Graco 24M398 Instructions Manual Download Page 27

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Troubleshooting

3A0590R

Troubleshooting

Follow the

Pressure Relief Procedure

on page 21.

2. Check all possible causes and solutions in the

troubleshooting chart before disassembling the
manifold.

Problem

Cause

Solution

Little or no resin output.

Fluid inlet is plugged.

Clean inlet; remove obstruction.

Fluid container is empty.

Refill.

Little or no hardener output.

Fluid inlet is plugged.

Clean inlet; remove obstruction.

Fluid container is empty.

Refill.

Hardener screen (18) is plugged.

Clean hardener screen. See

Clean

“B” Side Screen

, page 26.

Mixed fluid will not flush out.

Fluid is hardened in static mixers or
whip hose.

Clean with compatible solvent. See

Maintenance

, page 26. Replace as

necessary.

Solvent supply container is empty.

Refill.

Solvent is not compatible with fluid.

Change to compatible solvent.

Hardener pressure higher than
normal.

Hardener is cold.

Correct heat problem.

Restrictor or screen plugging up.

Open restrictor or clean screen. See

Clean “B” Side Screen

, page 26.

Hardener pressure lower than
normal.

Resin is cold. Flow rate is low.

Correct heat problem.

Worn hardener restrictor.

Adjust restrictor. See

Adjust

Restriction at the Mix Manifold

page 24.

Spray pattern developing tails.

Static mixer and/or whip hose
plugging up.

Clean Static Mixers

, page 26.

Clean spray gun and tip. See gun
manual.

Low pressure from proportioner.

Check air supply pressure. Check
inlet air gauges while spraying.

Cold material.

Increase heat.

Too much pressure drop.

Use larger hoses or more heat.

Not enough air supply. Gauge drops
while spraying.

Air hose is too small.
Compressor is too small.

Motor is icing.

Use De-Ice Bleed Air on motor. Dry
or cool air before use.
Wait for motor to thaw.

Dirty filter in pumps or spray gun.

Clean filters.

Summary of Contents for 24M398

Page 1: ...nt sprayers For professional use only See page 3 for model information including working pressure and approvals Important Safety Instructions Read all warnings and instructions in this manual and in your proportioner manual before using the equipment Save these instructions 3A0590R EN 24M398 Shown ...

Page 2: ...nd B Material Inlets 16 Solvent Inlet 16 Mixed Material Outlet 16 Converting to Remote Mix Manifold 17 Installing Remote Recirculation Manifold 17 Grounding 18 Flush Before Using Equipment 18 Ratio Check 18 Operation 19 Prime Remote Mix Manifold 19 Prime Solvent Hose Mixed Material Hose and Gun 19 Pressure Relief Procedure 21 Trigger Lock 21 Dispensing and Spraying 22 Flushing 23 Volume Balancing ...

Page 3: ...c Heated Hose Model Mix Manifold Maximum Working Pressure A and B Materials Maximum Solvent Pressure Maximum Fluid Temperature Approvals 262807 Standard XP Mix Manifold 7250 psi 50 MPa 500 bar 5000 psi 34 5 MPa 345 bar 160 F 71 C 24M398 Quickset Mix Manifold 7250 psi 50 MPa 500 bar 5000 psi 34 5 MPa 345 bar 160 F 71 C II 2G Ex h IIC T5 Gb II 2G Ex h IIC T5 Gb Model Description Maximum Working Pres...

Page 4: ...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 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 compo...

Page 5: ...e 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 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 sw...

Page 6: ...ct your material supplier for compatibility PERSONAL PROTECTIVE EQUIPMENT Always wear appropriate personal protective equipment and cover all skin when spraying servicing equipment or when in the work area Protective equipment helps prevent serious injury including long term exposure inhalation of toxic fumes mists or vapors allergic reaction burns eye injury and hearing loss This protective equip...

Page 7: ...maintained and adjusted according to instructions in the manual To prevent inhalation of isocyanate mists vapors and atomized particulates everyone in the work area must wear appropriate respiratory protection Always wear a properly fitting respirator which may include a supplied air respirator Ventilate the work area according to instructions in the fluid manufacturer s SDSs Avoid all skin contac...

Page 8: ...patible with ISO Never use reclaimed solvents which may contain moisture Always keep solvent containers closed when not in use Always lubricate threaded parts with an appropriate lubricant when reassembling NOTE The amount of film formation and rate of crystallization varies depending on the blend of ISO the humidity and the temperature Changing Materials Changing the material types used in your e...

Page 9: ... Inlet AC Solvent Inlet 1 4 npt m AE Dual Shutoff Handle AF Hardener Restrictor Adjustment AG Solvent Shutoff Handle AH Mix Manifold Outlet 1 2 npt f with 3 8 npt m adapter AP Accessory Ports see Accessory Ports page 36 AR Solvent Inlet Check Valve AV Fasteners assembled on Mix Manifold 5 3 9 WL D FIG 1 Mix Manifold Component Identification ...

Page 10: ...rriage 262522 and 24Z934 Ref Description BC Remote Manifold Carriage BD Long Fasteners shipped loose BE Heater Block WL D Remote Manifold Carriage with Heater Block 24Z934 Remote Manifold Carriage FIG 2 Remote Manifold Heater Block Component Identification ...

Page 11: ...nlet CD Recirculation Hose Shut Off Valve CE Remote Recirculation Handle CF Remote Recirculation Tube CG Remote Recirculation Hose CH Bushing shipped loose CJ Adapter Fitting shipped loose CK A Fitting End CL B Fitting End CR Remote B Recirculation Port CS Remote A Recirculation Port WL D 6 5 FIG 3 Remote Recirculation Kit Component Identification ...

Page 12: ...AV Fasteners BC Remote Manifold Carriage DB B Side Solvent Line DC B Side Solvent Shutoff DD A Side Solvent Line DE A Side Solvent Shutoff DF Solvent Inlet Tree DG Primary Mix Housing DH Static Mixing Element not shown inside DH DJ Fluid Whip Hose shipped loose DK Adapter Fitting shipped loose DL XHF Gun shipped loose WL D 9 FIG 4 Quickset Manifold Component Identification ...

Page 13: ...p Hose L Airless Spray Gun M Static Mixing Element not shown inside J or P N Fluid Mix Hose WL D 6 5 5 6 5 0 0 1 3 0 6 A B A B Ref Description P Clean up Mixer Tube R B Recirculation Hose S A Recirculation Hose AD Mix Manifold AE Dual Shutoff Handle AG Solvent Shutoff Handle BC Remote Carriage CE Remote Recirculation Handle CF Remote Recirculation Tube CR Remote B Recirculation Port CS Remote A Re...

Page 14: ...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 On the standard XP 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 va...

Page 15: ...he mix manifold assembly when mounted remotely 24Z934 Remote Mix Manifold Heater Block Kit The remote mix manifold carriage 262522 with heating block is used with water jacketed heated hoses heating fluid is circulated under the mix manifold to maintain temperature See your water jacketed heated hoses manual for details for connecting heated hoses 24M398 Quickset Manifold The remote mix manifold w...

Page 16: ...vent inlet AC For Quickset Mix Manifold 24M398 Connect the solvent supply hose G to the solvent inlet tee DF Use a Graco approved grounded hose rated to withstand the maximum fluid working pressure of the solvent pump The hose core must be chemically compatible with the solvent being used such as nylon or PTFE Mixed Material Outlet 0 3 0 0 WL D Standard XP Mix Manifold 262807 Connect the outlet to...

Page 17: ...nection instructions Installing Remote Recirculation Manifold 1 Follow the Converting to Remote Mix Manifold procedure on page 17 2 Connect the remote recirculation manifold to the mix manifold by connecting the A fitting end CK to A material inlets AA and the B fitting end CL to B material inlets AB 3 Connect A and B material hoses to the recirculation manifold inlet CA CB 4 Connect the recircula...

Page 18: ...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 pres...

Page 19: ...r NOTE If a remote recirculation manifold is not installed disconnect the material hoses at the material inlets AA and AB Prime the material hoses over grounded metal pails then reconnect the material hoses 4 Run the XP pumps until fluid flows through the A and B material hoses Prime Solvent Hose Mixed Material Hose and Gun 1 Connect a ground wire not included to a metal pail of solvent WL D WL D ...

Page 20: ...ock and trigger the gun into a grounded pail Use a pail lid with a hole to dispense through NOTE To prevent splash back use a rag to seal around the hole and gun Be careful to keep fingers away from the front of the gun 7 Close the solvent flush valves and trigger the gun to relieve pressure Engage the trigger lock ...

Page 21: ... until you are ready to spray again 10 If you suspect the spray tip or hose is clogged or that pressure has not been fully relieved after following 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 fro...

Page 22: ...f handle AE 5 Disengage the trigger lock 6 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 7 Proceed spraying NOTICE To prevent damage to the valve balls and seats always fully open or fully close the dual shutoff handle Also increase the fluid pressure after opening the b...

Page 23: ...ove the spray tip and soak in solvent 3 Close the dual shutoff handle AE 4 Open the shutoff valve AG For the Quickset manifold close the A side flush valve DE 5 Turn on solvent flush pump 6 Disengage spray gun trigger lock 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 dispenses a For the standa...

Page 24: ...t from plugging 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 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 Only one mix man...

Page 25: ...y Q Vis poise centipoise 100 V Gallons per minute L Length ft D Inside diameter in Typical flow rates are usually 0 4 0 8 gpm 1 5 3 l mn per gun depending on tip size and viscosity Example 1 What is the pressure loss of a 2000 cps material through 150 ft of 3 8 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 That is a lot ...

Page 26: ... first Clean B Side Screen 19 21 20 18 17 The following instructions apply only when using the strainer accessory for low viscosity fluids See Accessories on page 36 1 Loosen swivels 19 and remove shutoff handle 21 and valves 20 See FIG 7 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 4 Clean or replace screen...

Page 27: ...le with fluid Change to compatible solvent Hardener pressure higher than normal Hardener is cold Correct heat problem Restrictor or screen plugging up Open restrictor or clean screen See Clean B Side Screen page 26 Hardener pressure lower than normal Resin is cold Flow rate is low Correct heat problem Worn hardener restrictor Adjust restrictor See Adjust Restriction at the Mix Manifold page 24 Spr...

Page 28: ...valve 2 See manual 306861 Off ratio condition after increasing spray pressure in spray mode with a remote mix manifold Hoses not volume balanced Volume balance A and B remote material hoses closer to volume mix ratio See Hose Selection for Feeding A Remote Mix Manifold page 24 and Maintenance page 26 Problem Cause Solution ...

Page 29: ... 2d spring 2c and o ring 2b from housing 2a 6 Inspect parts for damage and replace as necessary 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 8 Apply lubricant to o ring 2b and end seal 2f 9 Apply ana...

Page 30: ...12 15 16 r_255684_256980_312749_12a 1 Insert seat 10 with larger tapered end facing up in manifold 1 2 Apply blue thread lock to external threads to set screw 11 and install in manifold 3 Install o rings 13 14 and insert stem 12 into restrictor housing 15 Turn stem 12 counter clockwise until in open position 4 Loosely install lock nut 16 on stem 12 5 Tighten restrictor housing 15 into manifold 1 6...

Page 31: ...Repair 3A0590R 31 ...

Page 32: ...into manifold Then back out two turns and lock in place Large end of inside taper faces out Push assembly hard against a flat surface to snap retainer seal 2f in place Shipped loose Use when a mix manifold is replaced on a Series A XP Plural Component Sprayer 1 2 3 4 5 6 7 8 19 16 12 13 14 10 11 3 19 7 8 9 2 4 5 6 2f 2a 2e 2b 2c 2d 2 6 3 1 4 5 5 3 2 2 2 2 2 2 2 2 2 1 1 4 3 ti18943c r_258987_3a0590...

Page 33: ...100721 PLUG pipe 1 4 npt 7 4 15R378 TUBE injector hardener 1 5 15R067 PIPE outlet mixer manifold 1 6 159239 FITTING nipple pipe reducing 3 7 100840 ELBOW street lapped 1 8 156823 UNION swivel 1 4 m x f 1 9 214037 VALVE ball solvent 1 4 18 npt see manual 306861 1 10 183951 SEAT valve carbide 1 11 15R382 SCREW set hollow 3 4 16 1 12 235205 STEM valve 1 13 110004 O RING PTFE white 1 14 113137 O RING ...

Page 34: ...hen back out two turns and lock in place Large end of inside taper faces out Push assembly hard against a flat surface to snap retainer seal 2f in place 1 2 3 4 5 6 7 1 21 16 15 12 13 14 2 5 5 2 20 19 49 8 30 31 3 30 3 32 9 34 34 19 2 10 6 2 2 2 3 1 4 2 28 29 4 5 33 43 44 37 45 3 2 2 2 2 2 2f 2a 2e 2b 2c 2d 1 1 4 3 r_258987_3a0590_3a ti18946a ti18945b 30 2 8 2 31 9 30 2 32 1 7 46 36 30 35 36 34 48...

Page 35: ...REW set hollow 3 4 16 1 12 235205 STEM valve 1 13 110004 O RING PTFE white 1 14 113137 O RING solvent resistant black 1 15 15M969 NUT packing restrictor 1 16 110005 NUT jam hex 1 19 156684 UNION swivel 1 2 npt m x f 4 20 262740 VALVE ball 1 2 npt f see manual 306861 2 21 24M421 LEVER valve 1 22 158491 NIPPLE 1 2 14 npt 2 28 113161 SCREW flange hex hd 1 4 20 x 1 2 in 12 7 mm 2 29 262522 CARRIAGE re...

Page 36: ...e screen 24F375 Ratio Check Kit Use to check ratio at mix manifold See manual 3A0421 for instructions Accessory Ports AP1 and AP2 These 1 4 npt ports are located after A and B shutoff handle Can be used for an inlet pressure gauge These are before the fluid check valves and hardener restrictor AP3 and AP5 Can be used for a pressure gauge to measure outlet pressure or check ratio with the 24F375 ki...

Page 37: ...1 2 in 3 8 in or 1 4 in hoses A B Recirculation Outlets 3 8 npt m Mixed Material Outlet 3 8 npt m Solvent Inlet Tee 1 4 npt m Maximum Solvent Working Pressure 5000 psi 34 5 MPa 345 bar Manifold block and internal parts 302 and 303 stainless steel PTFE tungsten carbide electroless nickel plated steel zinc plated steel UHMWPE Flush valves and fittings 440 stainless steel plated carbon steel hardened...

Page 38: ... 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 warra...

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