1-92
Conforms to UL std 61010A-1
CSA std C22.2 No 1010.1-92

Manual Conventions
4309535G
Manual Conventions
Note
Components A and B
IMPORTANT!
Material supplier s can vary in how they refer to plural
component materials.
Be aware that in this manual:
Component A refers to resin or major volume.
Component B refers to catalyst (curing agent) or minor
volume.
WARNING
WARNING: a potentially hazardous situation which, if
not avoided, could result in death or serious injury.
Warnings in the instructions usually include a symbol
indicating the hazard. Read the general Warnings
section for additional safety information.
CAUTION
CAUTION: a potentially hazardous situation which, if
not avoided, may result in property damage or
destruction of equipment.
Hazard Symbol Additional helpful information.

Warnings
309535G 5
Warnings
The following general warnings are related to the safe setup, use, grounding, maintenance, and repair of this equip-
ment. Additional more specific warnings may be found throughout the text 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.
• Ground equipment and conductive objects in 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 fire extinguisher in the work area.
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and regu-
lations.
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 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.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.

Warning
6309535G
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• 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.
• Check equipment daily. Repair or replace worn or damaged parts immediately.
• Do not alter or modify equipment.
• For professional use only.
• Use equipment only for its intended purpose. Call your Graco distributor for information.
• 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.
• Comply with all applicable safety regulations.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns,
do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.
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.
• Read MSDS’s 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 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, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
• Hearing protection
RECOIL HAZARD
Gun may recoil when triggered and cause you to fall and be seriously injured if you are not standing
securely.
Warning

Warning
309535G 7

Overview
8309535G
Overview
Usage
The Xtreme Mix can mix most two-component epoxy
and urethane paints. Only Model 248842 is for use with
“quick-setting” paints (those with a pot life of less than
15 minutes). Other models cannot be used with such
paints without modification. Contact your distributor for
information.
The Xtreme Mix is operated with the User Interface, Air
Controls and Fluid Controls, described below and on
page 9. Refer to FIG. 1 and FIG. 2.
User Interface
The User Interface has 6 main interfaces.
1. Knob to select functions:
2. Start button to initiate functions
3. Stop button to terminate functions
4. Key switch to change ratio or reset pump cycle
counter
5. Display (five-digits) to view:
•Ratio
• Alarm codes
• Pump cycles
6. Data port allows for connection to a PC serial port
to download cycle count, operation, ratio setting,
and error alarm data.
Icon Function
Spray: proportion and spray material
Run pump A: operate pump A independent
of pump B (priming, flushing) for 12 cycles
Run pump B: operate pump B independent
of pump A (priming, flushing) for 12 cycles
Batch Dispense: dispense proportioned
amounts of A and B
Pump Test: dispense predetermined
amount of A and B to verify pump operation
and metering
Cycle Counter: totalize A and B pump
cycles
When run independently, A and B light indicators
(L) will show which pump is running.
A
B
The display includes an alarm code label in
English. See page 2 to order additional lan-
guages.
WARNING
The PC must be in a non-hazardous location and a
safety barrier must be installed between the PC and
Xtreme Mix unit. See Xtreme Mix software manual.
FIG. 1
I
O
PSI
Bar
MPa
PSI
Bar
MPa
BA
B
A
0
3
5
1
2
6
4
L

Overview
309535G 9
Air Controls
A. Main air shutoff valve (bleed-type) to shutoff all
air to Xtreme Mix (including controller power)
B. Supply air pressure gauge to monitor air pressure
to Xtreme Mix
C. Pump air pressure regulator with gauge to adjust
and monitor pump air pressure
Solenoid Module
There are 4 solenoids inside the controller.
Fluid Controls
D. Sampling valves A and B to batch dispense or test
pumps
E. Shutoff valves A and B to shutoff fluid A or B from
entering the fluid manifold
A minimum air pressure supply of 50 psi (0.35
MPa, 3.5 bar) must be maintained for the Xtreme
Mix to operate properly.
Push in regulator knob to lock setting. Be careful
when pulling knob out to change setting as knob
is removable. To reinstall, push knob to snap into
place.
FIG. 2
I
O
PSI
Bar
MPa
PSI
Bar
MPa
BA
B
A
0
A
B
C
FIG. 3
Solenoid ON/OFF for:
1 Metering valve A
2 Metering valve B
3 Pilot valve A - turns pump A ON/OFF
4 Pilot valve B - turns pump B ON/OFF
There are 2 metering valves, one for fluid A (F1)
and one for fluid B (F2). The metering valves are
turned on and off by solenoids 1 and 2.
FIG. 4
1234
D
E
F2
B Side
D
E
A Side
F1
AB

Pressure Relief Procedure
10 309535G
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 .
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.
5. Disengage trigger lock.
I
O
SUPPLY AIR
PRESSURE
PLURAL COMPONENT PROPORTIONER
I
O
PSI
Bar
MPa
PSI
Bar
MPa
AB
Close Close
Close Close
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.
9. Close sampling valve A and B.
AB
Close Close
Open Open
Close
A
Close
B