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Graco 309909H manual

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Table of contents for the manual

  • Page 1

    309909H ENG Repair - P ar ts Self-contained, single color , electroni c plural component paint proportioner . For prof essional use only . Important Safety Instructions Read all warnings and instr uctions in this manual. Sav e these instructions. See page 3 for model inf ormation, including maxi- mum working pressure and approv als . TI4909a[...]

  • Page 2

    Manual Conventions 2 309909H Contents Manual Con ventions . . . . . . . . . . . . . . . . . . . . . . . . 2 ProMix Easy Models . . . . . . . . . . . . . . . . . . . . . . . . 3 Related M anuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 W arnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pressure Relief Proced[...]

  • Page 3

    ProMix Easy Models 309909H 3 Pr oMix Easy Models * cst=carbon steel. ** sst=stainless steel. WA R N I N G Do not install e quipment appro v ed only f or non-haz- ardous location in a ha zardous area. Substit ution of components ma y impair intr insic safety and cause per- sonal injury . Read page 5. Appr oved f or Hazard ous Location Class I, Div 1[...]

  • Page 4

    Related Manua ls 4 309909H Related Manuals Component Manua ls in English This manual a vailab le in the f ollowin g languages: Manual De scription 309908 ProMix Easy Oper ation 309909 ProMix Easy Repair-P ar t s 310654 Fluid Mix Manif old 310655 Dispense V alve 310662 UltraMix and Hydr aMix Displacement Pumps 310671 UltraMix Pumps 310672 HydraMix P[...]

  • Page 5

    Warnings 309909H 5 Wa r n i n g s The following general warn ings are related to the safe setup, use, grounding, maintenance, a nd repair of this equip- ment. Additional more specific warnings may be foun d throughout the text of this manual where applicab le. W ARNING FIRE AND EXPLOSION HAZARD Flammab le fumes, such as solve nt and paint fumes , i[...]

  • Page 6

    Warnings 6 309909H EQUIPMENT MISUSE HAZARD Misuse can cause deat h or ser ious inju r y . • Do not e xceed the maximum w orking pressure or temper ature rating of the low est rated system component. See Te c h n i c a l D a t a in all equipment m anuals. • Use fluids and solv ents t hat are compatib le with equ ipment wette d par ts. See T echn[...]

  • Page 7

    Pressure Relief Procedure 309909H 7 Pressure Relief Pr ocedure Fluid Manif old to Gun W ARNING Relie v e pressure from fluid manif old to gun whene v er you sto p spra ying and bef or e ser vicing gun or remov- ing spra y tip . In addition , reliev e pressure fr om pump to f luid mani- f old at end of da y and bef ore cle aning, chec king, or ser v[...]

  • Page 8

    Pressure Relief Procedure 8 309909H Pump to Fluid Manif old 1. Close shutoff v alves G A and G B . 2. Place waste cont ainer under sampling v alv es H A and H B . 3. T ur n function k nob to pre ssure relief/pa rk . 4. Press . Indicator A comes on , and Pump A pres- surizes. TI4699a H B G B H A G A 5. Open sampling v alv e A slo wly to b leed off p[...]

  • Page 9

    Maintenance 309909H 9 Maintenance Preventive Maintenance Schedule Estab lish a pre v entiv e maintenan ce schedule, b ased on the pump’ s repair histor y . Mix Manif old See mix manif old m anual 310654 . Dispense V alve See dispense v alv e manual 31065 5. Pump See applicab le pump man ual 310671, 310672 , or 310662. T urbine Alternator Replace [...]

  • Page 10

    Troubleshooting 10 309909H T r oub leshooting WA R N I N G Read wa r nings, pa ge 5-6. If an alarm code displays , see page 13 . Pr oblem Cause Solution Displa y not lit. No electri c power . Air va lve not turned on. T ur n on main air v alv e to system. Air supply pressure too low . In crease pressure to 60 psi (0.42 MP a, 4.2 bar) or greater . A[...]

  • Page 11

    Troubleshooting 309909H 11 P aint does not cure consistently . Ratio not set correctly . Check that correct ratio is set and set b y volume . See ProMix Easy Operation manual. Material not mixing correctly . T est pump . P age 9. Make sure mix er is clean; flush as needed. See ProMix Easy Operation manual. Pump not operating correctly . Obser ve wh[...]

  • Page 12

    Troubleshooting 12 309909H Flow rate too low . Inadequate a ir supply . Use larger CFM compre ssor . Air pressure to pumps too low . Increase pressure. Fluid A or B filters plugged. Clean filters. Spra y tip too small. Relie ve pressure . Install larger tip . F ollow gun manual instructions. Mixer or hoses par tially plugged or too restrictive . In[...]

  • Page 13

    Alarms 309909H 13 Alarms * Indicates error where audible alar m sounds once brie fly . ** Indicate s error where audible alar m sound pulses. Code Alarm Active Pro blem Cause Startup Errors 01 Sensor Error A* Alwa ys No signal from pump A sensor Loose cable, f ailed sensor or cable, f ailed magnet assembly 02 Sensor Error B* Alwa ys No signal from [...]

  • Page 14

    Alarms 14 309909H Operating Err ors (continued) 22 High Ratio (units with meter[s] only) Spra y Mix ratio higher than Ta r g e t + To l e r a n c e Flow rate too high Slow actuation of dispense valv e A or B Clogged flow meter 23 Low Ratio (units with meter[s] only) Spra y Mix ratio l ower than T arget - T olerance 24 Dose Timeout A (units with met[...]

  • Page 15

    Repair 309909H 15 Repair Flush bef ore repairing equipment, if possible . See Pro- Mix Easy Operation man ual. F ollow Pressure Relie f Procedure , page 7, if service time ma y e xceed pot lif e ti me, bef ore ser vicing fluid components , and bef ore t ransporting equipment to a ser vice area . Replacing Air Filter Element There are 2 air filter s[...]

  • Page 16

    Repair 16 309909H User Interface Re m ova l 1. Close main air shutoff v alv e on air supply line and on unit. 2. Remov e side panels (21). 3. Remov e f astener s (45). Gently pull user inter fa ce (11) a wa y from pn eumatic control (10). 4. T o completely remo v e user interf ace (11), discon- nect groun d wire (315), and wires (4 16 and 406) from[...]

  • Page 17

    Repair 309909H 17 Replacing Main Cir cuit Board 1. Remov e User Int erf ace co ver . See page 16. 2. Disconnect all wire connector s from board (301). F IG . 3. 3. Remov e f our scr ews (3 02) and replace boar d (301). 4. Reasse mble . Refer to Electrical Schematic , page 22. 5. Recalibrate sys tem. See ProM ix Easy Operation Manual . CA UTION T o [...]

  • Page 18

    Repair 18 309909H Replacing Display Cir cuit Boar d 1. Remov e User Int erf ace co ver . See page 16. 2. Disconnect wires from displa y boar d (410). F IG . 4. 3. Remov e t wo scre ws (411). 4. Loosen setscre w (419) from knob (405) and remo ve knob assembly . Remov e jam nut (N). 5. Remov e and repla ce displa y board (410). 6. Reassemble. Ref er [...]

  • Page 19

    Repair 309909H 19 Pneumatic Contr ol Alternator Repair T urbine Alternator Repair Kit 22368 8 is av ailab le to replace turb ine bearings. 1. Remov e User Int erf ace co ver . See page 16. 2. Disconnect power supply wires (P). F IG . 5. 3. Disconnect two air lines (310) f rom alternator (304). F IG . 6. 4. Remove top nut (305) and loosen bottom nut[...]

  • Page 20

    Repair 20 309909H Replacing Solenoids F ollow this pr ocedure to replace a single soleno id. 1. Remov e User Int erf ace co ver . See page 16. 2. Disconnect two sole noid wires (V) from main boa rd. F IG . 8. 3. Disconnect dispense valv e pilot lines (A1, A2, B1, B2). F IG . 8. 4. Remove two scre ws (S). 5. Remove and replace solenoid (306b ). 6. R[...]

  • Page 21

    Repair 309909H 21 Dispense V alve/Mix Manifo ld Assembl y See the Pa r t s dra wing f or y our model. 1. Follo w Pressure Relief Pr ocedure , page 7. 2. Label all air and fluid lin es, and disco nnect from fit- tings on mani fo ld assemb ly . 3. Remov e f astener s. 4. Remove mix manif old (2). 5. T o repair mix ma nif old, see manual 310654. T o r[...]

  • Page 22

    Electrical Schematic 22 309909H Electrical Schematic RED ORANGE ORANGE RED +- A 4 3 7 2 2 4 1 18 15 12 9 6 3 12 9 6 3 1 BLACK WHITE RED SHIELD BLUE WHITE_W/BLUE WHITE_W/ORANGE GREEN WHITE_W/GRN BLUE WHITE_W/BLUE WHITE_W/ORANGE GREEN WHITE_W/GRN SHIELD + RED 4 1 3 BLACK RED RED GREEN BLACK BROWN GREEN BLACK WHITE B 3 TX 1 GND 2 1 1 2 3 4 5 6 J1 5 2 [...]

  • Page 23

    248349 Main Control Board Schematic 309909H 23 248349 Main Contr ol Boar d Sc hematic 246899 Pump Solenoid Expansion Boar d Sc hematic 248349 Main Control Boar d LEDs LED Descript ion D2 In normal operation D2 flashes on and off in 1 second intervals . If D2 is off (not flashing), software is not bo oting; ch eck f or power to the board or a short [...]

  • Page 24

    Parts 24 309909H Pa r t s P art No. 234596 Series A, Pump-based, Car t-m ounted Air Spray Unit 10 22 85 22 21 71 30 73 81 84 72 20 45 71 51 22 21, 28 11 41 98 TI4769a 100 101 101 (Ref) 102 103 104 101 (Ref) 38 79 39[...]

  • Page 25

    Parts 309909H 25 P art No. 234596 Seri es A, Pump-based, Car t-moun ted Air Spray Unit, continued 37 47 46 74 82 76 1 65 67 63 75 17 16 9 32 33 15 15 5 3 15 7 8 32 33 24 (Ref) 6 4 25 24 31 23 14 2 63 78 (Ref) 78 12 45 44 17 16 40 49 48 TI4770a 65 (Ref) 39 45 16 17 47 TI11228a Pump Solenoid Cable Con nections Downstroke solenoid is on the outside . [...]

  • Page 26

    Parts 26 309909H P art No. 234596 Seri es A, Pump-based, Car t-moun ted Air Spray Unit, continued ▲ Replacement Danger and Warning labels, tags, and cards are av ailable at no cost. Ref. No. P art No. Description Qty . 1 15D771 FRAME, wall mount 1 2 234593 MIX MANIFOLD; see 310654 1 3 287230 CONTR OL, air ; see page 53 1 4 109544 ELBO W , pipe; 3[...]

  • Page 27

    Parts 309909H 27 Pump and Meter- based, W all-mounted Air Spra y Units P art No. 234597 Series A, Ult raMix carbon steel pump and G3000 Meter P art No. 234598 Series A, Ult raMix stainles s steel pump and G3000 Mete r 10 22 21 20 45 22 21, 28 11 TI4901b 38 39 79[...]

  • Page 28

    Parts 28 309909H Pump and Meter- based, W all-mount ed Air Spra y Units, continued 37 47 65 67 63 17 16 9 32 33 13 5 3 7 8 32 33 24 (Ref) 6 4 25 24 31 23 14 2 63 78 (Ref) 78 12 45 44 17 16 40 49 48 TI4902a 80 53 88 90 91 86 89 83 87 46 1 65 (Ref) 39 15 16 17 45 TI11262a Pump Solenoid Cable Connec tions Downstroke solenoid is on the outside . Upstro[...]

  • Page 29

    Parts 309909H 29 Pump and Meter- based, W all-mount ed Air Spra y Units, continued See page 27 f or model number s and descriptions. ▲ Replacement Danger and Warning labels, tags, and cards are av ailable at no cost. Ref. No. P art No. Description Qty . 1 15D771 FRAME, wall mount 1 2 234593 MIX MANIFOLD; cst; carbon steel models only; see 310654 [...]

  • Page 30

    Parts 30 309909H Pump-based, W all-mounted Air Spra y Units P art No. 234599 Series A, carbon steel, intrins ically saf e P art No. 234600 Series A, carbon steel, non-intrins ically saf e P art No. 234601 Series A, st ainless steel, i ntrinsicall y safe P art No. 234825 Series A, stai nless steel, non-i ntrinsicall y safe 10 22 21 20 45 22 21, 28 1[...]

  • Page 31

    Parts 309909H 31 Pump-based, W all-mounted Air Spra y Units, continued TI4905a 37 1 17 16 9 32 33 15 15 5 3 13 7 8 32 33 24 (Ref) 6 4 25 24 31 23 14 2 63 78 (Ref) 78 12 45 44 17 16 40 49 48 39 45 17 16 TI11228a Pump Solenoid Cable Connect ions Downstroke solenoid is on the outside . Upstroke solenoid is on the inside. 1 2 2 1[...]

  • Page 32

    Parts 32 309909H Pump-based, W all-mounted Air Spra y Units, continued See page 30 f or model number s and descriptions. ▲ Replacement Danger and Warning labels, tags, and cards are av ailable at no cost. Ref. No. P art No. Description Qty . 1 15D771 FRAME, wall mount 1 2 234593 MIX MANIFOLD; cst; carbon steel models only; see 310654 1 234451 MIX[...]

  • Page 33

    Parts 309909H 33 Meter- based, W all-mounted High Pressure Units P art No. 234618 Series A, carbon steel P art No. 234619 Series A, stai nless steel 10 22 21 20 45 22 21, 28 11 TI4917a 38 39[...]

  • Page 34

    Parts 34 309909H Meter- based, W all-mounted High Pressure Units, continued TI4918a 37 47 65 67 63 17 16 9 32 33 5 7 8 32 33 24 (Ref) 6 4 25 24 31 14 2 45 44 17 16 40 80 53 88 90 91 86 89 83 87 3 46 1 65 (Ref) 39 45 16 17 Wires to circuit board; see Electrical Schematic , page 22. 1 1[...]

  • Page 35

    Parts 309909H 35 Meter- based, W all-mounted High Pressure Units, continued See page 33 f or model number s and descriptions. ▲ Replacement Danger and Warning labels, tags, and cards are av ailable at no cost. Ref. No. P art No. Description Qty . 1 15D771 FRAME, wall mount 1 2 234593 MANIFOLD , mix (23 4618); cst; see 310654 1 234451 MANIFOLD , m[...]

  • Page 36

    Parts 36 309909H Pump-based, W all-mounted High Pressure Units P art No. 234606 Series A, Hy draMix 500 carbon steel , intrinsica lly saf e P art No. 234607 Series A, Hydra Mix 500 carbon steel , non-intrinsi cally sa fe P art No. 234609 Series A, Hy draMix 600 carbon steel , intrinsica lly saf e P art No. 234610 Series A, Hydra Mix 600 carbon stee[...]

  • Page 37

    Parts 309909H 37 Pump-based, W all-mounted High Pressure Units, continued TI4911b 37 1 17 16 9 32 33 15 15 5 3 13 7 8 32 33 24 (Ref) 6 4 25 24 31 23 14 2 35 12 45 44 17 16 40 34 36 50 69 68 93 39 94 95 96 45 16 17 50 34 Detail of B Side Muffler 15 Pump Solenoid Cable Connect ions TI5294a Downstroke solenoid connection. Upstroke solenoid connection.[...]

  • Page 38

    Parts 38 309909H Pump-based, W all-mounted High Pressure Units, continued See page 36 f or model number s and descriptions. Ref. No. P art No. Description Qty . 1 15D771 FRAME, wall mount 1 2 234593 MIX MANIFOLD; cst; carbon steel models only; see 310654 1 234451 MIX MANIFOLD; sst; stainless steel models only; see 310654 1 3 287230 CONTROL, air ; s[...]

  • Page 39

    Parts 309909H 39 ▲ Replacement Danger and Warning labels, tags, and cards are av ailable at no cost. 50 102656 MUFFLER 2 56 598095 TUBE; nylon; 5/32 in. (4 mm) OD; clear ; see pages 45 and 47 2 ft 57 054753 TUBE; nylon; 5/32 in. (4 mm) OD; blac k; see pages 45 and 47 2 ft 58 054754 TUBE; nylon; 5/32 in. (4 mm) OD; red; see pages 45 and 47 2 ft 59[...]

  • Page 40

    Parts 40 309909H Pump and Meter- based, W all-m ounted High Pressure Units P art No. 234602 Series A, Hydra Mix 500 carbon steel pump and G3000 Meter P art No. 234603 Series A, Hy draMix 500 stain less steel pump and G3000 Meter P art No. 234604 Series A, Hydra Mix 600 carbon steel pump and G3000 Meter P art No. 234605 Series A, Hy draMix 600 stain[...]

  • Page 41

    Parts 309909H 41 Pump and Meter- based, W all-mounted High Pressure Units, contin ued TI4908a 37 17 16 9 32 33 15 13 5 3 7 8 32 33 24 (Ref) 6 4 25 24 31 23 14 2 35 12 45 44 17 16 40 34 36 50 69 68 93 47 80 53 88 65 67 63 90 91 86 89 83 87 46 1 65 (Ref) 39 45 16 17 Pump Solenoid Cable Connec tions TI5294a Downstrok e solenoid connection. Upstroke so[...]

  • Page 42

    Parts 42 309909H Pump and Meter- based, W all-mount ed High Pressure Units, continued See page 40 f or model number s and descriptions. Ref. No. P art No. Description Qty . 1 15D771 FRAME, wall mount 1 2 234593 MIX MANIFOLD; cst; carbon steel models only; see 310654 1 234451 MIX MANIFOLD; sst; stainless steel models only; see 310654 1 3 287230 CONT[...]

  • Page 43

    Parts 309909H 43 ▲ Replacement Danger and Warning labels, tags, and cards are av ailable at no cost. 70 054123 TUBE; nylon; 1/4 in. (6 mm) OD; see pages 45, 46, and 47 3.5 ft 79 195889 BUSHING, strain relief 1 80 100206 BUSHING; 1/2 npt(m) x 1/4 np t(f) 1 83 501867 CHECK V AL VE 1 86 114339 UNION, swiv el; 1/4 npsm(f) x 1/4 npt(m) 1 87 15D957 HAR[...]

  • Page 44

    Parts 44 309909H T ube Connections, Lo w Pressure Pumps Find the k eys on the dra wing to ensure proper connections . Key Description Ref. No. Length, in. (mm) A1 Dispense V alv e A OFF 56 24 (610) A2 Dispense V alv e A ON 57 24 (610) B1 Dispense V alv e B OFF 59 24 (610) B2 Dispense V alv e B ON 58 24 (610) C1 Air to Pneumatic Control (10) 60 8 (2[...]

  • Page 45

    Parts 309909H 45 T ube Connections, Hi gh Pressure Pumps Find the k eys on the dra wing to ensure proper conne ctions. Key Description Ref. No. Length, in. (mm) A1 Dispense V alv e A OFF 56 24 (610) A2 Dispense V alv e A ON 57 24 (610) B1 Dispense V alv e B OFF 59 24 (610) B2 Dispense V alv e B ON 58 24 (610) C1 Air to Pneumatic Control (10) 60 8 ([...]

  • Page 46

    Parts 46 309909H T ube Connections, Meters Find the k eys on the dra wing to ensure proper connections . This page sho ws a unit with meters on both sides. I f your model is a pump/meter co mbination unit, al so ref er to pages 44 and 45 f o r additional connect ions. Key Description Ref. No. Length, in. (mm) A1 Dispense V alve A OFF 56 24 (610) A2[...]

  • Page 47

    Parts 309909H 47 Pneumatic Schematic MOT OR DOWN A MOT OR UP A PUMP UP , 12 VDC PUMP DOWN, 12 VDC GAUGE AIR REGULA TOR 3/8 AIR FIL TER AUT O DRAIN 5 MICRON 3/4" BALL V AL VE BLEED TYPE 110 PSI RELIEF VA LV E TO MANIFOLD SOLENOID 12 VDC METERING VA LV E B A METERING VA LV E SOLENOID 12 VDC AIR REGULA TOR SET @ 22 PSI TURBINE / POWER SUPPL Y AIR[...]

  • Page 48

    Parts 48 309909H 248270 Intrinsically Saf e Pneumatic Control * When ordering 248349 as a replace ment par t, you m ust al so order a data d ownload kit to prog ram the circuit board to the specific ma chine configura tion. Order Kit 248403 f or hazardous loca tions or Kit 248404 f or non-haz- ardous locations . See manu al 309623 f or fur ther ins[...]

  • Page 49

    Parts 309909H 49 248270 Intrinsically Saf e P neumatic Contr ol, continued 320 302, 321 314 304 310 308 313 322 306 315 311 301 323 307 306h 306e 306m 306s 306t 306u 306b 306n 306c 306j 306k 306n 306f 306p 306n 306a 306f 306d 306g 306f TI4561b TI4558a 304d 304e 304a Solenoid Module (306) Detail Alternator Module (304) Det ail 304c 304b 330 AB AB[...]

  • Page 50

    Parts 50 309909H 248316 Non-intrinsically Saf e Pneumatic Control * When ordering 248349 as a replace ment par t, you m ust al so order a data d ownload kit to prog ram the circuit board to the specific ma chine configura tion. Order Kit 248403 f or hazardous loca tions or Kit 248404 f or non-haz- ardous locations . See manu al 309623 f or fur ther[...]

  • Page 51

    Parts 309909H 51 248316 Non-intrinsically Saf e Pneumatic Contro l, continued 320 302 330 305 308 313 322 306 315 311 301 323 307 306n 306r 306u 306b 306c 306j 306k 306n 306f 306p 306n 306a 306d TI4567b TI4564a Solenoid Module (306) Detail 321 309 312 317 318 328 314 AB AB[...]

  • Page 52

    Parts 52 309909H User Interface 234620, f or pump-based and pump/met er units 234621, f or meter -based uni ts only Ref. No. Part No. Description Qty . 401 15B062 DISPLA Y 1 403 15A851 HARNESS, wire 1 404 15A801 GASKET; neopre ne 1 405 15D853 KNOB, control 1 406 15A850 HARNESS, wire 1 407 15A852 HARNESS, wire, switch 1 408 15D796 LABEL, control, up[...]

  • Page 53

    Parts 309909H 53 287230 Pump Air Contr ol 287231 Meter Air Control Ref. No. Part No . Descriptio n Qty . 201 15D814 MANIFOLD , air ; 287230 only 2 15D814 MANIFOLD , air ; 287231 only 1 202 206197 REGULA T OR, air ; 1/2 npt(f) inlet and outlet; 28 7230 only; see manu al 308168 1 203 119240 CAP , pipe, 1/2 in. (13 mm) 1 204 101689 GA UGE, air pressur[...]

  • Page 54

    Technica l Data 54 309909H T ec hnical Data Mix ratio range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1:1-10:1 (in 0.1 inc rements), p ump-base d sys tems 0.1:1-30:1 (in 0.1 incremen ts), meter-ba sed systems Ratio tolerance range . . . . . . . . . . . . . . . . . . . . . . . . . . . . up to +/- 1% Flow rates Minimum . . .[...]

  • Page 55

    Technical Data 309909H 55 Exter nal P ower Supply Requirem ents . . . . . . . . . . . . . . . 93-250 V ac, 50/60 Hz, 1.2 amps maximum draw 15 amp maxim um circuit break er requir ed 14 A W G pow er supply wire gauge Environmental Condition s Rating . . . . . . . . . . . . . . . . . . . Indoor/outdoor Altitude up t o 4000 me ters Maximum rela tive h[...]

  • Page 56

    All written and visual data con tained in th is document reflects the late st product information availabl e at the time of publica tion. Graco reserves the right to make changes at any time without notice. Original instructions. This manual contains English. MM 309909 Graco Headquarters: Minneapoli s Internationa l Offices: Belgium, China, Japan, [...]