Graco ti18496b - Manual

Accessories 3A2012J 5 Accessories The following items can be purchased separately from the system to gain additional functions. Many of the items require user installation; refer to the System Assembly section beginning on page 18 for the required procedures. To avoid fire and explosion and electric...

Warnings 6 3A2012J 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 manua...

Important Two-Component Material Information 3A2012J 9 Polyester Resins and Gel-Coats Spraying and Lamination Operations Graco recommends that you consult OSHA Sections 1910.94, 1910.106, 1910.107 and NFPA No. 33, and NFPA No. 91 for further guidance. Important Two-Component Material Information Mat...

Overview 10 3A2012J Overview The FRP proportioner dispenses pigmented, tooling, low-VOC, and specialty gel coats, as well as polyester resin and vinyl ester chemicals. The FRP proportioner supplies the individual catalyst and resin materials, and fiberglass roving to the gun. On internal mix systems...

Component Identification 3A2012J 11 Component Identification Key: A Cart B Air Motor C Resin Displacement Pump D Catalyst Pump E Solvent Flush (Diaphragm Pump Option Shown, Pressure Pot Options also available)* F Catalyst Reservoir G Boom (not shown) H Air Control Panel J Heater (not shown) K Ground...

Component Identification 12 3A2012J Air Control Panel Air inlet (AA): from air line. Air regulator 1 (AB): controls air to resin pump. Air outlet 1 (AC): air line to resin pump. Air pressure gauge 1 (AD): indicates air pressure to resin pump. Air regulator 2 (AE): for external mix guns only: con- tr...

Component Identification 3A2012J 13 Air Motor and Resin Displacement Pump The air motor powers the resin displacement pump which supplies resin to the spray gun. Air inlet (M): connect air hose to the air inlet. Fluid filter (N): removes particles from the fluid. Pressure relief/recirculation valve ...

Component Identification 14 3A2012J Catalyst Pump The catalyst pump supplies catalyst to the spray gun. Pump arm (U): controls catalyst flow. Ratio adjustment knob (V1): use to lock/unlock pump position and adjust the resin to catalyst ratio. It is easiest to adjust the ratio when the pump is at the...

Component Identification 3A2012J 15 Solvent Flush Systems Solvent Flush Diaphragm Pump The solvent flush diaphragm pump provides solvent to the gun to clear out mixed fluid and prevent it from cur-ing in the gun. See the diaphragm pump manual listed on page 3 for detailed component identification. S...

Setup 16 3A2012J Setup FRP proportioners are not approved for use in hazard-ous locations unless all accessories, all kits, and all wir-ing meet local, state, and national codes. See Agency Approvals on page 3. This section provides instructions for basic system setup of the FRP proportioner. See th...

Setup 18 3A2012J System Assembly When the system is shipped from the factory some items may be shipped loose. Perform the following instructions to properly install each of the component items. 1. For cart and boom systems only, install legs: a. With the system still on the pallet, use the sup- plie...

Setup 20 3A2012J Grounding General Grounding Guidelines Pump: use ground wire and clamp (supplied). Connect ground clamp to a true earth ground. Air and fluid hoses: use only electrically conductive hoses. Spray gun: ground through connection to a properly grounded fluid hose and pump. Fluid supply ...

Setup 3A2012J 21 Connect Fluid and Air Lines NOTE: When connecting gun hose bundle, the whip end connections in the bundle should be connected to the gun and the non-whip end connections should be connected to the proportioner. The whip end of the bun-dle is the end with more flexible lines. See gun...

Setup 3A2012J 23 Solvent Flush Connections (if applicable) NOTE: See Solvent Flush Systems component identi- fication on page 15 for connection locations. 13. Connect solvent air line from air control panel to dia- phragm pump or pressure pot air inlet. 14. Connect solvent suction tube from solvent ...

Operation 24 3A2012J Operation 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. Boom Operation The height of the boom can be adjusted by adjusting which link in the chain is secured to the boom ar...

Operation 26 3A2012J Startup NOTE: Do not exceed 20 psi (0.14 MPa, 1.4 bar) on the material air pressure regulator until a steady material flow has been established. 1. Verify wetcup is filled with Graco Throat Seal Liquid (TSL ™ ). 2. Ensure main air line is connected to the air control panel air i...

Operation 3A2012J 27 Prime Perform this procedure upon initial system setup, when-ever hoses are disconnected, if the supply hose is removed from the supply container, or if either pump is run dry. If done properly, this will prime the lines with fluid and/or remove any air bubbles from the fluid li...

Operation 3A2012J 31 Spray NOTE: If using an NXT air motor with DataTrak, see DataTrak Operation , page 33, for instructions on using the DataTrak counter/totalizer. Prior to production use, spray onto a clean piece of paper until all system settings are adjusted to optimize the spray pattern. Perfo...

Operation 3A2012J 33 DataTrak Operation For DataTrak installation instructions, see NXT Air motor for FRP manual. Controls and Indicators NOTE: See F IG . 31. The display (Y) will turn off after 1 minute of inactivity in Run mode or 3 minutes in Setup mode. Press any key to wake up the display. Data...

Operation 3A2012J 35 Setup Mode 1. See F IG . 31. Press and hold for 5 seconds until Setup menu appears. 2. To enter settings for runaway, lower size, and flow rate units, and to enable runaway, E1, E2, and E5 error options, press to change the value, then to save the value and move the cursor to th...

Operation 38 3A2012J Replace DataTrak Battery or Fuse Replace Battery 1. Unscrew cable from the back of the reed switch assembly. See F IG . 33. 2. Remove the cable from the two cable clips. 3. Remove DataTrak module from bracket. Take mod-ule and attached cable to a non-hazardous location. 4. Remov...

Maintenance 3A2012J 39 Maintenance Components See component manuals listed on page 3 for mainte-nance schedules and procedures for each component. Task Schedule Inspect pump wetcup and fill with TSL and remove any particles or residue Daily Remove resin pump outlet filter and flush debris Daily Insp...

Troubleshooting 40 3A2012J Troubleshooting Problems Try the recommended solutions in the order given for each problem, to avoid unnecessary repairs. Catalyst Pump See Catalyst Slave Pumps parts illustration on page 66 for parts identification. Resin Pump See Resin Pumplines on page 61 for parts iden...

Repair 42 3A2012J Repair General Information • Reference numbers and letters in parentheses in the text refer to the callouts in the figures and the parts drawing. • Always use Genuine Graco Parts and Accessories, available from your Graco distributor. If you supply your own accessories, be sure the...

Repair 44 3A2012J Disconnect the Air Motor See manual 3A2315 for air motor service and parts information. See F IG . 36 on page 45. 1. Relieve the pressure, see page 24. 2. Disconnect main air supply line from the inlet on the air control panel (AE). 3. Disconnect grounding wire. 4. Disconnect items...

Repair 46 3A2012J Replace Pumpline This procedure is only needed if the entire pumpline will be replaced. If just installing repair parts in the air motor and/or displacement pump, see Disconnect the Dis- placement Pump on page 42, Disconnect the Air Motor on page 44, displacement pump manual 3A2313...

Repair 3A2012J 47 Repair Catalyst Pump See F IG . 37 on page 49 for reference numbers. Remove Catalyst Pump from System 1. Flush the pump, see page 30. 2. Relieve the pressure, see page 24. 3. Close catalyst supply ball valve and disconnect fluid lines. 4. Remove top pivot knob securing catalyst pum...

System Parts 50 3A2012J System Parts Systems 107 106 121 114,115,116 108 110 105 111 102 104 108 113 103 109 122 113 Loosen grounding lug locknut and washer, insert grounding wire into slot in lug and tighten locknut securely. Apply grease to outer diameter, not to the threads. Torque to 45-55 ft-lb...

System Parts 3A2012J 55 Carts ◆ Included in Catalyst Outlet Kit 16N854. 201 202 204 203 205 Apply sealant to threads. 1 1 210 211207 209 208 1 Ref Part Description Quantity Cart, for use with boom Cart, not for use with boom 201 --- CART, chop 1 --- CART, pole 1 202 16P425 RESERVOIR, gravity feed, 2...

System Parts 3A2012J 59 Air Panel 512 525 533 501 517 506 505 503 514 509 522 515 541 510 Plug supplied with regulator (504). Apply sealant to all non-swiveling pipe threads. 1 2 504 522 511 502 539 522 531 519 529 1 ti19058b 510 537 542 540 527 520 509 504 521 538 541 509 Ref Part Description Qty 5...

System Parts 62 3A2012J Resin Pumpline Kits NOTE: For displacement pump repair kits , see man- ual 3A2313. For air motor repair kits , see manual 3A2315. Air Motor and Pump for Resin Pumpline See air motor manual 3A2313 and pump manual 3A2315 for parts identification. Gun See RS gun manual 3A0232 fo...

System Parts 3A2012J 63 Resin Filter 24F620 ▲ Replacement Danger and Warning labels, tags and cards are available at no cost. * Strainer Options: Press fit spring (710) to bottom of filter bowl (701). Apply thread lubricant. Apply grease. Apply thread sealant to all non-swiveling pipe threads. 3 4 5...

System Parts 64 3A2012J Resin Supply Hose 16M736 * Other filter meshes available: 50 mesh (20397-03), 100 mesh (20397-02). 805 804 803 802 801 807 Apply pipe sealant to all non-swiveling pipe threads. 1 Ref Part Description Qty 801 220372 HOSE, coupled, 6 ft 1 802 197682 TUBE, suction 1 803 114967 C...

System Parts 3A2012J 67 Catalyst Pumps Installation Tools (not shown): Foot valve seat installation tool, 16N966 Foot valve seat deluxe removal tool, 24N253 (includes foot valve seat installation tool, 16N996) Weep seal installation tool, 16N967 ✿ Rod Assembly Bullet Installation Tool, 16D007 ✿ --- ...

System Parts 68 3A2012J Catalyst Reservoir 16P425 1001 1002 1010 1001 1011 Apply pipe sealant to threads. Apply sticker so that the level line is even with the 2.5 gallon mark on tank (1001). 1 2 1 2 For outlet strainer and filter, see Carts on page 55. 1012 Ref Part Description Qty 1001 --- TANK, g...

System Parts 70 3A2012J Hose Bundles 1114 1102 1104 1109 1101 1111 1107 1103 1113 1108 1102 (Catalyst) 1105 (External Atomizing Air/ Internal Chop AAC Air) 1101 (Chopper Air/Internal Gel AAC) 1103 (Resin) 1104 (Internal Solvent/ External AAC) 1115 1106 ti21345a1 1105

System Parts 72 3A2012J Accessory Parts Heater Kits 1201 1202c 1202f 1202b 1210 1202a 1204 1206 ti21347a 1215 1213 1211 1203 1202e 1202d 1205 1204 1202d 1214 1210 1204 1203 1202d 1202a 1202b 1202f 1202e 1202d 1202a 1202c 1215 1214 1210 1213 1211 1208 ti21346a 1213 1210 1 Use 1/2-14 npt x 3/8-18 npt ...

System Parts 3A2012J 73 Heater Kits * Items are available in heater hardware kit 16N119. † Parts available in pipe clamp kit 16P291. ★ Heaters can be disassembled to remove cured material. Ref Part Description Quantity 16N014, 120v, FM ★ 16N015, 240v, FM ★ 16N016, 120v, hazardous 16N017, 240v, hazar...

System Parts 74 3A2012J Solvent Pressure Pot Kits ASME Pressure Pots, 2-gallon 16M893 and 5-gallon 16M894 1304 1305 1302 1301 1303 1309 1310 1306 1307 1311 To assemble strainer (1311), remove the dip tube from tank (1301). Slide strainer onto bottom end of dip tube. Hold strainer in place while posi...

System Parts 76 3A2012J Solvent Diaphragm Pumps 2-gallon 16M560 and 5-gallon 16M561 Base System shown for reference only 1501,1503 1502,1503 1504 1505 Ref Part Description Qty 1501 16M559 PUMP, solvent, FRP, flush 1 1502 16M652 TANK, solvent, 2.5 gal assembly(assembly 16M560 only) 1 16M651 TANK, sol...

System Parts 3A2012J 77 DataTrak Upgrade Kit 16M881 * See FRP air motor manual. 1602 1602 Ref Part Description Qty 1601 * 24A354 SMART AIR VALVE (not shown) 1 1602 24A576 DATATRAK CONVERSION KIT 1

System Parts 3A2012J 79 Roving Box Bracket 16M961 † Long bolts are only used if two kits will be installed side by side. Ref Part Description Qty 1801 16M619 BRACKET, roving 1 1802 16M622 BRACE, roving box 1 1803 122741 SCREW, hex cap, 1/4 x 0.50 2 1804 104123 WASHER, lock, spring 2 1805 112248 NUT,...

System Parts 80 3A2012J Extension Hoses ▲ Replacement Danger and Warning labels, tags and cards are available at no cost. * Series C and prior chop hoses use 123554. Series D or later chop hoses are shown in the table. 1904 1901 1907 1903 1906 1913 1902 1903, 1907 (Resin) 1904, 1912 (Internal Solven...

Dimensions 3A2012J 81 Dimensions Cart and Boom ¡ ¡ C A B ti18526b Ref. A (Max Width) B (Max Height) C (Max Depth) E (Radius) F (Radius) Description 144 in. (3658 mm) 100 in. (2540 mm) 192 in. (4877 mm) 144 in. (3658 mm) 72 in. (1828 mm) * Rotate unit to fits cart and boom system through a 3 ft 6 in....

Technical Data 3A2012J 83 Pumpline Wall Mounting Bracket Dimensions The pumpline bolts directly to this mounting plate. Technical Data System Technical Data * Maximum fluid temperature rating determined by lowest rated component in system. Maximum fluid working pressure . . . . . . . . . . . . . . ....

Technical Data 84 3A2012J Pumpline Technical Data Catalyst Pump Technical Data ** Series A and B systems (built prior to April 2013) have non-metallic nylon catalyst tube fittings. To covert your system to stain- less steel fittings, see the FRP Proportioner manual 332451. Whip Hose Technical Data R...

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. For patent information, see www.graco.com/patents. Original instructions. This manual contains Eng...