Instructions - Parts
3A0590G
EN
Mix Manifold
For mixing two component reactive materials with plural-component sprayers.
For professional use only.
Approved for use in explosive atmospheres.
Part No. 262807
Mix Manifold, Single Flush
Part No. 24M398
Quickset Mix Manifold, Dual Flush with Carriage, Gauges, and Static Mixers
7250 psi (50 MPa, 500 bar) Maximum Working Pressure
5000 psi (34.5 MPa, 345 bar) Maximum Flush Inlet Pressure
160 °F (71 °C) Maximum Fluid Temperature
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
262807
24M398
ti19004a
ti18954a
cT5
II 2 G
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Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual, refer back to these 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.
• Ground all equipment in the 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 working fire extinguisher in the work area.
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.
• 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. 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.
• Use equipment 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.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
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Warnings
WARNING
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 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.
• Do not 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 and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
THERMAL EXPANSION HAZARD
Fluids subjected to heat in confined spaces, including hoses, can create a rapid rise in pressure due to
the thermal expansion. Over-pressurization can result in equipment rupture and serious injury.
• Open a valve to relieve the fluid expansion during heating.
• Replace hoses proactively at regular intervals based on your operating conditions.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and
cause serious injury.
• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
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
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.
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Warnings
WARNING
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical
reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or
property damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier
for compatibility.
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, hearing loss, inhalation of
toxic fumes, and burns. This equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
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Important Two-Component Material Information
Important Two-Component Material Information
Isocyanate Conditions
Moisture Sensitivity of
Isocyanates
Isocyanates (ISO) are catalysts used in two component
foam and polyurea coatings. ISO will react with moisture
(such as humidity) to form small, hard, abrasive crystals,
which become suspended in the fluid. Eventually a film
will form on the surface and the ISO will begin to gel,
increasing in viscosity. If used, this partially cured ISO
will reduce performance and the life of all wetted parts.
Spraying or dispensing materials containing
isocyanates creates potentially harmful mists, vapors,
and atomized particulates.
Read material manufacturer’s warnings and material
MSDS to know specific hazards and precautions
related to isocyanates.
NOTE: The amount of film formation and rate of crystal-
lization varies depending on the blend of ISO, the
humidity, and the temperature.
Prevent inhalation of isocyanate mists, vapors, and
atomized particulates by providing sufficient
ventilation in the work area. If sufficient ventilation is
not available, a supplied-air respirator is required for
everyone in the work area.
To prevent exposing ISO to moisture:
•
Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere. Never
store ISO in an open container.
To prevent contact with isocyanates, appropriate
personal protective equipment, including chemically
impermeable gloves, boots, aprons, and goggles, is
also required for everyone in the work area.
•
Keep the ISO pump wetcup or reservoir (if installed)
™
filled with Graco Throat Seal Liquid (TSL ), Part
206995. The lubricant creates a barrier between the
ISO and the atmosphere.
Material Self-ignition
•
•
Use moisture-proof hoses specifically designed for
ISO.
Never use reclaimed solvents, which may contain
moisture. Always keep solvent containers closed
when not in use.
Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings and
material MSDS.
•
•
Never use solvent on one side if it has been contam-
inated from the other side.
Always lubricate threaded parts with TSL or grease
when reassembling.
Keep Components A and B
Separate
Foam Resins with 245 fa
Blowing Agents
Some foam blowing agents will froth at temperatures
above 90°F (33°C) when not under pressure, especially
if agitated. To reduce frothing, minimize preheating in a
circulation system.
Cross-contamination can result in cured material in
fluid lines which could cause serious injury or
damage equipment. To prevent cross-contamination
of the equipment’s wetted parts, never interchange
component A (isocyanate) and component B (resin)
parts.
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Important Two-Component Material Information
Changing Materials
•
Changing material types used in your sprayer
requires special attention to avoid equipment dam-
age and downtime.
•
•
Always clean the fluid inlet strainers after flushing.
When changing between epoxies and urethanes or
polyureas, disassemble and clean all fluid compo-
nents and changes hose sets.
•
•
•
Check with your material manufacturer for chemical
compatibility.
Most materials use ISO on the A side, but some use
ISO on the B side.
Epoxies often have amines on the B (hardener)
side. Polyureas often have amines on the B (resin)
side.
A and B Component Designations
Material suppliers and markets refer to plural component materials differently. The table below summarizes the differ-
ent designations for the components used in various machines.
Machine Left Machine Right
Market
Equipment
Designations
Side
Side
A
B
Letter
Color
Foam and Polyurea
Urethane Pour
Red
Blue
™
All Reactors, HFR ,
ISO, Hardener, Polyol, Resin,
Component Names
™
Catalyst
Base
and VRM
Low Volume
Side
High Volume
Side
Major or Minor Component
(when not 1:1 mix)
A
B
Letter
Color
Blue
Green
®
Hydra-Cat , Xtreme-
Epoxy and Urethane
Protective Coatings
Hardener, Cata-
lyst
Low Volume
Side
™
™
Mix , XM , XP, and
Resin, Base
Component Names
™
PR70
High Volume
Side
Major or Minor Component
(when not 1:1 mix)
A
B
Letter
Color
Red
Blue
Epoxy, Silicone, Ure-
thanes, and other mate-
rials
Polyol, Resin, ISO, Hardener,
PR70 and PR
Component Names
Base
Catalyst
High Volume
Side
Low Volume
Side
Major or Minor Component
(when not 1:1 mix)
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Component Identification
Component Identification
B
Key:
A
B
C
D
E
F
G
H
J
Resin (High Volume) Inlet (A material)
Hardener (Low Volume) Inlet (B material)
Solvent Inlet Valve, 1/4 npt(m)
Manifold
Dual Shutoff Handle
Hardener Restrictor Adjustment
Hardener Center Inject Tube (not shown; inside outlet H)
Mix Manifold Outlet, 1/2 npt(f) with 3/8 npt(m) adapter
Static Mix Housing
Fluid Whip Hose
Airless Spray Gun
Static Mixing Element (not shown; inside J)
Fluid Mix Hose
B Side Flush Inlet Check Valve
A Side Check Valve Cartridge (B side not shown)
A Side Solvent Inlet Valve (Quickset Manifold)
A Side Solvent Check Valve (Quickset Manifold)
A
E
D
P
F
R
S
C
K
L
G, H
M
N
P
R
S
T
J, M★
J, M★
N ★
U
J, M★
on page 22.
K ★
L ★
ti19003a
Quickset Manifold
T
ti18954a
U
FIG. 1: Typical Installation
8
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Overview
Overview
The left side of the mix manifold is intended for the major
volume material, or the higher viscosity material if using a
1:1 volume mix. This side is referred to throughout the
manual as the resin side or “A” side.
The resin and hardener enter the mix manifold through the
manifold inlet ports and spring loaded carbide ball checks.
The “A” material flows through the manifold to the material
outlet port. The injector tube creates a hollow stream of “A”
material for the “B” material to fill once the hardener exits
the injector tube. The resin and hardener material mix after
they have left the mix manifold block (B).
The right side is referred to as the Hardener side or “B”
side. The “B” side incorporates an adjustable restrictor for
balancing the system back pressure and flow.
When the manifold is mounted remote from the propor-
tioner, adjust the “B” side restrictor (F) to balance the sys-
tem back pressure and flow.
See FIG. 2 to view flow of “A” and “B” material inside the
Mix Manifold.
On the standard mix manifold, mixed material is flushed out
by sending a flush solvent through the B side center tube.
On the quickset mix manifold, solvent is also flushed across
the A side fluid check valve.
“A” Side of Mix Manifold
“B” Side of Mix Manifold
“A” Inlet Ball Valve
“B” Inlet Ball Valve
F
F
“A” side solvent
flush inlet
across check
ball added on
Quickset model.
Solvent Fluid Inlet
(on “B” side)
“B” side solvent
flush inlet after
restrictor (Used on
both models)
“B” side flow
after check
valve
Carbide
Check Valve
(on each side)
H
r_258987_3a0420_3a
H
r_258987_3a0420_2a
Mixed Material
A Side Material
B Side Material
FIG. 2: Cross-Section Side Views of A and B Flow
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Installation
Installation
For assistance in setting up a plural component sprayer,
contact your Graco distributor, to ensure that you select
the proper type and size equipment for your system.
Fluid Outlet
Connect the outlet to two primary static mixer tubes (J),
with mixer elements (M), to the mix hose (N), cleanup
mixer (J), whip hose (K), and spray gun (L).
NOTICE
Fluid Inlets
To prevent creating a flare on the mixer tube, do not
use a union swivel end on the mix tube inlet.
The A and B fluid inlets (A and B) are equipped with 1/2
npt(f) ball valves. Connect 1/2 in., 3/8 in., or 1/4 in.
npsm(f) fluid hoses with adapter nipples as needed. See
brochure 339361 for high pressure hose and fitting part
numbers.
Add mixed material hose as necessary between the mix
hose and cleanup mixer.
NOTICE
NOTE: If the manifold is remote, the hoses must be
information.
Never split the flow to multiple guns until the two flu-
ids are mixed after the mix manifold assembly.
Mounting
Solvent Inlet
Connect the solvent supply line (D) from the solvent
pump to the 1/4 npt(m) solvent inlet valve (C), or inlet
tee on the Quickset model.
Remote Mix Manifold
The mix manifold can be removed from the proportioner
and mounted closer to the gun. This reduces the volume
of mixed material and flush solvent for quick setting
materials (less than 10 minute pot life). See Volume
remote setup information.
NOTE: Use a Graco approved grounded hose rated
to withstand the maximum fluid working pressure of
the solvent pump. The hose core must be chemi-
cally compatible with the solvent being used, such
as nylon or PTFE.
Use Remote Mix Manifold Carriage 262522 for in-line
hose mount locations. The carriage protects the mani-
fold and valves from accidental operation which could
cause a plugged line.
Bare Manifold
To mount the bare manifold, drill two holes in the mount-
ing surface, and secure with the two 1/4-20 screws (28).
9/32 diameter
1.1 in. (27.94 mm)
10
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Grounding
Grounding
Flush Before Using
Equipment
The equipment was tested with lightweight oil, which is
left in the fluid passages to protect parts. To avoid con-
taminating your fluid with oil, flush the equipment with a
compatible solvent before using the equipment. See
Your system must be grounded. Read warnings in
your sprayer manual. Check your local electrical
code.
•
•
Pump: use ground wire and clamp as instructed in
your sprayer manual.
Ratio Check
Perform the ratio check procedure after any changes to
the proportioning system. Use Ratio Check Kit 24F375
to check the ratio at the mix manifold. See manual
3A0421 for instructions and parts.
Air and fluid hoses: use only electrically conduc-
tive hoses. with a maximum of 500 ft. (150 m) com-
bined hose length to ensure grounding continuity.
Check electrical resistance of hoses. If total resis-
tance to ground exceeds 29 megohms, replace
hose immediately.
NOTICE
•
•
Air compressor: follow manufacturer’s recommen-
dations.
To prevent an inaccurate ratio check when feed
pumps are used in your system, the feed pressure
cannot be more than a maximum of 25% of the pro-
portioner outlet pressure while dispensing. High
feed pressure can float the proportioner pump
check balls, resulting in an inaccurate ratio check.
Spray gun: ground through connection to a prop-
erly grounded fluid hose and pump.
•
•
•
Fluid supply container: follow local code.
Object being sprayed: follow local code.
Solvent pails used when flushing: follow local
code. Use only conductive metal pails, placed on a
grounded surface. Do not place the pail on a non-
conductive surface, such as paper or cardboard,
which interrupts grounding continuity.
•
To maintain grounding continuity when flushing
or relieving pressure: hold metal part of the spray
gun firmly to the side of a grounded metal pail, then
trigger the gun.
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Operation
Operation
8. Hold a metal part of the gun firmly to a grounded
metal pail. Trigger the gun to relieve pressure.
Pressure Relief Procedure
Follow pressure relief procedure when you stop
spraying or dispensing; and before cleaning,
checking, servicing, or transporting equipment.
Relieve A and B Fluid Pressure
ti1953a
1. Engage the trigger lock.
9. Engage the trigger lock.
ti1949a
ti1949a
2. Turn off the sprayer.
10. Open all fluid drain valves in the system, having a
waste container ready to catch drainage. Leave
drain valves open until you are ready to spray again.
3. Close the bleed-type master air valve.
4. Open the dual shutoff handle (E).
11. If you suspect the spray tip or hose is clogged or
that pressure has not been fully relieved after follow-
ing the steps above, VERY SLOWLY loosen tip
guard retaining nut or hose end coupling to relieve
pressure gradually, then loosen completely. Clear
hose or tip obstruction.
Trigger Lock
Always engage the trigger lock when you stop spraying
to prevent the gun from being triggered accidentally by
hand or if dropped or bumped.
5. Shut off fluid heaters, if used on your sprayer.
6. Shut off feed pumps, if used.
7. Disengage the trigger lock.
ti1950a
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Operation
4. Open the solvent inlet valve (C). For the quickset
Flushing
manifold, close the A side flush valve (T).
C
C
T
Read warnings and grounding instructions in your
sprayer manual. If your system uses heaters, shut off
the main power to the heaters and heated hose
control before flushing.
ti18994a
NOTICE
5. Place the siphon tube in a grounded metal pail con-
taining cleaning fluid.
To prevent fluid from setting up in the dispensing
equipment, flush the system frequently. Be sure
there is an adequate amount of solvent in the sol-
vent supply before spraying.
6. Set pump to the lowest possible fluid pressure, and
start pump.
NOTE:
7. Trigger the gun into a grounded metal pail with lid.
Use a lid with a hole to dispense through to avoid
splashing. Trigger the gun until clean solvent dis-
penses.
•
•
•
Ensure flushing fluid is compatible with dis-
pense fluid and the equipment wetted parts.
Use a solvent that dissolves the material you are
mixing.
Solvent may channel through viscous fluids and
leave a coating of mixed fluid on the inner tube
of your hose. Be sure all fluid is thoroughly
flushed from the hose after each use.
ti1953a
a. For the standard mix manifold, go to step 8.
•
•
•
Remove spray tip for more thorough cleaning of
the whip hose and static mixers.
b. For the quickset mix manifold, after briefly flush-
ing with the B side valve, close the B side flush
valve (C) and open the A side flush valve (T).
Repeat step 7 until clean.
Always leave equipment filled with fluid to avoid
drying and scaling.
C
Frequently remove, clean and replace the static
mixer elements
T
2. Remove the spray tip and soak in solvent.
3. Close the dual shutoff handle (E).
ti18995a
8. Turn off the solvent pump air supply.
9. Hold the metal part of the gun firmly to a grounded
metal pail with lid in place. Trigger the gun until all
fluid pressure is relieved.
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Dispensing and Spraying
10. Engage the trigger lock.
4. Disengage the trigger lock.
ti1949a
ti1950a
11. Close solvent inlet valve (C).
5. Hold the metal part of the gun firmly to a grounded
metal pail with a lid to avoid splashing. Trigger the
gun until mixed coating material is evident and
purge solvent is gone.
12. Remove the gun from the hose. See gun manual to
further clean the gun.
Dispensing and Spraying
1. Close the solvent inlet valve (C) and A side solvent
valve (T) if equipped.
ti1953a
6. Proceed spraying.
2. Open the dual shutoff handle (E).
NOTICE
To prevent damage to the valve balls and seats,
always fully open or fully close the dual shutoff han-
dle. Also increase the fluid pressure after opening
the ball valves to allow valves to last longer.
3. Turn on sprayer. See sprayer operation manual.
14
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Volume Balancing the Mix Manifold
Volume Balancing the Mix Manifold
If the mix manifold is mounted on the machine, you do
not need to adjust the restrictor (F). Leave open two
turns minimum.
Hose Selection for Feeding A
Remote Mix Manifold
The mix manifold can be removed from the machine and
used closer to the spray gun to minimize the mixed
material in the hoses and reduce flush solvent with the
following restrictions.
When the manifold is remote, two things must be done
to reduce momentary ratio errors that can occur due to
the compressible nature of paint hoses.
•
•
Adjust Restriction
Select correct sized hoses
•
•
Only one mix manifold can be used on a propor-
tioner.
Splitting flow to two or more guns can only be done
after the two fluids are mixed.
Adjust Restriction at the Mix
Manifold
The B side restrictor (F) in the mix manifold is only used
when the mix manifold is positioned remote from the
machine with a short mix hose to the spray gun.
NOTE: This applies to applications that are not 1:1
ratio, and don’t have near balanced viscosities.
Balance the hoses inside area sizes in relation to the
mix ratio by volume. This is most important when the
mix manifold gets close to the spray gun.
The restrictor (F) controls “lead/lag” ratio errors of the A
and B flow into the static mixer tubes. These errors
occur momentarily when the gun opens. The error is
caused by differences in viscosity, volume, and hose
expansion between the proportioner outlets and the mix
point.
The proportioner will put out the two materials in the
exact ratio by volume. If the hose sizes are not balanced
to the ratio, one hose will always come up to pressure
first. This ratio error at the mix point can occur anytime
that there is a change in pressure. Balance the hose
sizes by effective area, not by inside diameter.
Adjust the restrictor (F) stem clockwise while spraying
until you see a slight rise in the B side pressure gauge.
The point where the pressure starts to rise is a good
adjustment setting.
2
Area = (3.1416 * radius ) or see Table 1.
NOTE: For balancing purposes, it is always
assumed that the A side is the high volume side.
restrictor stem
Table 1: Volume Ratio of “A” to “B” Hose
Hose Selection
Mix Ratio
“A” x “B”
Volume Ratio
1:1
1/2 x 1/2
3/8 x 3/8
1/2 x 3/8
3/8 x 1/4
3/8 x 1/4
1.0:1
1.5:1, 2:1
2:1
2.5:1
3:1
1.78:1
2.25:1
2.25:1
NOTE: Unless you are dispensing directly out of the
mix manifold and mixer, this an approximate adjust-
ment.
For low viscosity fluids, an optional 40 mesh screen can
be installed in the mix manifold, in front of the restrictor.
This keeps the carbide tapered stem and seat from
plugging.
4:1
1/2 x 1/4
4.0:1
Example: At a 4:1 mix ratio, a 1/2 in. ID resin hose and
a 1/4 in. ID hardener hose matches the 4:1 volume ratio.
For high viscosity 1:1 applications, the entire restrictor
assembly and seat can be removed and replaced by a
high pressure 3/4 npt plug.
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Volume Balancing the Mix Manifold
Use Table 2 and the examples provided to approximate
how much pressure drop you can expect for every 50 ft
(15.2 m) of hose at 1 gpm flow in that particular hose for
a 1000 cps viscosity material. Adjust for your applica-
tions flow rate and viscosity.
NOTE: Typical flow rates are usually 0.4-0.8 gpm
(1.5-3 l/mn) per gun depending on tip size and vis-
cosity.
Table 2: Hose Selection by Pressure Drop
Reference Formula
Pressure drop per 50 ft
section per 1000 cps at 1
gal/min.
Pressure Drop per 15.24
meter section per 1000
4
Pressure drop = 0.0273 QVL/D
Hose ID
(in.)
cps at 1 liter/min.
(Bar)
(psi)
Key:
Q = Vis poise (centipoise/100)
V= Gallons per minute
L= Length (ft)
1/8
3/16
1/4
3/8
1/2
5/8
3/4
55910
11044
3494
690
1018
201
64
D=Inside diameter (in.)
13
218
4
89
1.62
0.78
43
#1 Example: What is the pressure loss of a 2000 cps
#2 Example: What is the pressure loss of a 2000 cps
material through 150 ft of 3/8 in. ID hose at 0.75 gpm?
material through 150 ft of 1/2 in. ID hose at 0.75 gpm?
690 psi (from chart) x 2 (viscosity factor 2 x 1000 cps) x
3 (3 x 50 ft hoses) x 0.75 (% of gpm) = 3105 psi loss
218 psi (from chart) x 2 (viscosity factor 2 x 1000 cps) x
3 (3 x 50 ft hoses) x 0.75 (% of gpm) = 981 psi loss
That is a lot of pressure loss before the spray gun. Let’s
try 1/2 in. hose. See example #2.
NOTE: Avoid under sizing the high volume side.
Pressure drop during flow conditions will increase
momentary hose induced ratio errors. See Table 2.
16
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Maintenance
Maintenance
NOTE: The o-ring (18) is used as a retainer ring, not a
seal. It may be scratched or deformed from pushing the
screen (17) back in.
Clean Static Mixers
ings are connected to the mix manifold outlet (H). These
housings use plastic mix elements, available in a pack-
age of 25 (Part No. 248927).
NOTICE
21
Never use a swivel union on the mixer inlets. The
union will compress the tube and make it impossible
to remove the mix element.
20
To clean the housing and replace the mix element:
19
18
housings (J) from whip hose (K).
2. Place flats of mixer housing (J) in a grounded vise.
Push mix element (P) out of the inlet end.
17
3. If necessary, use a 1/2 in. drill bit to drill out old
material and the mix element from the inlet end,
down to the internal shoulder at the outlet end.
4. Use a brush to clean any debris in housing (J).
5. Insert new mix element, wide end first.
FIG. 3: “B” Side Screen
Clean “B” Side Screen
6. Install “B” inlet union (19) from manifold block (1).
NOTE: The following instructions apply only when
using the strainer accessory for low viscosity fluids.
Clean Mix Manifold Outlet
1. Remove outlet fitting (5) to expose “B” center injec-
tion tube (4).
1. Loosen swivels (19) and remove shutoff handle (21)
2. Clean any build-up on, around, or inside the tube
(4).
2. Remove “B” inlet union (19) from manifold block (1).
3. Pull “V” screen (17) and retainer o-ring (18) straight
up and out with a needle nose pliers.
3. Reinstall outlet fitting (5).
4. Clean or replace screen (17).
5. Reinstall screen (17) and o-ring (18) with accessory
tool 15T630.
4
5
3A0590G
17
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Troubleshooting
Troubleshooting
1. Relieve the pressure before you check or service any sys-
tem equipment.
2. Check all possible causes and solutions in the trouble-
shooting chart before disassembling the manifold.
Problem
Cause
Fluid inlet is plugged.
Solution
Little or no resin output.
Clean inlet; remove obstruction.
Fluid container is empty.
Fluid inlet is plugged.
Refill.
Little or no hardener output.
Mixed fluid will not flush out.
Clean inlet; remove obstruction.
Refill.
Fluid container is empty.
Hardener screen (18) is plugged.
Clean hardener screen. See Clean “B”
hose.
sary.
Solvent supply container is empty.
Solvent is not compatible with fluid.
Hardener is cold.
Refill.
Change to compatible solvent.
Correct heat problem.
Hardener pressure higher than normal.
Hardener pressure lower than normal.
Spray pattern developing tails.
Restrictor or screen plugging up.
Open restrictor or clean screen. See
Resin is cold. Flow rate is low.
Worn hardener restrictor.
Correct heat problem.
Adjust restrictor. See Adjust Restriction
Static mixer and/or whip hose plugging
up.
Clean spray gun and tip. See gun man-
ual.
Low pressure from sprayer.
Check air supply pressure. Check inlet air
gauges while spraying.
Cold material.
Increase heat.
Too much pressure drop.
Use larger hoses or more heat.
Air hose is too small.
Compressor is too small.
Not enough air supply. Gauge drops
while spraying.
Motor is icing.
Use De-Ice Bleed Air on motor. Dry or
cool air before use.
Wait for motor to thaw.
Clean filters.
Dirty filter in pumps or spray gun.
Resin or hardener does not shut off.
Damaged ball or seat or seal in valve
(20).
Replace or rebuild valve (2). See manual
306861.
Off ratio condition after increasing spray Hoses not volume balanced.
pressure in spray mode with a remote mix
manifold.
Volume balance A and B remote material
hoses closer to volume mix ratio. See
18
3A0590G
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Repair
Repair
5. Remove the seat (2e), ball (2d), spring (2c), and
o-ring (2b) from housing (2a).
2f
Follow pressure relief procedure when you stop
spraying or dispensing; and before cleaning,
checking, servicing, or transporting equipment.
2e
2b
2d
NOTICE
2c
Be sure to label all fluid parts “resin” or hardener”
when disassembling them. Doing so prevents inter-
changing resin and hardener parts during reassem-
bly and prevents contamination of the materials and
fluid path through the equipment.
2a
Color-coded chemically resistant tape may be used
to label the parts. Use blue for resin and green for
hardener.
6. Inspect parts for damage and replace as necessary.
Cartridge Assemblies
7. Assemble parts in reverse order from steps above.
Press the assembly against a flat clean surface until
seal (2f) snaps into place on the end of housing
(2a). The seal (2f) will hold the spring (2c), ball (2d),
seat (2e), and o-ring (2b) in place during assembly.
2. Use a wrench to remove the cartridge assemblies
(2) from the manifold.
3. Use a 90° allen wrench to pop the seat (2e) and
seal (2f) out of the housing, or tap them out from the
“A” and “B” inlet side.
8. Apply lubricant to o-ring (2b) and end seal (2f).
9. Apply anaerobic sealant to external threads of car-
tridge.
NOTE: Seat retainer seal (2f) normally splits into two
pieces when it is fully torqued into the housing. The lip is
meant to retain the seat, spring, and ball during assem-
bly. The seat retainer seal (2f) must always be replaced
once it is disassembled.
10. Install cartridge assemblies in manifold and torque
to 125 ft-lbs (170 N•m).
NOTE: The high torque crushes the seal (2f) for a
reliable seal up to 7250 psi (50 MPa, 500 bar).
4. Use a soft bristle brush to clean the manifold pas-
sageways.
3A0590G
19
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Repair
Remove Restrictor
Assemble Restrictor
1. Note number of turns from open to closed position.
Remove restrictor housing (15) from manifold (1).
1. Insert seat (10) with larger tapered end facing up in
manifold (1).
2. Place restrictor housing (15) in a vice and remove
nut (16).
16
15
16
15
12
1
13 (black)
14 (white)
1
11
r_258987_3a0590_4a
10
3. Unscrew stem (12) clockwise and remove from
restrictor housing (15).
r_255684_256980_312749_12a
2. Apply blue thread lock to external threads to set
screw (11) and install in manifold.
15
16
12
13
14
3. Install o-rings (13, 14) and insert stem (12) into
restrictor housing (15). Turn stem (12) coun-
ter-clockwise until in open position.
4. Loosely install lock nut (16) on stem (12).
r_258987_3a0590_5a
5. Tighten restrictor housing (15) into manifold (1).
4. Remove and replace o-rings (13, 14).
6. Tighten stem (12) down until it bottoms on seat (10).
Then back stem out to previously noted position or
two full turns and lock in place with lock nut (16).
5. Remove set screw (11) and seat (10) from manifold.
NOTE: For high volume or high viscosity “B” side
applications, the restrictor parts can be replaced by
a high pressure 3/4 npt plug.
11
10
r_258987_3a0590_6a
20
3A0590G
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Repair
3A0590G
21
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Parts
Parts
262807 Mix Manifold
6
8
1
2
Apply lubricant to o-rings and cartridge o-ring and end seal.
Apply taper thread pipe sealant to all non-swiveling threads
except cartridge (2) and needle (12).
2
19
3
4
5
Apply anaerobic medium thread locker to external threads.
Torque to 125 ft-lbs (70 N•m).
20
21
20
Turn stem fully into manifold. Then back out two turns and
lock in place.
6
7
Large end of inside taper faces out.
22
19
Push assembly hard against a flat surface to snap retainer
seal (2f) in place.
22
8
2
Shipped loose. Use when a mix manifold is replaced on a
Series A XP Plural-Component Sprayer.
2
19
12
16
15
5
2
1
2
5
11
3
3
14
13
10
2
6
3
2
28
1
7 2
26
7 2f
3
51
8
2
1 2e
1
2b
2
2d
9
2c
1
3
4 2
4
2
5 2
3
2a
4
2
6
r_258987_3a0590_3a
ti18943c
22
3A0590G
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Parts
262807 Mix Manifold
Ref.
No. Part No. Description
Qty.
1
2
24P869 BLOCK, manifold, mix
258986 CARTRIDGE, valve, check;
includes items 2a-2f
1
2
2a
16D614 HOUSING, check valve
1
1
1
1
1
1
7
1
1
3
1
1
1
2b★ 121138 O-RING, PTFE, white
2c★ 15M530 SPRING, check valve
2d★ 116166 BALL
2e★ 15A968 SEAT, foot valve
2f★ 15K692 SEAL, retainer
3
4
5
6
7
8
9
100721 PLUG, pipe; 1/4 npt
15R378 TUBE, injector, hardener
15R067 PIPE, outlet, mixer manifold
159239 FITTING, nipple, pipe, reducing
100840 ELBOW, street, lapped
156823 UNION, swivel; 1/4 m x f
214037 VALVE, ball, solvent; 1/4-18 npt;
see manual 306861
10
11
12
183951 SEAT, valve, carbide
15R382 SCREW, set, hollow, 3/4-16
235205 STEM, valve
1
1
1
1
1
1
1
4
2
13★ 110004 O-RING, PTFE, white
14★ 113137 O-RING, solvent resistant, black
15
16
19
20
15M969 NUT, packing, restrictor
110005 NUT, jam, hex
156684 UNION, swivel; 1/2 npt m x f
262740 VALVE, ball; 1/2 npt (f); see manual
306861
21
22
24M421 LEVER, valve
158491 NIPPLE, 1/2-14 npt
1
2
1
2
26† 501867 VALVE, check, mxm, 1/4 npt
28
113161 SCREW, flange, hex hd; 1/4-20 x
1/2 in. (12.7 mm)
50✖ 126786 TOOL, restrictor
51 113093 COUPLING, 1/4 npt
1
★ Provided in mix manifold repair kit 258992. See
✖ Not shown.
† Older models used mxf solvent check valves. If
replacing the mxf check valve (563210) with mxm
check valve (32), you must also order coupling (51).
3A0590G
23
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Parts
24M398 Quickset Mix Manifold
1
2
Apply lubricant to o-rings and cartridge o-ring and end seal.
19
21
2
Apply taper thread pipe sealant to all non-swiveling threads except
cartridge (2) and needle (12).
3
4
5
6
7
Apply anaerobic sealant to external threads.
Torque to 125 ft-lbs (70 N•m).
Turn stem fully into manifold. Then back out two turns and lock in place.
Large end of inside taper faces out.
20
Push assembly hard against a flat surface to snap retainer seal (2f) in
place.
34
37
49
36
45
30
19
46
2
35
43, 44
16
5
36
48
2 15
33
2
5
2
12
1
2
5
4
2
14
10
48
13
28
ti18946a
29
6
2
8
2
30
3
31
1
8 2
7
2f
30
2
3
2
1 2e
1
30
32
2b
2d
30
2c
51
3
2
32
2
51
9
31
3
4
2a
2
1
3
4
9
34
34
ti18945b
r_258987_3a0590_3a
24
3A0590G
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Repair Kits
24M398 Quickset Mix Manifold
Ref.
No. Part No. Description
28
Qty.
Ref.
113161 SCREW, flange, hex hd; 1/4-20 x
2
No. Part No. Description
Qty.
1/2 in. (12.7 mm)
262522 CARRIAGE, remote manifold
100840 ELBOW, street
1
2
24P866 BLOCK, manifold, mix
258986 CARTRIDGE, valve, check;
includes items 2a-2f
1
2
29
30
31
1
5
2
2
1
2
1
2
1
2
1
1
2
1
1
2
1
114434 GAUGE, pressure, fluid, sst
2a
16D614 HOUSING, check valve
1
1
1
1
1
1
4
1
1
2
2
32† 501867 VALVE, check, mxm, 1/4 npt
2b★ 121138 O-RING, PTFE, white
2c★ 15M530 SPRING, check valve
2d★ 116166 BALL
2e★ 15A968 SEAT, foot valve
2f★ 15K692 SEAL, retainer
33
34
35
36
37
43
44
45
46
47
48
49
121433 BUSHING, 1/2 x 3/8, 7250 psi
H42503 HOSE, coupled, 1/4 ID, 3 ft
15R875 TEE, 1/4 (m x f x f)
162453 FITTING, 1/4 npsm x 1/4 npt
157705 UNION, swivel, 1/4 m x 3/8 f
262478 HOUSING, mixer
248927 MIXER, 1/2-12 element (bag of 25)
156173 UNION, swivel, 3/8 fbe
114958 STRAP, tie
3
4
5
8
9
100721 PLUG, pipe; 1/4 npt
15R378 TUBE, injector, hardener
15R067 PIPE, outlet, mixer manifold
156823 UNION, swivel; 1/4 m x f
214037 VALVE, ball, solvent; 1/4-18 npt;
see manual 306861
119400 SEALANT, pipe, sst
15U654 LABEL, identification, A/B
158491 NIPPLE, 1/2 in. npt
10
11
12
183951 SEAT, valve
15R382 SCREW, set, hollow, 3/4-16
235205 STEM, valve
1
1
1
1
1
1
1
4
2
50✖ 126786 TOOL, restrictor
51 113093 COUPLING, 1/4 npt
13★ 110004 O-RING; PTFE, white
14★ 113137 O-RING; solvent resistant, black
★ Provided in mix manifold repair kit 258992. See
15
16
19
20
15M969 NUT, packing, restrictor
110005 NUT, jam, hex
156684 UNION, swivel; 1/2 npt m x f
262740 VALVE, ball; 1/2 npt (f); see manual
306861
✖ Not shown.
† Older models used mxf solvent check valves. If
replacing the mxf check valve (563210) with mxm
check valve (32), you must also order coupling (51).
21
22
24M421 LEVER, valve
158491 NIPPLE, 1/2-14 npt
1
2
Repair Kits
258992 Mix Manifold Repair Kit
217560 Flush Valve (9) Repair Kit
Ref.
24M601 Inlet Ball Valve (20) Repair Kit
No. Part No. Description
Qty.
2b
2c
2d
2e
2f
13
14
121138 O-RING, PTFE, white
15M530 SPRING, check valve
116166 BALL, carbide
15A968 SEAT, foot valve
15K692 SEAL, retainer
110004 O-RING, PTFE, white
113137 O-RING, solvent resistant, black
2
2
2
2
2
1
1
1
38✖ 113500 ADHESIVE, anaerobic
✖ Not shown.
3A0590G
25
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Accessories
Accessories
10,000 psi Fluid Pressure Gauge (2.5 in)
Accessory Ports
114434 - 1/4 npt(m) back mount pressure gauge can be
used in ports as gun pressure gauge.
P1 and P2:
These 1/4 npt ports are located after “A” and “B” shutoff
handle.
551387 - 1/4 npt bottom mount version.
High Pressure Hoses and Accessory
Fittings
Can be used for an inlet pressure gauge. These are
before the fluid check valves and hardener restrictor.
See brochure 339361 for parts and accessories.
P3 and P5:
Can be used for a pressure gauge to measure outlet
pressure or check ratio with the 24F375 kit. These ports
are downstream of the check valve.
262522, Remote Mix Manifold Carriage
The carriage holds and protects the mix manifold
assembly. Use two screws (28) to mount the mix mani-
fold to the carriage.
The P3 port is used as the second flush inlet on the
quickset model of the mix manifold. It flushes across the
resin check ball, but not through it.
15E592, 7250 psi Static Mixer Housing
3/8 npt(m) holds 1/2 in. 12 element plastic sticks.
P4:
Can be used for a pressure gauge to measure hardener
pressure before the restrictor, but after the check valve.
511352, Mixer
Stainless 3/8 npt(m) pipe with 12 element stainless
welded stick; 7250 psi (50 MPa, 500 bar).
248927, Plastic Mix Elements
25 pack of 1/2 in. x 12 element plastic sticks.
P1
P3
P2
P4
B-side screen
40 mesh strainer for low viscosity fluids only.
Ref.
No. Part No. Description
Qty.
17
18
185416 STARINER, 40 mesh
121410 PACKING, screen retainer; PTFE
1
1
P5
15T630, Screen Installation Tool
Use to reinstall B-side screen.
r_258987_3a0590_9a
24F375, Ratio Check Kit
FIG. 4: Accessory Ports
Use to check ratio at mix manifold. See manual 3A0421
for instructions.
26
3A0590G
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Technical Data
Technical Data
Mix Manifolds
US
Metric
50 MPa, 500 bar
71° C
Maximum A, B, and mix working pressure
Maximum fluid temperature
Fluid inlet
7250 psi
160° F
1/2 npt(f) ball valves
Fluid outlet
1/2 npt(f) with 3/8 npt(m) adapter nipple
Solvent inlet valve
1/4 npt(m)
Maximum working pressure at solvent inlet
5000 psi
34.5 MPa, 345 bar
Wetted parts
Manifold block and internal parts
302 and 303 stainless steel, PTFE, tungsten carbide, elec-
troless nickel plated steel, zinc plated steel, UHMWPE
Flush valves and fittings
440 stainless steel, plated carbon steel, hardened alloy steel,
acetal, PTFE, aluminum
3A0590G
27
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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
TO 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.
Original instructions. This manual contains English. MM 3A0590
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2010, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
Revised June 2013
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