Graco 2K device EcoMix 2000 Operation manual

USER INFORMATION
6000303E
KEEP FOR FUTURE USE Rev. C
B.8.20.60
2K device EcoMix
®
2000
ND 85 20
ND 85 35
ND 85 50
ND 85 85
HD 50 20
HD 50 35
HD 50 50
GRACO
®
GRACO N.V.
Industrieterrein “Oude Bunders”
Loc. 2206 - Slakweidestraat 31
3630 Maasmechelen - Belgium
Tel.: [phone] Fax: [phone]

REGULAR TESTING OF THE APPLIANCES
Person responsible
Test certificate No. Test date Company Name
The fluid spraying equipment is intended in particular for surfacing (e.g. airless paint spraying
equipment, two-component coating equipment).
The operator must ensure that fluid spraying equipment is tested for proper operation after an
operating pause of more than 6 months, and at least every 12 months by a competent person1).
The operator must ensure that the test results are properly recorded in writing for every fluid spraying
equipment 2) and kept until the next test.
The operator must ensure that the test certificate is available at the place of use 3) of the fluid
spraying equipment.
1) A competent person is somebody that has sufficient knowledge in the field of fluid spraying
equipment based on professional training and experience; and is sufficiently conversant with
the relevant national health and safety regulations, accident prevention regulations,
recommendations and generally accepted rules and industrial norms to evaluate fluid spraying
equipment.
2) Written records (test results) can be for exemple test certificates.
3) At the place of use, a copy of the test certificate or a test stamp on the appliance is considered
as in compliance with the requirements.
-Extract from: Arbeiten mit Flüssigkeitsstrahlern (VBG 87)
Issued on: 10th October 1993
§ 23 (1), (3) and (4)
Durchführungsanweisung VBG 87
to § 1 Para. 1 and to §23 Para. 1, Para. 3, Para. 4

1
Subject to change Cont’d 1of 38
Prepared by
Checked by
25.07.96
B 8.20.60-B
Issued
06.02
USER INFORMATION
OPERATING INSTRUCTIONS
29.07.96
GRACO
ECOMIX 2000
BASIC VERSION, BASIC APPLIANCE, COMPLETE APPLIANCE
The original manufacturer's nameplate is on the 2K device.
Please compare all specifications and supplement, if
necessary.
CONTENTS OF USER INFORMATION
OPERATING INSTRUCTIONS Page
CORRECT USE 2
FUNCTIONAL DIAGRAM 2
DESCRIPTION OF FUNCTIONS 4
EQUIPMENT COMPONENTS – IMPORTANT INFORMATION 4
LIST OF TOOLS 9
INSTALLATION 9
START UP 12
IMPORTANT INFORMATION CONCERNING COMMISSIONING AND OPERATION 17
OPERATION 18
MAINTENANCE AND INSPECTION, REPAIR 19
TORQUES 30
SHUT DOWN 32
COMPONENTS FOR ND MODELS ONLY – IMPORTANT INFORMATION 33
TROUBLE SHOOTING 36
NOTES 37
Self-monitoring system
Important directives, regulations and rules to comply with; user information;
Customer Service
TECHNICAL PRODUCT DESCRIPTION Page
DESCRIPTION OF THE 2K DEVICE 01
SUITABILITY, FLUID 02
TECHNICAL DATA 03
Key
Construction kit; data; sound emission
Construction materials of wetted parts
Dimensions, threaded screw connection, rated diameters
NOTES 07
LIST OF REPLACEMENT PARTS (KITS)
REPLACEMENT – LOWER PUMPS, REPLACEMENT ACCESSORIES (extract from sales catalogue)
The following are included separately:
TEST CERTIFICATE (Final acceptance)
EC – DECLARATION OF CONFORMITY (to be attached to 2K device)
BRIEF OPERATING INSTRUCTIONS, WARNING SIGNS
Read and follow up the operator
manual and the safety instructions
before taking the pump into
operation
In this manual important information is
marked with the following symbols:
Information affecting your safety
Important operational directions
Ensure that all other users know and
understand all safety directions.

B.8.20.60-B
- 2 -
3.1
9, 10, 23
11, 12,
13, 14
15, 16
2.1
CORRECT USE
ECOMIX 2000 equipment is exclusively manufactured for common applications in surfacing
technology, for spraying or discharging or similar work with 2K fluids.
Any other purpose above and beyond this is considered as incorrect use. We are not liable for any
damage or injury resulting from this; the user will bear sole liability in such cases.
Correct use includes observing operating, maintenance and inspection conditions and regulations laid
down by us.
The ECOMIX 2000 may only be operated, maintained and repaired by personnel familiar with, and
trained to recognize the inherent dangers.
The relevant accident prevention regulations as well as safety and medical rules must be respected.
Unauthorized modifications to the appliance releases us from any liability for damages arising from
this.
The user is responsible for the correct installation of the appliance.
FUNCTIONAL DIAGRAM
See figure on the page
D2K-DEVICE
ECOMPRESSED AIR SUPPLY
FAIR EXHAUST SOUND SUPPRESSION
GFLUID SUCTION SYSTEM
HFLUID PRESSURE SYSTEM
ISUPPORT (not shown)
JFLUSHING PUMP
KFLUID PRESSURE SYSTEM (ND MODELS ONLY) see page 33
1Compressed air container Fluid container
2Pipeline or hose Suction pipe
Air filter Hydraulic unit
3Pressure regulation valve High-pressure screen
Manometer bs Valve unit
4Ball valve bt Static mixer
5Ball valve bu Hose line
6Safety valve cl Spray gun
7Safety valve cm Strainer
8Silencer cq Wet cup
cr Pressure regulation valve with manifold for
bursting disc

B.8.20.60-B
- 3-
For ND models only

B.8.20.60-B
- 4 -
2.1
DESCRIPTION OF FUNCTIONS
Compressed air is fed from a pressure tank 1to the 2K device Dvia a tube or hose line 2and a
pressure regulation valve 3, if possible through a separate air filter .
The air supply from the pressure tank to the 2K device can be interrupted by the ball valve 5.
The ball valve 4is used to release condense manually, - an automatic moisture trap is
recommended here.
The safety valve 6protects the pressure tank against unacceptable air pressure increases (e.g.
when heated).
Because it is required and the compressed air supply Eis usually not installed for the 2K device
alone, the piston pump also features a safety valve 7.
During operation of the piston pump air motor, the compressed air escapes into the atmosphere via
the silencer 8, thus relieving its pressure.
The fluids (A = base and B = hardener ) are sucked out of the containers (A = 9and B = bl) into the
piston pump bo and bp through suction lines bm and bn and supplied separately under high pressure
through the high-pressure screen bq and br the valve unit bs and the static mixer bt. Here they are
mixed well and the fed over the hose line bu to the spray gun cl.
The strainers cm protect the 2K device against foreign substances that might have accidentally
entered the fluid.
A wet cup (flushing agent tank) cq is indispensable for hydraulic units
as well as for valve units of this design and is decisive for its installation.
If the equipment is not operated for a longer period of time (exceeding the processing time), it must be
flushed from the valve unit bs to the spray gun cl. This is done with the flushing pump Jalong the
suction line cn from container co.
During the flushing procedure the pressurized solvent is led to the valve unit bs, then to the mixer bt,
along the suction line bu to the spray gun cl.
The ND models have a pressure regulation valve with a manifold for a bursting disc bt behind the
mixer cr, that protects the hose line bu and the spray gun cl against overpressure.
EQUIPMENT COMPONENTS – IMPORTANT INFORMATION
The following components are required in an operational system:
DTHE 2K DEVICE
The functional description of the 2K device can be found in the corresponding section in the
"Technical Product Description B. 8.20.60-P".
ETHE COMPRESSED AIR SUPPLY
The compressed air supply consists of the compressor, the pressure tank with moisture trap, possibly
a compressed air drier and pipeline. The compressed air supply is generally already available to the
user.

B.8.20.60-B
- 5-
3.1
−When compressed air supply needs to be installed, the relevant accident prevention regulations,
safety rules and user information must be respected, in particular the information supplied by the
compressor manufacturer.
The connection between the 2K device and the compressed air line must be flexible to avoid rupture
caused by vibration.
A hose line is most suitable
−Rated diameter DN16 or more
−Working pressure = maximum system pressure, preferably > 16 bar (for max.
system pressure on the 2K device, see pages 22 and 23).
−Air and ambient temperatures -20° to +50 °C
In areas with a danger of explosion compressed air lines and hose lines must be electrically
conductive to avoid electrostatic charging.
The pressure regulation valve and the manometer in the functional diagram
are part of the 2K device.
Every 2K device features a shut-off mechanism (a ball valve)
- This enables a quick and safe shut-off of the 2K device for operational breaks, maintenance work
and in cases of errors.
The rule for ball valves: wings transverse to flow direction means that the line is shut off
Do not use PTFE tape hemp to seal connections, this leads to pressure regulation valve malfunction
due to residue from the compressed air supply.
The following special requirements apply to the quality of the compressed air supplied to the 2K
device. −Condense and residue oil from the compressor are separated mechanically
(pressure tank, compressed air filter)
−Lubrication of compressed air not necessary
−Temperature of compressed air < 50 °C
In painting processes the compressed air must be free of substances (oil, silicone) that can lead to the
formation of pits.
−This also applies to all components of the compressed air supply.

B.8.20.60-B
- 6 -
FAIR EXHAUST SILENCER
The sound emission of an air powered 2K device is damaging to hearing in the absence of a silencer
[> 115 dB(A)].
As there is a relation between sound absorption and the formation of ice on the air motor control
system, the sound level cannot be reduced with a silencer as much as would be desired [not to
70 dB(A)].
All basic and complete ECOMIX 2000 systems are therefore fitted with correctly proportioned
silencers.
For detailed information on the sound pressure level, see the
corresponding section in the "Technical Product Description
B. 8.20.60-P"
Do not remove the silencer of the flushing pump when the 2K equipment is operating.
−The necessity to wear hearing protection depends on the working pressure and the
resulting sound pressure level.
GFLUID SUCTION SYSTEM
The suction connections of ECOMIX 2000 equipment are constructed to allow that a swivel unit
(angular or T-shaped) and a connector can be screwed in.
Connection units 1 and 2 are used to connect the suction system, the suction line and the suction cup.
All wetted metal parts of the suction unit are made from
austenitic stainless steel (- suitable for water-based paints).
Most of the 2K devices are equipped with a connector 1and a suction
system 2(suction hose, tube and suction sieve).
The swivel connector enhances the flexibility of the suction hose so an
almost empty fluid container will not be turned over by the recoil force of
the suction hose.

B.8.20.60-B
- 7 -
The diameter of the suction line is designed to enable suction of fluids with a kinematic viscosity of up
to 750 mm²/s (cSt) by the 2K device without difficulty. A higher viscosity rating can result in reduced
suction performance, or even interrupted suction, that can be identified by an increasing pressure drop
during the change of direction (pulsating pressure).
−Measures for improvement are:
keeping the suction line as short as possible or a short suction hose with a larger diameter, or a
suction cup.
Specifications of suction assembly:
•Electrically conductive, maximum permissible resistance 3 x 104Ohm/m (tested to ISO 8031) or
leakage resistance to earth < 106Ω•
(- Suitable for use in locations with an explosion hazard.)
•The individual parts of the suction line are designed to withstand an overpressure of 12 bar
(- suitable for suction heights of up to 8.5 m).
•The suction hose and the strainer are resistant to solvents commonly used in surface coating, and
are silicone-free.
•Minimum rated width DN 19
•Fluid temperature 10 to 85 °C
•Mesh size of screen 1.8
In case of a fixed installation, the connection between the 2K device >
fluid circulation line or between the 2K device > pressure tank must be
flexible (- to avoid rupture caused by vibration).
The suction line 3therefore consists of the connector 1, a nipple 4
and the smooth, stainless steel braided suction hose 5and threaded
connection on the side of the pressure tank. A threaded connection
G 1/2 A with 60° sealing core is required.
The inlet pressure (pressure in a supply system, e.g. in the circulation line), acting on the
hydraulic units and the suction line must not exceed 10 bar.
It is recommended to install a small container 6to the connector 1on the
hardener side to mix smaller amounts of fluid.
The container, the connector, the cover and the inserted screen are made of
austenitic stainless steel (- suitable for water-based paints).
* The container can be protected with an additional burst disc (Part No. 76188 020002) against
rupture by vibration.
•The capacity of the container is 5 l
•Design certification for highly inflammable liquids of classes AI and AII is not required, since the
container is made entirely from stainless steel.
•Suitable for use in areas with explosion hazards, because electrostatic charging cannot be
generated.

B.8.20.60-B
- 8 -
HFLUID PRESSURE SYSTEM
The fluid pressure system consists of the hose line and the discharge or spray gun. In some cases a
pressure regulation valve has been installed as well.
A pressure regulation valve 7(mechanically or pneumatically controlled) can be
fitted at the fluid outlet of the 2K device.
Follow the relevant user information.
If we supply the pressure-regulation valve, the user information has been provided.
The hose line 8connects the 2K device with the spray gun.
The hose line is connected to the 2K device without seal rings (sealed head
screwed joint).
For surface coating applications, the hose line must have the following
specifications:
•Electrically conductive, max. resistance 3 •104Ohm/m (tested to ISO 8031)
•The inside pipeline coating must be resistant to normal solvents, the outer coating resistant under
certain conditions.
•Silicone-free
•Operating temperature -40 to +80 °C
•Complies with relevant standards (dimensioning, marking)
•The sealing head nipples of the hose fittings are made from austenitic stainless steel or zinc plated
and yellow chrome plated steel.
•Working pressure must be higher than the pressure of the 2K device (approx. 250 bar)
•Connection thread normally G1/4.
The nozzle or spray gun 9is installed at the end of the hose line (thread size
G 1/4).
Follow the relevant user information.
The user information has also been provided when we supplied the
nozzle/spray gun.
ISUPPORT
The equipment support (trolley) is a regular part of every 2K device.
The trolley has four wheels.
Since the trolley wheels cannot be locked, the floor surface must incline as little
as possible. Secure with wedges, if necessary.
The wheels are not electrically conductive.
This means that the 2K device can only be used in locations with explosion
hazards (i.e. Zone 1), when specific safety measures are taken. There are no
objections to its use in Zone 2.
The label on the right is affixed to the trolley and refers to
the guidelines to be respected.