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.: 32 89 770 700 Fax: 32 89 770 777

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

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.

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