Instructions-Parts

Integrated Air

Control Modules

311239C

Integrated air controls for use with NXT

™

Model 2200, 3400, and 6500 Air Motors.

100 psi (0.69 MPa, 6.9 bar) Maximum Regulated Working Pressure

NXT011, Series E

With locking air regulator and 110 psi (0.76 MPa, 7.6 bar) relief valve

NXT021, Series E

With non-locking air regulator and 110 psi (0.76 MPa, 7.6 bar) relief valve

NXT031, Series E

With locking air regulator and 75 psi (0.51 MPa, 5.1 bar) relief valve

Important Safety Instructions

Read all warnings and instructions in this manual and in NXT air motor manual 311238. Save these instructions.

Integrated Air Control Module shown mounted on an NXT Air Motor

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441

Copyright 2006, Graco Inc. is registered to I.S. EN ISO 9001

TI8233c

2

Warnings

Contents

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . 12

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 14

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 14

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. Refer back to these Warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.

WARNING

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 Pressure Relief Procedure in this manual, 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.

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, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

• Gloves

• Hearing protection

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 forms from distributor or retailer.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco replacement parts only.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your Graco 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.

311239C

Installation

Installation

Air Control Modules NXT011 and NXT031 (locking air regulator) and NXT021 (non-locking air regulator) are available.

3.

Turn air regulator knob (C) fully counterclockwise.

C

1.

Install supplied o-ring (43) into counterbore on upper side of air control module (D). Fasten module to air motor (M) with two supplied screws (44). Start threading screws by hand before using a tool.

Torque to 20 ft-lb (27.1 N•m).

TI8322c

1 Screws are thread-forming. Start threading by hand before using a tool. Torque to 20 ft-lb (27.1 N•m).

4.

Hold the 3/4 npt(f) air inlet fitting (A) with a 1-5/16 in. wrench to prevent it from turning while securely connecting the air supply hose.

M A

TI8235c

43

D

2.

Close bleed-type master air valve (B).

44

1

TI8323c

B

TI8322c

311239C 3

4

Operation

Operation

Component Identification

Air Control Modules NXT011 and NXT031 (locking air regulator) and NXT021 (non-locking air regulator) include air line components in an integrated assembly. See F IG . 1.

Key for F IG . 1

A Air Inlet, 3/4 npt(f)

B Bleed-type Master Air Valve

C Air Regulator Adjustment Knob (locking or non-locking)

D Air Pressure Gauge

E Air Filter (partially hidden)

F Safety Relief Valve

Bleed-type Master Air Valve (B)

Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from splashing or moving parts.

The bleed-type master air valve is required in your system to relieve air trapped between it and the air motor when the valve is closed.

Air Regulator (C)

Adjusts air pressure to the motor and fluid outlet pressure of pump. View the gauge (D) to read air pressure.

Air Filter (E)

Removes harmful contaminants from entering the air control module and air motor.

Safety Relief Valve (F)

Automatically opens to relieve air pressure, to prevent pump overpressurization.

D

C

A

E

B

F

TI8233c

F IG . 1: Air Control Module Mounted on NXT Air Motor

311239C

Startup

1.

Turn air regulator knob (C) fully counterclockwise.

Operation

Locking Regulator (NXT011 and

NXT031 only)

1.

To lock pressure setpoint, push knob (C) in.

C

C

2.

Open bleed-type master air valve (B).

TI8322c

TI8236c

2.

Pull knob out to unlock, then adjust regulator to desired pressure setpoint.

C

B

TI8236c

3.

Turn air regulator knob (C) clockwise until air pressure reaches desired setpoint.

C

Shutdown

Close bleed-type master air valve (B).

TI8236c

TI8236c

B

TI8235c

311239C 5

6

Troubleshooting

Troubleshooting

Problem Cause Solution

Air leaking from regulator housing, or gauge shows unstable regulated pressure.

Loose or worn diaphragm (17d).

Tighten housing or repair regulator

using repair kit NXT095. See page 8.

Worn seat (17e) or poppet (17f).

Repair regulator using repair kit

NXT095. See page 8.

Main spool seals or relief valve worn. Replace with spool kit NXT098,

page 8.

Quick exhaust poppet (20b) or seat

(20a) worn.

Worn poppet o-ring (20c).

Air leaking from quick exhaust vent hole.

Quick exhaust poppet (20b) or seat

(20a) worn.

Air leaking from ball valve vent hole.

Loose inlet fitting (32a).

Worn valve seals (32b, 32d).

Replace with quick exhaust repair kit

NXT099, page 8.

Replace with quick exhaust repair kit

NXT099, page 8.

Replace with quick exhaust repair kit

NXT099, page 8.

Tighten inlet fitting. See page 9.

Repair ball valve using repair kit

NXT097. See page 9.

Regulator does not regulate pressure.

Worn spool o-rings or worn/damaged diaphragm (17d).

With air on and bleed-type master air valve (B) open, unscrew the regulator housing (19).

• If pressure drops, diaphragm is damaged. Install Repair Kit

NXT095, page 8.

• If air leaks out bottom orifice, spool o-rings are worn. Install

Repair Kit NXT098, page 8.

311239C

Repair

Repair

Pressure Relief Procedure

Follow Pressure Relief Procedure when you stop

spraying and before cleaning, checking, or servicing equipment.

1.

Close bleed-type master air valve (B).

Replace Filter Element

1.

Relieve pressure, page 7.

2.

Remove filter bowl (E) with wrench. Remove filter element (G).

3.

Install new filter element (G) on boss within the bowl

(E). Reinstall bowl 1/4 turn past handtight.

G

B

TI8235c

2.

Make sure gauge (D) reads zero (0). If not, pull on pressure relief ring to bleed off air pressure.

Replace Gauge

1.

Relieve pressure, page 7.

E

TI8237b

2.

See Parts drawing, page 10. Using a 7/16 open-end

wrench on the flats, unscrew old gauge (31).

D

TI8235c

3.

Turn air regulator knob (C) fully counterclockwise.

3.

Apply PTFE tape to threads before installing new gauge.

C

TI8322c

311239C 7

8

Repair

Spool Repair Kit NXT098

1.

Relieve pressure, page 7.

4.

Using #2 Phillips screwdriver, remove valve seat

(17e) slowly to avoid damaging flutes. Remove valve assembly (17f) and spring (17g).

2.

See Parts drawing, page 10. Using a 3/8 in. deep

well socket, remove 7 screws (37) and disassemble front cover (5) from housings (1, 2). Remove spring

(16).

5.

Use all new parts in the kit. Reinstall the spring

(17g), valve assembly (17f), and valve seat (17e).

Tighten seat slowly to avoid damaging flutes.

3.

Pull the spool assembly (8) out of the housing (1).

6.

Do not apply any lubricant on the seating area of the diaphragm (17d). Reinstall diaphragm, slip ring

(17c), spring (17b), and adjustment screw (17a).

4.

Clean and lubricate the bore in the housing (1).

5.

Install the new spool (8).

Quick Exhaust Repair Kit

NXT099

1.

Relieve pressure, page 7.

Regulator Repair Kit NXT095

1.

Relieve pressure, page 7.

2.

See Parts drawing, page 10. Using a 3/8 in. deep

well socket, remove 7 screws (37) and disassemble front cover (5) from housings (1, 2).

2.

See Parts drawing, page 10. Using a 1-3/8 in.

open-end wrench, unscrew the regulator housing

(19).

3.

Remove seat (20a) with large flat blade screwdriver.

Push out the poppet (20b) using a soft dowel or an allen wrench.

3.

Remove adjustment screw (17a), spring (17b), slip ring (17c), and diaphragm (17d).

4.

Liberally grease housing threads to avoid damaging o-ring (20c) on new poppet (20b). Install new poppet with o-ring. Install new seat (20a).

311239C

Repair

Ball Valve Seal Repair Kit

NXT097

1.

Relieve pressure, page 7.

2.

See Parts drawing, page 10. Remove the inlet fit-

ting.

6.

Install the new outboard seal (32b) and inlet fitting (32a).

The stem seal components (32e-32k) do not need replacement unless leakage is noted. If necessary,

replace parts as shown on page 10.

3.

See F IG . 2. Move the handle to the 7:30 position.

Remove the outboard seal (32b) with an o-ring pick.

9:00

4.

See F IG . 2. Move the handle to the 6:00 position.

Remove the ball (32c) using a magnet or adhesive tape. Remove the inboard seal (32d) with an o-ring pick.

7:30

6:00

F IG . 2. Valve Handle Positions

5.

Install the new inboard seal (32d). Install the new ball (32c) with the notch (N) facing the front of the module, so it engages the valve stem (33). The flat spot on the ball must face inward.

TI8803a

311239C 9

Parts

Parts

NXT011 and NXT031 Locking Integrated Air Control Module

NXT021 Non-Locking Integrated Air Control Module

1

37

32a

2

32b

32c

32d

2 20a 20b 20c

32f

32g

32h

32j

32e

32k

N

3

1

37

5

4

34 35 33

31

1

7

48

17g

17f

6

43

38

16

8

18

18

3

17a

17b

17c

17d

17e

50

4

5

TI8234d

1 Torque to 140 in-lb (16 N•m).

2 Torque to 500 in-lb (56 N•m).

3 Torque to 240 in-lb (27 N•m).

4 Torque to 130 in-lb (15 N•m).

5 Install bowl 1/4 turn past handtight.

6 Screws are thread-forming. Start threading by hand before using a tool.

Torque to 20 ft-lb (27.1 N•m).

44

6

TI8323b

10 311239C

Accessories

Ref.

No.

Part No. Description Qty

7*

8

16

17

1

2

3*

4

15G298 HOUSING, right

15G299 HOUSING, left

15G439 GASKET; nitrile

277109 BOWL, filter

5 277107 COVER, front

6 ✓ NXT092 ELEMENT, filter, 40 micron; package of 10

103209 O-RING; fluoroelastomer

NXT098 SPOOL, valve

119987 SPRING, compression

NXT095 KIT, repair, regulator; includes

18 items 17a-17g

NXT090 KNOB ASSEMBLY, regulator, locking; NXT011 and NXT031

NXT091 KNOB ASSEMBLY, regulator,

20 non-locking; NXT021

NXT099 KIT, relief valve; includes items

20a-20c

31 ✓ 108190 GAUGE, pressure, air

32 NXT097 KIT, repair, ball valve; 3/4 npt(f)

33 inlet; includes items 32a-32k

15F726 STEM, ball valve

34 15F727 INSERT, threaded, ball valve

35* C20145 O-RING; buna-N

37 119426 SCREW, machine, hex washer hd, thread-forming; 1/4-20 x 1 in. (25

1

1

1 mm)

38* 115078 O-RING; nitrile

43

44

110782 O-RING; buna-N

1

1

120089 SCREW; 3/8-16 x 1-3/4 in. (44 mm) 2

48

50

151395 WASHER, flat

113498 RELIEF VALVE, safety; 110 psi

1

1

(0.76 MPa, 7.6 bar); NXT011 and

NXT021

108124 RELIEF VALVE, safety; 75 psi (0.51

MPa, 5.1 bar); NXT031

1

1

1

1

1

1

1

1

1

1

7

1

1

1

1

1

1

* Parts included in Seal Repair Kit NXT096 (purchase separately).

✓

Recommended spare parts. Keep on hand to avoid downtime.

Accessories

Kit Description

NXT090 Locking knob kit

NXT091 Non-locking knob kit

NXT092 Filter element, 40 micron, package of 10

NXT093 Coalescing filter with automatic drain

NXT094 Coalescing filter with manual drain

NXT095 Regulator repair kit

NXT096 Seal repair kit

NXT097 Ball valve repair kit

NXT098 Spool valve kit

NXT099 Relief valve kit

311239C 11

Schematic Diagram

Schematic Diagram

Bleed-Type Ball Valve

Air Filter

AIR IN

Quick Air Purge

ATMOSPHERE

TO MOTOR

Spool

Air Pressure

Gauge

Air Regulator

Adjustment Knob

Overpressure Safety

Relief Valve

12 311239C

Technical Data

Maximum air inlet pressure

Maximum regulated working pressure

Maximum operating temperature

Air Inlet Size

Air Gauge Port Size

Height

Width

Depth

Weight

Materials of construction

Technical Data

140 psi (0.97 MPa, 9.7 bar)

100 psi (0.69 MPa, 6.9 bar)

140°F (60°C)

3/4 npt(f)

1/8 npt(m)

6.5 in. (165 mm)

6.75 in. (171 mm)

4.75 in. (121 mm)

5.1 lb (2.3 kg)

Chrome, brass, aluminum, acetal, fluorocarbon rubber, nylon, nitrile rubber, fluoroelastomer

311239C 13

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.

1-800-328-0211 Toll Free

612-623-6921

612-378-3505 Fax

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.

This manual contains English. MM 311239

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441 www.graco.com

11/2006 Revised 4/2007