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3A2012B - FRP Proportioner, Instructions - Parts

1. j zl lit lt r 3 4 npt f Fluid Outlet Fic 4 Solvent Pump Components Solvent Flush ASME Pressure Pot 3 4 npt f Fluid 3 4 npt f Fluid Outlet ti9078a1 The pressure pot works by using the incoming air pres sure to expel the solvent in the pot out of the fluid outlet Verify supply tube is installed on fluid outlet port Air Inlet Fluid Outlet 3A2012B Component Identification Solvent Flush ASME and CE Approved Pressure Pot The pressure pot works by using the incoming air pres sure to expel the solvent in the pot out of the fluid outlet See the ASME and CE approved Pressure Pot manual listed on page 3 for detailed component identification Air Inlet Fill Cap Fluid Outlet ti18531a 17 Setup Setup Aw A To avoid fire and explosion and electric shock FRP proportioners are not approved for use in hazardous locations unless all accessories all kits and all wiring meet local state and national codes See Agency Approvals on page 3 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
2. eu DONO Inscr nyloc se LIE ETE dris St RI hhahaha 10 ele eee lee eee Pieleleloleiele lee 121141 elbow Swivel 3 81 1 11 11 11 1 11 1111 111 ELE e BORING nyon 4 3131319313 131313 1313 1199 238909 per Sate VBE nyon uno 2 122 124071 PLUG titing push to connect 1 129 15 558 bundle 25 N externar ger A rrjg ggg rpg 16 557 bundle 25 Ttimema ge ET EI uFSE DUhdleresTcexiemalger qp qu rpg 10 590 bundle 35 mtema pa TE TdT TT HOSE BOSE erna e ye Se m LI 16 583 HOSE bundle 50 ft chop hry ay 124 UN external mix chop with cutter 1113 1 1 EIS ms gel ELI ee PT tT eT eT PENA AA T ER E
3. Press fit bearings Ad Torque piston rod 910 to top link 926 to gt 80 100 in Ib 9 0 11 3 Nem 920 918 52 924 N 922 62 3A2012B Catalyst Pumps x c Ew gt lt Description 01 6 197 HOUSING slave pump 1 02 246470 KIT cartridge FRP 03 TT 506 18972 spring 907 113641 4 GAUGE pressure fluid 124432 GAUGE 160 psi 308 123595 PIN quickrelease 509 124195 CABLE lanyard Sinoh 920 124061 RING backup 0 518 ID 2 2 IL 9269 LINK Yop lave oft T T 92 BEARING spherical p pee e M tOO Bebo c c c e gt NO 2012 System Parts Description SEALANT anaro LUBRICANT grease 645 24 586 FITTING nptx S76 tbe T 55 24 588 FITTING 1 8 x 1 4 tube x lt gt eo lt lt Q Not for sale Parts available in repair kit 16 617 63 System Parts Catalyst Reservoir 24M161 Apply pipe sealant to threads A Apply sticker so that the level line is even with the 2 5 gallon mark on tank 1001 Ref Part Description Qty 1001 TANK gravity feed 2 5 gallon 1 1002 24 159 STRAINE
4. BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2012 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com Revised 01 2012
5. 25 ft 7 6 168208 17 1 Wall Mount 35 10 7 16R211 17 1 Wal Mount 50 15 2 Wall Mount 16R214 17 1 v 50 ft 15 2 LI ae 25 ft 7 6 m lt gt lt lt lt 35 ft 10 7 m 50 ft 15 2 m 6 3A2012B Accessories proportioner systems are approved for use in hazardous locations when the base model all acces sories and all kits meet all wiring meet local state and national codes 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 20 for the required procedures Solvent Flush Diaphragm Pumps 16M874 2 Gallon ASME and CE approved Solvent Flush Pressure Pot 16M875 5 Gallon ASME and CE approved Solvent Flush Pressure Pot 16M893 2 Gallon ASME Solvent Flush Pressure Pot 5 Gallon ASME Solvent Flush Pressure Pot 16N014 120V Viscon Heater for hazardous loca tions 16N015 ini Viscon Heater for hazardous loca 16N016 120V Viscon Heater for hazardous loca tions and explosive atmospheres 240V Viscon Heater for hazardous loca tions and explosive atmospheres 120V Viscon Heater for non hazardous locations 240V Viscon Heater for non hazardous locations 16N017 16N018 16N019 3A20
6. tel EN R 12 Component Identification 13 Air Control 14 Air Motor and Resin Displacement Pump 15 Catalyst P rmp 2e n RR 16 Solvent Flush Systems 17 EOS RS EE E 18 Before Installation 18 Location Requirements 18 System Mounting Wall Mount Systems Only 18 System Assembly 20 Ca FO LIB CHIC su scu it ab icd 22 Connect Fluid and Air Lines 23 Flush Before First Use 25 Fill Supply Tanks 25 26 26 Boom Operation 26 Pressure Relief Procedure and Shutdown 26 PETER 28 TITIO S RAE Vasa 29 Ul PM T CTETUR 32 pc P COE 33 DataTrak Operation 35 Maintenance 37 dod ien 37 Replace DataTrak Module Battery or Fuse 37 Troubleshooting 38 Catalyst Pulmnp 38 38 DataTrak Diagnostics 40 2 xis Giro Sca cavis me Rasa 41 General Information 41 Disconnect the Displacement Pump 41 Hecon
7. 205 16H973 chop 201 16M627 pole 202 24 161 203 100023 204 110837 SCHEW flange hex BUSHING filter tank FITTING 1 4 npt x 3 8 tube FITTING 1 209 054106 TUBE polyethylene 0375 OD 210 054118 TUBE polyethylene sf 071 20764 1 1 021 76 465 CASTER locking not shown 4 222 1189062 WASHER 5 00881 notshown Included in Catalyst Outlet Kit 16N854 Cart for Cart not use with Description i 109973 02 2012 Apply sealant to threads System Parts 53 System Parts Wall Mount Kit 16 169 NOTE For systems that do not use a cart Ref 301 302 303 304 305 306 307 308 309 310 311 312 313 54 Pole 16M670 not included in kit shown for reference only Part 16M666 16M466 19891 00 19892 00 115211 113962 100321 100018 24 161 100521 100023 111303 309 301 Description BRACKET pump pole mount BRACKET catalyst 5 gal CLAMP pipe set PLATE cover clamp SCREW cap hex head WASHER hardened sae NUT WASHER lock spring HESERVOIR gravity feed 2 5 gallon SCREW cap hex head WASHER flat NUT hex SEALANT anaerobic 2 lt a A AAR 1185280 310 311 312 3A2012B Ref 401 402 403 404 405 406 407 408 409 410 411
8. EORR 16M810 strap amp quick start 8752 e ltem shown A Heplacement Danger Warning labels tags cards are available at no cost 3A2012B 51 System Parts 02 161169 WALL MOUNT No Cart ART for use with boom 03 W13DFC W17CFS 111799 16M787 119999 24M092 24E230 246480 120476 111040 16 564 16 565 16 994 UMP 13 1 UMP 17 1 CREW cap hex head ARNESS slave linkage OLT shoulder IN quick release 1 5 x 0 25 UMP slave external mix UMP slave internal mix BOLI shoulder 5 16 NUT lock insert nylock 5 16 LABEL ratio 13 1 FRP ABEL ratio 17 1 FRP SUPPORT boom mast PANEL air control WASHER flat ASHER 5 16 external tooth lock CREW cap hex head ITTING elbow male swivel FITTING elbow swivel 3 8t U UO HSS JJ 438 04 05 06 07 108 6 09 111 12 14 15 16 117 108788 555630 105328 114109 121141 18 19 21 22 123 12508 238909 54139 124071 16 588 16M587 16M586 16M591 16M590 16M589 16M585 16M584 16M583 TUBING nylon round WIRE grounding TUBE nylon round LUG fitting push to connect OSE bundle 25 ft external gel OSE bundle 25 ft internal gel OSE bundle 25 ft chop OSE bundle 35 ft external gel OSE bundle 35 ft internal gel OSE b
9. 412 413 408 409 410 403 404 405 A Item shown for reference only Part 22546 00 16M626 22486 00 100016 100015 16N186 100103 16M811 112248 105170 444 555626 16M808 Not shown 3A2012B Description STRAP binding rubber reusable COVER roving guides GUIDE roving ceramic WASHER lock NUT hex KIT legs cart PIN cotter CHAIN spring boom NUT hex SCREW cap hex head SPRING boom WASHER 1 4 plain flat big PIN clevis with cotter pin System Parts 55 System Parts Air Panel Plug supplied with regulator 504 A Apply sealant to all non swiveling pipe threads Ref 501 502 503 504 505 506 507 508 509 510 511 512 513 514 515 516 517 518 519 520 521 522 56 Part 15T536 15T538 116513 116514 15T500 123985 123986 15T866 1517498 114469 123990 123989 123988 121212 867222 16M789 155541 124071 C12508 054139 054753 Description Qty PANEL air control 1 REGULATOR air 3 8 1 NUT regulator 1 REGULATOR air 2 NUT regulator 2 GAUGE pressure air 1 8 3 FITTING cross 3 8 OD tube 1 FITTING elbow 3 8 OD tube 2 FITTING elbow swivel 2 1 8nptx5 32t FITTING 90 swivel 5 32t x 3 1 etnpt FITTING elbow male swivel 1 VALVE ball 1 2 npt x 1 2 npt 1 FITTING tee 1 2 OD tube x 1 3 4 npt FITTING straight 1 2 x 3 8 tube 1 FITTING elbow swivel 1 2t 3 amnpt FITTING fitting 1 8 x 1 4 LABEL air
10. 945 not shown Repair Apply pipe sealant to threads A Apply adhesive lubricant to mating surfaces or threads A Apply grease to mating surfaces or threads A Torque to 240 in lb 27 1 Nem A Torque to 225 275 in lb 25 4 31 1 Nem Loop large end lanyard over gauge prior to assembling gauge Attach small end of lanyard to split ring on pin AA Note orientation of u cup By Torque to 30 50 in lb 3 4 5 6 Nem Clean cylinder inner diameter with soft cloth or equivalent prior to assembly Ads Hand tighten cylinder 918 and bottom out to housing 901 Back off cylinder 918 less than 1 2 turn Assembly pin 908 Press fit bearings Torque piston rod 910 to top link 926 to 80 100 in Ib 9 0 11 3 Nem 47 System Parts System Parts Systems E Lays EN B A Loosen grounding lug locknut and washer insert grounding wire into slot in lug and tighten locknut 122 i securely A Apply grease to outer diameter not to the threads A Torque to 45 55 ft lb 61 75 Nem VN Connect tubing to catalyst pump By Torque to 20 30 27 41 Nem 48 3A2012B System Parts straight edge such as the edge of a blank piece of paper below that row of the table If necessary use a second straight edge vertically in the table to identify the part number of each item used in the system z SIBI Ss Description
11. Replace transfer housing seal Pressure being relieved through relief Relief valve or check valve has a weak Replace relief valve or check valve valve or check valve at a low pressure spring Pump will not prime Fluid inlet ball valve is closed Open fluid inlet ball valve Resin Pump See Resin Pumplines on page 57 for parts identification Case Does not operate not operate Valve closed or clogged closed or clogged Clear air line increase air supply Check that air line increase air supply Check that valves are open Fluid hose or gun obstructed Clean hose or gun Dried fluid on displacement rod Clean rod always stop pump at bottom of stroke keep wet cup filled with Throat Seal Liquid TSL Air motor parts dirty worn or damaged motor parts Air motor parts dirty worn or damaged worn or damaged Clean or repair air motor air motor manual or Clean or repair air motor air motor manual air motor See air motor manual Runaway error on DataTrak tripped if DataTrak See DataTrak Operation Runaway Monitor installed page 36 38 3A2012B Troubleshooting mam Sa strokes closed or clogged valves are open Open or worn intake valve Suction tube too restrictive causing pump to cavi Use larger diameter tube tate Erratic accelerated Fluid supply exhausted clogged suction supply and prime pump Clean
12. 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 r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 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 Original instructions This manual contains English MM 3A2012 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES
13. 7 mists 60 timin CA TI8623b Fic 30 DataTrak Controls and Indicators Key CA Runaway Limit in cycles per minute user settable BT Batch Totalizer 00 GT Grand Totalizer CB Lower Displacement user settable HT Runaway Toggle enable disable l E1 Error Option enable disable CC Flow Rate Units user settable to min US DT E2 Error Option enable disable Imperial oz min US oz min Imperial or 9 Error Option enable disable CD LED fault indicator when lit CE Diagnostic Reference Card see TABLE 1 page 40 CF Display PF Prime Flush Key Enables Prime Flush mode While in Prime Flush mode runaway protection is disabled and the batch totalizer BT will not count RK Reset Key Resets faults Press and hold for 3 seconds to clear the batch totalizer CF Cycle Flow Rate 2012 35 Operation Setup Mode 1 See Fic 30 Press hold lt gt for 5 seconds until Setup menu appears 2 enter settings for runaway lower size and flow rate units and to enable runaway E1 E2 and E5 error options press 5 to change the value then lt gt to save the value and move the cursor to the next data field Run Mode Runaway Monitor 1 See Fic 30 If pump runaway occurs the runaway solenoid will actuate stopping the pump The LED CD will flash and the display CF will indicate a runaway condition
14. 8 nptm x 3 8 npsm STRAINER mesh screen 100 Qty Ll N ol ll System Parts A Press fit spring 710 to bottom of filter bowl 701 A Apply thread lubricant A Apply grease Apply thread sealant to all non swiveling pipe threads 59 System Parts Resin Supply Hose 16M736 801 802 807 Apply pipe sealant to all non swiveling pipe threads 803 804 805 Ref Part Description Qty 801 220372 HOSE coupled 6 ft 1 802 197682 TUBE suction 1 803 114967 COUPLING pipe 1 in 1 804 195151 TUBE intake 1 805 20397 01 FILTER mesh 24 1 in npt 1 806 SEALANT pipe 1 807 16M776 FITTING elbow 3 4 npsm x 1 1 60 3A2012B System Parts Gun See RS gun manual 3A0232 for parts identification 2012 61 System Parts Catalyst Slave Pumps Apply pipe sealant to threads A Apply adhesive lubricant to mating surfaces or threads A Apply grease to mating surfaces or threads A Torque to 240 in lb 27 1 Nem Ay Torque to 225 275 in lb 25 4 31 1 Nem A Loop large end of lanyard over gauge prior to assembling gauge Attach small end of lanyard to split ring on pin Note orientation of u cup By Torque to 30 50 in lb 3 4 5 6 Nem Clean cylinder inner diameter with soft cloth or equivalent prior to assembly Ads Hand tighten cylinder 918 and bottom out to housing 901 Back off cylinder 918 less than 1 2 turn Assembly pin 908
15. For ease of operation and service make sure the pump air inlet fluid inlet and fluid outlet ports are easily accessible Mount the catalyst reservoir above the cata lyst pump to enable gravity feed Be sure the bracket is level Shown with wall mount pole 16M670 NOTICE To prevent damage to the system caused by the sys tem falling off the wall be sure the wall can support the weight of the pump bracket hoses and accesso ries and stress caused during pump operation 1 For systems using pole 16M670 a Use four bolts and washers not supplied to attach the two mounting brackets A to the wall 3A2012B b Insert pole clamp bolts through catalyst reser voir mounting plate then each of the two upper pole clamps then install and tighten nuts to secure mounting plate and clamps in place c Insert pole clamp bolts through pumpline mounting plate then each of the two lower pole clamps then install and tighten nuts to secure mounting plate and clamps in place d Use four bolts and washers to secure catalyst reservoir to catalyst reservoir mounting plate e Use four bolts and washers to secure pumpline to pumpline mounting bracket 2 For systems bolting directly to wall not using a pole a Use four bolts washers and nuts to install cata lyst reservoir mounting bracket to wall b Use four bolts washers and nuts to install cata lyst reservoir onto the catalyst reservoir mount ing bracket C
16. Use four bolts washers and nuts to secure pumpline mounting bracket to wall d Use four bolts washers and nuts to secure pumpline to pumpline mounting bracket 3A2012B Setup 19 Setup 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 20 For cart and boom systems only install legs a With the system still on the pallet use the sup plied hardware to install the legs onto the base as shown below The two longer legs should be installed on the air control panel side of the machine b Use a forklift to raise the system off of the pallet remove the pallet then place item directly on the floor ZW e Improperly installed or connected equipment may 2 Connect heater if ordered create a hazardous condition that can cause fire explosion or electric shock e Refer to heater manual listed on page 3 for detailed instructions and warnings e You must have a qualified electrician connect heater wiring Ensure wiring and installation com ply with local electrical codes for hazardous areas e Wiring wiring connections switches and electrical distribution panel must all meet flame proof explo sion proof requirements a Use supplied hardware to install heater onto pole as shown below Position the heater to ease hose routing be
17. about your material request MSDS from distributor or retailer Do not leave the work area while equipment is energized or under pressure Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use Check equipment daily Repair or replace worn or damaged parts immediately with genuine manufacturer s replacement parts only Do not alter or modify equipment Alterations or modifications may void agency approvals and create safety hazards Use equipment only for its intended purpose Call your distributor for information 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 27 BURN HAZARD Equipment surfaces and fluid that s heated can become very hot during operation To avoid severe burns Do not touch hot fluid or equipment 3A2012B 9 Important Methyl Ethyl Ketone Peroxide Safety Information Important Methyl Ethyl Ketone Peroxide MEKP Safety Information Include this entire section on MEKP pages 10 11 immediately AFTER the Warnings pages in any instruction man ual for equipment that is used with MEKP MEKP is among the more hazardous materials found in commercial channels Proper handling of the unstable reactive chemicals presents a serious challenge to the plastics in
18. and Shut A enough to remove down on page 26 before checking or servicing the the coupling collars equipment B and then remove To prevent contact with fluids flush the system the coupling nut A prior to disassembling any components that con Use a magnet to aid removing the two collars B tain catalyst or resin ti12815a General Information e Reference numbers and letters in parentheses the text refer to the callouts in the figures and the parts drawing eR Hm m e Always use Genuine Graco Parts and Accessories available from your Graco distributor If you supply 112812a your own accessories be sure they are adequately sized pressure rated and made of materials com 7 Pullup on TSL reservoir C to remove patible with your system B brass rod to loosen the Disconnect the Displacement jam nut as far as possi Pump ble I 9 Protect hands with a J rag then unscrew the i displacement pump by hand and place on work bench 1281 See manual 2313 for displacement pump service and parts information 1 Flush the pump see page 32 2 Stop the pump in the middle of the stroke Threads are very sharp Use a rag to protect hands when hand turning or carrying the pump 3 Relieve the pressure see page 26 4 Disconnect the air supply and fluid hoses 10 See displacement pump manual 3A2313
19. catalyst ratio It is easiest to adjust the ratio when the pump is at the bottom of the stroke Pivot point V2 when pump is moved to adjust ratio this point stays stationary High pressure relief valve W directs catalyst to gun or back to tank to relieve pressure It also automatically relieves pressure if it exceeds normal working pressure Fluid pressure gauge X indicates catalyst fluid pres sure Fluid inlet Y fluid inlet from the catalyst reservoir Fluid Inlet Ball Valve Y2 controls flow of catalyst to the catalyst pump Weep line Z In the event of a throat seal failure the fluid will flow into the weep line and back to the catalyst reservoir Fluid outlet Z1 fluid out to the gun Fluid recirculation high pressure relief Z2 fluid out let to the catalyst reservoir Low pressure relief valve Z3 External mix systems only Directs catalyst to gun or back to tank to relieve pressure 16 V2 118500 7 ti18547a 3 Catalyst Pump Components 3A2012B 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 1 4 npt f Air Inlet
20. 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
21. ground 4 f wall power is used to power the heater ground electrical connection according to local codes 5 Forcart proportioners Connect the other end of the second supplied grounding clamp to the cart For wall proportioners Connect the other end of the second supplied grounding clamp to a true earth ground 3A2012B Connect Fluid and Air Lines Aw Oil left in the system at the factory can react with cata lyst and create a fire or explosion e Flush before first use e Do not add catalyst to the catalyst reservoir until the system has been flushed 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 con nected to the proportioner The whip end of the bundle is the end with more flexible lines See gun manual for hose bundle connection details and individual hose identification Air Connections 1 Verify air line from air outlet 1 AC on air control panel is connected to air inlet M on air motor See FIG 2 on page 15 and 6 FRONT AD AK AH AB AG AE Fic 6 Air Control Panel Components Air Outlet Fitting Details Internal Chop Air Outlet 3 AM 1 4 tube Air Outlet 4 AN 3A2012B External Chop Air Outlet 2 AF 3 8 tube 1 4 tube Setup Connect AAC air line from gun hose bundle to air outlet 3 AM on air control panel See gun manual for AAC air l
22. is the system has been flushed 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 lines 2 Verify the resin suction tube is in the resin supply container Verify catalyst pump suction tube is prop erly connected to the catalyst reservoir and catalyst pump fluid inlet ball valve is open Verify both the resin supply container and catalyst supply reservoir have adequate fluid levels NOTE For systems with Data Trak When priming pumps it is normal to get cavitation or pump runaway 2 alarms Clear alarms 5 and press lt gt again as Never allow the pump to run dry of the fluid being necessary These alarms prevent excessive pump pumped A dry pump quickly accelerates to a high speeds which will damage pump packings speed possibly damaging itself and causing overpres surization and equipment rupture If your pump accel erates quickly or is running too fast stop it immediately and check the fluid supply If the supply container is empty and air has been pumped into the lines refill the container and prime the pump and the lines with fluid or flush and leave it filled with a compatible solvent Be sure to eliminate all air from the fluid system NOTE If using an NXT air motor with DataTrak see DataTrak Operation page 35 1 To enable the user
23. no residues remain Spillage can heat up to the point of self ignition Dispose in accor dance with manufacture s recommendation Store MEKP in a cool dry and well ventilated area in the original containers away from direct sunlight and away from other chemicals It is strongly recommended that the storage temperature remain below 86 F 30 C Heat will increase the potential for explosive decomposition Refer to NFPA 432 Keep MEKP away from heat sparks and open flames Current catalysts are premixed and do not require any diluents Graco strongly recommends that diluents not be used Diluents add to the possibility of contaminates entering the catalyst system Never dilute MEKP with acetone or any solvent since this can produce an extremely shock sensitive compound which can explode Use only original equipment or equivalent parts from Graco in the catalyst system i e hoses fittings etc because a hazardous chemical reaction may result between substituted parts and MEKP To prevent contact with MEKP appropriate personal protective equipment including chemically impermeable gloves boots aprons and goggles are required for everyone in the work area 10 3A2012B Polyester Resins and Gel Coats Spraying materials containing polyester resin and gel coats creates potentially harmful mist vapors and atomized particulates Prevent inhalation by providing sufficient ventilation and the use of respirators in the wor
24. o o o 102 16N168 WALL MOUNT No Cart Fd ud dr forusewithboom t pmr I woe 7 1 HIT IL T LI E LS d I 245230 slave edema mx 1 PME sive ETE E ERIS TT 16 584 LABEL ratio TSJ FRP ABEL ate Tz FRE TI2e 16H994 5 mast 111 Qpa Tp rr 117 114109 FITTING elbow male swivel Pi 121141 FITTING elbow swivel 3 81 1 1 1 18 TUBING nyon omn 3 3 122 124077 PLUG titing push to connest T T T 123 T6M588 bundle 25 exemalgg 1 1 T I T6M586 HOSE bundle 25hchop T T T6M59T HOSE bundle 35 T6M590 HOSE bunde 35fimemal gd 1 1 1 1 16589 HOSE bundle 35th T6M585 HOSE bundle 50 1 1 T6M584 HOSE bunde S0fmema gd 1 1 T6M588 HOSE bundle S0Rchop 124 UN external mix chop with cuter 1 258971 GUN internal
25. psi 11 9 MPa 119 bar 100 psi 0 7 MPa 7 0 bar 10 psi 0 07 MPa 0 7 bar 120 F 49 C 160 F 71 C 2 0 in 51 mm See Technical Data in air motor manual 3A2315 Stainless steel tungsten carbide with 6 nickel UHMWPE PTFE LW100C displacement pump only Also includes carbon steel 3A2012B Catalyst Pump Technical Data Maximum fluid working pressure Internal catalyst pump version External catalyst pump Maximum fluid Ue m n Ern Wetted parts Whip Hose Technical Data Hose bundles maximum fluid working pressure and wetted materials Catalyst hose 1 2 in resin hose 3 8 in resin hose Solvent AAC air 3 8 in OD 1 4 OD atomizing AAC air Technical Data 2000 psi 14 0 MPa 140 bar 90 psi 0 63 MPa 6 3 bar 110 F 43 C 3 5 Ib 1 6 kg 301 303 304 316 and 17 4 PH grades of stainless steel silicon nitride acetal perfluoroelastomer PE PTFE UHWMPE nylon 3000 psi 21 0 MPa 210 bar PTFE 4000 psi 28 0 MPa 280 bar nylon 3300 psi 23 1 MPa 231 bar nylon 225 psi 1 6 MPa 16 bar nylon 125 psi 0 9 MPa 9 bar PET 125 psi 0 9 MPa 9 bar PET Resin Pump Catalyst Pump Solvent Pump and Heater Technical Data See component manuals listed on page 3 for technical data 3A2012B 7
26. pull the trig ger to relieve pressure in the fluid lines FiG 10 3A2012B 5 Engage trigger lock Fic 11 6 Turn catalyst pump pressure relief recirculation valve to the pressure relief position FiG 12 7 Verify that the resin pressure relief recirculation fluid line is routed to a grounded container then turn the pressure relief recirculation valve to the pressure relief position FIG 13 3A2012B Operation 8 After the pressure is fully relieved turn the pressure relief recirculation valve to dispense position Fic 14 A 9 If you suspect the spray tip hose or filter is com pletely clogged or that pressure has not been fully relieved after following the previous steps very slowly loosen the hose end coupling and relieve pressure gradually then loosen completely 10 See the gun manual listed on page 3 for shutdown and maintenance procedures 11 Perform the scheduled maintenance items listed on page 37 2f Operation 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 avoid overpressurization before turning on the main air supply ensure all regulators are adjusted fully counter clockwise so they are set to zero pressure 1 Verify wetcup is filled with Graco Throat Seal Liquid TSL 2 Ensure mai
27. pump adapter Carefully lower the air motor into place 3 Attach the tie rod nuts AF to tie rods then torque to 50 60 ft lb 68 81 Nem 4 Install and tighten the screws AG that secure air motor to mounting bracket AH 5 Install coupler spring guard TSL reservoir 6 With coupling collars B in place hand tighten the cou pling nut then torque to 75 80 ft lb 102 108 s 7 Connect the air and fluid hoses AM A The equipment must be grounded to reduce the risk of static sparking and electric shock Electric or static sparking can cause fumes to ignite or explode Improper grounding can cause electric shock Grounding provides an escape wire for the electric current 112817a 8 Attached grounding wire to true earth ground 3A2012B Fic 32 3A2012B Repair AK Not visible from current view 6 ti18456a 45 Repair 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 41 Disconnect the Air Motor on page 44 displacement pump manual 3A2313 and air motor manual 3A2315 1 Flush the pump see page 32 2 Relieve the pressure see page 26 3 Disconnect main air line from air panel AE 4 Disconnect items from the air motor see FIG 32 on page 45
28. see Table 1 2 Toreset runaway monitor close shutoff valve Wait for air to completely bleed off the air motor before going to the next step The screen will change to indicate this as shown below A psi bar O gt psi bar psi bar 3 e to clear the diagnostic code and reset the runaway solenoid e 4 Open shutoff valve AP to restart pump NOTE To disable runaway monitoring go to setup mode and set runaway value CA to O zero or disable RT see 30 36 NOTE When runaway E1 E2 and E5 error options are enabled will appear on the setup screen See FIG 30 3 Move the cursor to the error enable option field then press lt gt once more to exit Setup mode Prime Flush 1 See FiG 30 To enter Prime Flush mode press any key to wake up the display then press lt gt The Prime Flush symbol will appear flashing in the dis 2 lay and the LED will flash dic lt gt OF min 2 While in Prime Flush mode runaway protection is disabled and the batch totalizer BT will not count 3 To exit Prime Flush mode press any key to wake up the display then press lt gt The Prime Flush sym bol will disappear from the display and the LED will stop flashing Counter Totalizer See FIG 30 The last digit of the batch totalizer BT rep r
29. to better see fluid exiting each fluid port the front end of the RS gun can be removed This step is optional but can be very use ful a Follow Pressure Relief Procedure and Shut down on page 26 3 Units with runaway protection only enable the b Remove the RS gun front end See RS gun prime flush function by pushing the prime flush but manual list on page 3 if desired ton on the DataTrak 4 Verify the pressure relief recirculation valves on the catalyst pump is set to the pressure relief recircula tion position FiG 15 2012 29 Operation 5 Verify the pressure relief recirculation valves on the 10 Turn the catalyst pump pressure relief recirculation resin pump is set to the pressure relief recirculation valve to the dispense position position FiG 19 Fic 16 11 Disengage the trigger lock the gun See FIG 20 6 Turn the main air supply pressure regulator fully counter clockwise to relieve pressure and set to a 4 zero pressure See FIG 17 gt 7 Turn the main air supply ball valve to the open To reduce the risk of exposure to the dispensed mate tion See Fic 17 rial mist when performing the following step use a pail lid with a hole to dispense through Seal around hole 8 Slowly turn the main air supply pressure regulator and gun with a rag to prevent splash back clockwise until the pump starts to move and will change over by itse
30. 12B Accessories 25 ft Extension Hose Bundle for Chop Sys tems 25 ft Extension Hose Bundle for Internal Gel Systems 25 ft Extension Hose Bundle for External Gel Systems 55 Gallon Barrel Carts Cart for 55 Gallon Barrel for Cart and Boom Systems Warnings 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 manual refer back to these Warnings Product specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and explosion Use equipment only in well ventilated area Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present Ground all equipment in the work area See Grounding instructions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail If there is static sparking or you feel a shock stop operat
31. 25 7 6 168059 13 1 50 15 2 i6Roee 131 v v Boom ieRoes 131 Wall Mount v v v 25 ft 7 6 m No Cart 4 3A2012B lt lt lt lt 5 lt lt lt lt lt lt lt lt 5 Models Gun and Pump Type of Hose Bundle Hose Bundle Ratio Mount Chop Included Length 6 131 Wall Mount v v v 35 ft 10 7 m No Cart 168071 131 Wall Mount v v v 50 ft 15 2 m No Cart pies 168074 isa 169085 193 Cat MEME 2 ERES ci et eee t o Car o Cart M pis ee ac ae ERES lt roe oom oom 168132 13 1 Cart with 7 Wall Mount 16R144 13 1 Py 3A2012B 5 5 lt lt lt lt TR lt Models Gun and Hose Bundle Hose Bundle Included TUS MEN m NEN cb 25 ft 7 6 m 35 ft 10 7 m 50 ft 15 2 m 25 ft 7 6 m No Cart Wall M LEE Wall M LER NN E Wall M 16HiB4 def Oat p v mr Gam v Wall Mount 16R2 17 1
32. 3 16M769 1504 C12508 72 Description PUMP solvent FRP flush TANK solvent 2 5 gal assembly assembly 16M560 only TANK solvent 5 gal assembly assembly 16M561 only KIT pump fasteners TUBING nylon round gt E Qty 1 3A2012B Accessory Parts DataTrak Upgrade Kit 16 881 Description Qty 1601 24A354 SMART AIR VALVE not shown 1 1602 24 576 DATATRAK CONVERSION KIT 1 3A2012B 73 Accessory Parts Carts for 55 Gallon Barrel 1710 e 7 8 1705 1705 e p TT 1704 1702 Quantity 16M896 for Cart 16M897 for Cart Se mo EG eat snow 2 mms 1704 113962 WASHER 1706 a 185 BOLI carriage 1707 100132 WASHER flat 1708 100138 WASHER Tock 3 8 1709 100131 full hex 1710 16M667 BRHACKET 55 gal cart pole cart ll 113961 SCREW hex head 00078 WASHER Took spring 8 iN iN m 74 3A2012B Accessory Parts Roving Box Bracket 16M961 1802 1803 199p 1801 1804 1805 Ref Part Description Qty 1801 16M619 BRACKET roving 1802 16M622 BRACE roving box 1803 122741 SCREW hex cap 1 4 x 0 50 1804 104123 WASHER lock spring 1805 112248 NUT hex 1806 16M965 CLAMP u bolt 1807 15 889 SCREW
33. 362 LINK fixed pivot 116596 SCREW cap hex 100361 PLUG pip pipe 615 bial MN adapter 1 2 x 1 2 616 16 477 SPRING guard E inci FITTING elbow 1 2 npt x 1 2 tube 618 SEALANT pipe stainless steel Included in Connecting Kit See page 58 to order the correct kit for your pump 57 System Parts Resin Pumpline Kits Kit Description LW075S LW100C Wet Cup O Ring Package of 10 24A631 24A632 Coupling Collars 606 Connecting Kit Includes pump adapter 603 three tie rods 602 three tie rod nuts 605 TSL reservoir 608 and TSL bottle adapter 603 coupling nut 607 three coupling collars 606 tie rod spring guard 616 16N242 16N243 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 58 3A2012B Resin Filter 24F300 Ref 701 702 703 704 705 706 707 708 710 711 712 717 718 719 Part 179773 171942 238635 205447 061132 100509 104361 186075 171941 100040 172479 GC2069 167026 3A2012B 711 706 Description BOWL filter HEAD filter VALVE ball carbon steel COUPLING hose HOSE nylon 225 psi PLUG pipe PACKING o ring SUPPORT filter SPHING compression PLUG pipe SEALANT pipe TAG warning FITTING swivel 3
34. 3A2012B Operation 31 Operation Flush Zw Oil left in the system at the factory can react with cata lyst and create a fire or explosion e Flush before first use e Do not add catalyst to the catalyst reservoir until the system has been flushed To reduce the risk of fire and explosion and skin injec tion injury only use a solvent compatible with the sys tem wetted parts the resin and the catalyst Flush the system e Before first use e When changing fluids e Before repairing equipment Before fluid dries or settles out in dormant pump check the pot life of catalyzed fluids e Before storing the pump Flush at the lowest pressure possible Flush with a fluid that is compatible with the fluid you are pumping and with the wetted parts in your system Check with your fluid manufacturer or supplier for recommended flushing fluids and flushing frequency NOTE Always flush catalyst pump separately by hand remove pin from upper control arm and hand pump 1 Remove all fluid inlet recirculation and weep lines from the catalyst reservoir and insert in a container filled with a compatible solvent 2 Remove the resin pump fluid supply and recircula tion lines from the resin supply container and insert in a container filled with a compatible solvent NOTICE To prevent accidentally mixing resin and catalyst in the solvent container there must be two solvent con
35. 9 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
36. Instructions Parts lt gt g GRACO FRP Proportioner Low emission internal external mix gel coat and proportioners For use with resin and catalyst in hazardous and non hazardous locations For professional use only Important Safety Instructions e Read all warnings and instructions in this manual and all component manuals Save all instructions See page 4 for model and agency approvals information See page 78 for maximum working pressure and other specifications For patent information see www graco com patents FIRE AND EXPLOSION HAZARD Oil left in the system the factory can react with catalyst and create a fire or explosion e Flush before first use e Do not add catalyst to the catalyst reservoir until the system has been flushed Cart and Boom System Wall Mount System Cart System C x 19 PROVEN QUALITY LEADING TECHNOLOGY Contents Related Manuals 3 Agency Approvals 3 NIOGEIS ge RR I rnm 4 ACCOSSOTIGS kr iade 7 22 25 Sin 8 Important Methyl Ethyl Ketone MEKP Safety Information 10 Important Two Component Material Information 11 Material Self ignition 11 Keep Resin and Catalyst Components Separate 1 1 Changing Materials 11 OVEFVICW
37. OSE bundle 25 ft mtema ge T6M586 bundle 25chop T6M59T bundle 35 LL 590 bundle 35 16589 HOSEbunde chop T6M585 bundle 50 texemalge T6M584 HOSE bundle 50 f miemarge ttt itt LIE E LL T6M588 HOSE bundle S0Rchop 124 258970 GUN external mix chop with cutter L1 L1 LE LL 258840 GUN exema mx g 258971 GUN temal mix chop with cuter LLLI LEE CT TIE EE LL 258853 GUN infernal gel TT 125 T6M736 ISUPPLYHOSE 55galon _ TT 16M810 tie strap amp quick Start amp TSL 111 1 1 11 1 1 111111 11 1 1 11 uuu ltem shown A Heplacement Danger and Warning labels tags and cards are available at no cost 50 3A2012B System Parts IN HH er Cc Description 2 IONIGA EO Ca i EORR e o TREES 8 108 di MERE OUS RUND RE E ETE 105 16M787 HARNESS slave linkage LLENOS slave
38. R tank gravity feed 1 1008 SEALANT pipe stainless steel 1 1010 16M754 LABEL maximum fill line 1 1011 24 587 FITTING 1 8 npt x 1 4 tube 2 90 degree 64 3A2012B 2012 System Parts 65 System Parts Hose Bundles 66 3A2012B System Parts Hose Bundles Quantity M M M Description 1101 169767 TUBE 3 8 in 1 1 169768 3 8 in polyethyl 1 1 MEME 169769 TUBE 3 8 in polyethyl 1 1 TT 1102 1 24 540 coupled 1 8 in 1 1 1 Clo 24 541 coupled 1 8 in 1 1 1 246429 HOSE coupled 1 8 in 1103 240797 coupled 3 8 x p m ol EMI 277253 HOSE coupled 1 2 in x 1 1 1 C Bees pb 1104 24 543 coupled 1 4 in nylon 28 ft 24C544 HOSE coupled 1 4 in 12427 JACKET bue scuff22 111 NN 6 552 JACKET blue scuro 1o07 JACKET Bue scuff 15 a nylon 40 1105 1054130 polyethylene 53 53 28 38 mos seme JUNON iW m coupled 1 4 in x 3 ft 4000 psi 1 1110 electrical vinyl N NENNEN NE an one warning hose 2 2 nazi STRAP retaining Tt l d d reducer 1 1 M o Em _ 162449 _ FITTING nipple reducing 1 o
39. See Agency Approvals on page 3 This section provides instructions for basic system setup of the FRP proportioner See the separate component manuals for detailed information Before Installation Have all system and component documentation available during installation e See component manuals for specific data on compo nent requirements Data presented here applies to the FRP assemblies only sure all accessories are adequately sized and pressure rated to meet system requirements Acces sories are available from Graco Component identification illustrations are only a guide for selecting and installing system components and accessories Contact your Graco distributor for assis tance in designing a system to suit your particular needs Location Requirements Refer to Dimensions page 77 for mounting and clear ance dimensions Cart Mount Systems e Position the FRP proportioner so the air controls and catalyst ratio adjustment arm are easily acces sible 18 e f using a cart and boom system ensure there is enough space overhead and surrounding the pro portioner for the boom and mast to fully extend Place flat and level surface System Mounting Wall Mount Systems Only To reduce the risk of skin injection injury make sure the system is depressurized before mounting any pump assembly See the Pressure Relief Procedure and Shutdown on page 26
40. a Note location of all air hoses connected to air motor then disconnect the hoses from the air motor b Remove top pin AA connecting upper catalyst pump arm to air motor then remove bolts AB connecting lower catalyst pump arm to air motor then remove catalyst pump and control arms assembly AC c Remove two bolts AD securing air control panel to air motor then remove air control panel AE 5 Disconnect the air and fluid hoses 6 Disconnect the ground wire 7 Use socket to loosen the two screws con necting the air motor to the mounting bracket AH 8 Usea socket to remove the two screws AK secur ing the displacement pump to the mounting bracket 9 Lift up on the pumpline to slide pumpline out of bracket 10 Reassembly is reverse of assembly Repair Catalyst Pump 1 Flush the pump see page 32 2 Relieve the pressure see page 26 46 top pivot knob securing catalyst pump to upper control arm bolt securing catalyst pump to lower control arm then remove catalyst pump Disassemble catalyst pump See FIG 33 on page 47 for detailed disassembled view Discard items that need to be replaced then reas semble the pump using the new parts See FIG 33 on page 47 for detailed disassembled view along with torque specifications 3A2012B 932 N 947 shown A 924 AX 922 33 Catalyst Pump Disassembly and Assembly Details 3A2012B
41. aco com Component manuals in English Description 3A0232 RS Gun Instructions Parts 3A2313 U Cup Displacement Pump 3 2315 NXT Air Motor for 308981 Air Operated Diaphragm Pumps 309524 Viscon HP Heater Instructions 207363 Viscon Heater Instructions 313541 DataTrak Conversion Kit Instructions ASME and CE Approved Pressure Pot 308370 Instructions Solvent Flush Pressure Pot Agency Approvals FRP proportioner systems are approved for use in hazardous locations when the base model all acces sories and all kits meet all wiring meet local state and national codes Base FRP System with no accessories Cue DataTrak Module lt gt Eo C US 0359 APPROVED EEx ia T3 Conforms to Nemko FM std 3600 amp 3610 for use O6ATEX1 124 in Class Div 1 Group D T3C Hazardous locations Accessories See accessory manuals listed in Related Manu als section for approvals 3A2012B 3 Models Models iE EDO e e Em Pump Type of Hose Bundle Hose Bundle Ratio Mount Chop Included Length on 7 e Im eee NEN Dem Dr M oom oom oom Boom w e Meee 414 t je o Car o Car o Cart 13 1 18044 131 v v wee oy E D ETE 16R053 saart vitii
42. ally MEKP and resin usually polyester resin or gel coat parts CI MN 3A2012B Changing Materials e When changing materials flush the equipment mul tiple times to ensure it is thoroughly clean e Always clean the fluid inlet strainers after flushing e Check with your material manufacturer for chemical compatibility 11 Overview Overview The FRP proportioner dispenses pigmented tooling low VOC and specialty gel coats as well as polyester resin and vinyl ester chemicals The proportioner supplies the individual catalyst and resin materials and fiberglass roving to the gun On internal mix systems it also supplies solvent to the gun for clearing mixed mate rial from the gun Typical Applications e Marine and watercraft e Pool and spa e Bath ware e Transportation e Corrosion prevention e Cultured marble FRP proportioner systems are approved for use in hazardous locations when the base model all acces sories and all kits meet all wiring meet local state and national codes 12 3A2012B Component Identification Component Identification QQQ 50505050 0 06066 lt 50 00 0000 5050505050506060606006 0660605050005 b pe SV flush diaphragm pump exter Cart system shown with solvent nal mix gel gun 13 25 ft and 35 ft hose bundles only M Spray gun Heater not
43. as been flushed Flush the system before first use to prevent contaminat ing the resin or catalyst See page 32 Fill Supply Tanks Add fluid to the solvent flush supply tank if applicable the catalyst supply reservoir and the resin supply con tainer 3A2012B Setup 25 Operation 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 ti18532a The height of the boom can be adjusted by adjusting which link in the chain is secured to the boom arm 26 Pressure Relief Procedure and Shutdown The equipment stays pressurized until pressure is manually relieved To help prevent serious injury from pressurized fluid such as skin injection splashing fluid and moving parts follow the Pressure Relief Proce dure when you stop spraying and before cleaning checking or servicing the equipment 1 Close the main air supply ball valve NOTICE Stop the pump at the bottom of its stroke to prevent fluid from drying on the exposed displacement rod and damaging the throat u cup seals 2 Turn the main air supply pressure regulator fully counter clockwise FIG 9 3 Disengage the trigger lock on the gun See FiG 10 4 With a grounded bucket below the gun press the gun against the side of the bucket and
44. circulation valve to the dispense position FIG 25 5 Turn the catalyst pump pressure relief recirculation valve to the dispense position See FIG 26 6 Bring catalyst pump fluid outlet line to dispensing pressure see FIG 26 a Remove pin connecting upper catalyst pump arm to air motor rod then manually stroke the pump until the catalyst pressure gauge shows External mix systems 30 40 psi 0 21 0 28 MPa 2 1 2 8 bar Internal mix systems 300 400 psi 2 1 2 8 MPa 21 28 bar b Insert pin to connect upper catalyst pump arm to air motor FIG 26 33 Operation 7 Turn the main air supply ball valve to the closed position See FIG 27 8 Slowly turn the main air supply pressure regulator clockwise until the main air supply pressure gauge reads the desired pressure See FIG 27 Fic 27 9 Disengage trigger lock on the gun See FiG 28 10 Pull trigger to begin dispensing See FIG 28 Fic 28 34 NOTE In the following step to minimize catalyst over spray use as little catalyst atomization air pressure as possible to achieve desired spray pattern See the spray gun manual for instructions 11 FIG 12 13 14 15 16 If the spray pattern has not already been set up to perform as desired see RS gun manual for detailed instructions for how to optimize the spray pattern including adjusting the AAC air pressure at the sys tem or gun and adjusting the catalyst at
45. control panel FRP FITTING swivel 90 degree PLUG fitting push to connect 1 TUBING nylon round 0 85 TUBE nylon round 0 63 TUBE nylon round black 1 63 Ref 523 525 526 527 529 530 531 5393 Part 114381 120389 124496 16N403 124497 113498 Description SEALANT pipe SCREW cap button head FITTING tube VALVE air check BRACKET air control FITTING elbow swivel air VALVE safety 110 psi INSERT control panel 516 2 lt ea YO 02 3A2012B Resin Pumplines ti18457a A Torque to 50 55 ft lb 68 75 Nem A Torque to 50 60 ft lb 68 101 Nem A Assemble pump 604 to top of pump adapter 603 plus or minus one thread Packing nut will extend above the surface of pump adapter 603 Torque jam nut to 70 75 ft Ib 95 102 Nem A Torque to 250 28 2 Nem A Torque to 70 75 ft lb 95 102 Nem A Torque to 75 80 ft lb 102 108 Nem Apply thread sealant 3A2012B System Parts Quantity W1S3DFC W17CFS Description 13 1 17 1 MOTOR double we 4 5 in 15 662 ROD tie tie kea ioci dis placement pump dud ADAPTER dis iul ema pump LW100C PUMP 100 cc 75 pm 606 184128 COLLAR couping 2 157311 NUT 608 15 338 RESERVOIR TSL 75 lower 1571339 RESERVOIR TSL 1 100cc lower 609 16M784 LINK yoke upper 610 16
46. d a diagnostic code will appear on the display See Table 1 To acknowledge the diagnosis and return to the normal operating screen press 5 once to wake up the display and once more to clear the diagnostic code screen Table 1 em Codes Pump running than set runaway Increased air pressure limit Increased fluid output Exhausted fluid supply E 1 Diving Up Leak during upstroke Worn piston valve or packings Leak during downstroke Worn intake valve Low Battery Battery voltage too low to stop Low battery To replace battery see runaway manual 311238 Service Problem with stopping runaway Damaged solenoid Component 1 Damaged valve carriage E Disconnected Solenoid is disconnected Solenoid unplugged solenoid Damaged solenoid wires Service Problem with sensing valve movement Sensors unplugged Component 2 Sensors mounted incorrectly Damaged sensors Damaged valve carriage Blown Fuse Fuse is blown Faulty solenoid or solenoid wiring Extreme temperatures above 140 F 60 40 3A2012B 5 Hold the flats of the air Kim motor piston rod with a wrench Use another To reduce the risk of fire and explosion repair pro wrench to loosen the cedures must be performed in a non hazardous coupling nut location Move system to non hazardous location before performing any repair procedure 6 Lowerthe coupling nut Follow Pressure Relief Procedure
47. dustry The highly reactive property which makes MEKP valuable to the plastics industry in producing the curing reaction of polyester resins and gel coats also pro duces the hazards which require great care and caution in its storage transportation handling processing and dis posal Workers must be thoroughly informed of the hazards that may result from improper handling of MEKP especially in regard to contamination and heat They must be thoroughly instructed regarding the proper storage use and dis posal of MEKP and other hazardous materials used in the laminating operation MEKP is flammable and potentially explosive as well as potentially damaging to the eyes and skin Read material manufacturer s warnings and material MSDS to know specific hazards and precautions related to MEKP Contaminated MEKP can become explosive Prevent contamination of MEKP with other materials including but not limited to polyester overspray polymerization accelerators and promoters and non stainless metals Even small amounts of contaminates can make MEKP explosive This reaction may start slowly and gradually build up heat which can accelerate until fire or an explosion result This process can take from seconds to days Heat applied to MEKP or heat build up from contamination reactions can cause it to reach what is called its Self Accelerating Decomposition Temperature SADT which can cause fire or explosion Spills should be promptly removed so
48. e This hose is attached at the factory Connect resin recirculation hose to the pressure relief recirculation line P1 and route to the resin container Catalyst Pump Fluid Connections NOTE See FiG 3 on page 16 11 Verify the pressure relief recirculation valve W is set to pressure relief knob is horizontal 12 Connect the catalyst line from the gun hose bundle to the catalyst outlet Z1 3A2012B Solvent Flush Connections applicable NOTE See Solvent Flush Systems component identi fication on page 17 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 supply tank to solvent pump fluid inlet 15 Connect solvent line from gun hose bundle to sol vent fluid outlet Gun Connections 16 For 25 ft and 35 ft hose bundles only Place the coil of resin hose in the hose bundle on the hook sup port located on the pole Secure with the supplied rubber straps The hook support should be inserted through the center of the hose coil 17 Secure all connections on the whip end of the hose bundle to the gun See the gun manual listed on page 3 for detailed instructions Flush Before First Use Aw Oil left in the system at the factory can react with cata lyst and create a fire or explosion e Flush before first use Do not add catalyst to the catalyst reservoir until the system h
49. e from the inlet on the air control panel AE 3 Disconnect grounding wire 4 Disconnect items from the air motor a Note location of all air hoses connected to air motor then disconnect the hoses from the air motor b Remove top AA connecting upper catalyst pump arm to air motor then remove bolts AB connecting lower catalyst pump arm to air motor then remove catalyst pump and control arms assembly AC c Remove two bolts AD securing air control panel to air motor then remove air control panel AE 5 Hold the flats of the air motor piston rod with a wrench Use another wrench to loosen the coupling nut A Lower the coupling nut A enough to remove the coupling collars B then remove the coupling nut A ti12812a 6 Usea 23 mm socket to remove the tie rod nuts AF 7 Usea 13 mm socket to loosen the top two screws that secure air motor to mounting bracket AH 44 8 Lift up on the air motor to remove it The tie rods AJ will remain attached to the air motor 9 Use a socket on the flats of the tie rods AJ to remove them from the bottom of the air motor 10 See air motor manual 3A2315 for repair procedures and parts information Reconnect the Air Motor See FIG 32 on page 45 1 Screw the tie rods AJ into the bottom of the air motor With a wrench on the flats of the tie rods torque to 50 55 ft lb 68 75 2 Align the tie rods AF with the holes in the
50. ernal Chop External Chop Air Outlet 2 AF 3 8 tube 1 4 tube 3 8 tube 1 4 tube Air Outlet 3 AM 1 4 tube 1 8 npt 3 8 tube 1 8 npt Air Outlet 4 AN 3 8 tube 3 8 tube Plugged Plugged 14 3A2012B Component Identification 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 P relieves pres sure in the hose and gun Pressure relief recirculation fluid outlet P1 place container below fluid outlet or connect fluid hose and route back to the resin container or install container below the outlet Pressurized fluid outlet on filter R connect fluid hose to the 1 4 npt f fluid outlet reducer fitting supplied with Graco hoses Fluid inlet S connect fluid suction hose to the 3 4 npt m fluid inlet DataTrak T optional electronic monitoring for mate rial tracking system diagnostics and pump runaway control The DataTrak is located on the air control panel See the NXT Air Motor manual for details of the Data Trak controls and indicators 3A2012B P1 5 2 15 Component Identification 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
51. esents tenths of gallons or liters To reset the totalizer press any key to wake up the display then press and hold e for 3 seconds min NOTE If flow rate is set to both totalizers will display the number of pump cycles 3A2012B Maintenance Ze Inspect pump wetcup and fill with TSL and remove any particles or residue Inspect hoses for wear Weekly or damage and replace immediately if found Remove catalyst As needed reservoir filter and clean with solvent Replace catalyst As needed reservoir filter Flush system Components See component manuals listed on page 3 for mainte nance schedules and procedures for each component Replace DataTrak Module Battery or Fuse The battery fuse must be replaced non haz ardous location If you are using an NXT pump with DataTrak and need to replace the battery or fuse see the NXT Air Motor manual for instructions 3A2012B Maintenance 37 Troubleshooting Troubleshooting A 62 v Follow Pressure Relief Procedure and Shutdown on page 26 before checking or servicing the equip ment Problems Try the recommended solutions in the order given for each problem to avoid unnecessary repairs See Catalyst Pump See Catalyst Slave Pumps parts illustration on page 62 for parts identification Pressure loss on up stroke
52. for pump service procedures and parts information 3A2012B 41 Repair Reconnect the Displacement Pump 1 2 Disconnect air supply from air motor Hand turn the displacement pump into the adapter plate Install coupler spring guard and TSL reservoir Hold the air motor piston rod up with one hand With your other hand put the coupling nut A on the dis placement rod Put the coupling collars B into the coupling nut A so large flanges point upward Gently let the air motor piston rod drop onto the dis placement rod Hand tighten the coupling nut A 112817 Screw the displacement pump into the adapter plate D until the cylinder top is flush with the top of the adapter plate p k Cylinder not wet cup should be flush with al plate Pp ti12814a Fic 31 Align cylinder and adapter plate 42 10 11 Align fluid outlet as shown and tighten the jam nut Align the TSL reservoir C and push it down into place Hold the flats of the motor rod with a wrench Use another wrench to tighten the coupling nut A Torque to 75 80 ft lb 102 108 Nem Reconnect air supply to motor 3A2012B 3A2012B Repair 43 Repair Disconnect the Air Motor See manual 3A2315 for air motor service and parts information See FIG 32 on page 45 1 Relieve the pressure see page 26 2 Disconnect main air supply lin
53. hex ltem not shown m 3A2012B 75 Accessory Parts Extension Hoses 1904 1904 1901 1908 1907 1903 1908 1906 1913 1908 1903 1907 19041912 1902 1909 1905 1911 1901 1910 16 712 for cart boom 16M718 16M719 Description n for internal gel for external gel 1 1901 16 766 TUBE 3 8 in polyethylene 25 ft ro HOSE coupled 1 8 in 3000 psi ft indi 240796 HOSE coupled 3 8 x 25 16M731 HOSE coupled 1 2 in x 25 4000 psi 1904 244731 coupled 1 4 in nylon 25 ft 1905 054130 os polyethylene 0 250 OD EN Tous 24427 1909 128558 FITTING 4 J IEEE MEE 72554 COUPLER SB 1 7 25789 COUPLER ODubng 7 c 2 72552 FITTING nipple 1 7 1 9134 180659 ABEC waning hose bne 1 1 1 13 A Heplacement Danger and Warning labels tags and cards are available at no cost 76 2012 Dimensions Dimensions Cart and boom system shown Re Cart and Boom Cart Only Wall Pole Mount A Max Width B Max Height 144 in 29 5 in 39 0 in 3658 mm 749 mm 991 mm 100 in 47 75 in 46 6 in 2540 mm 1213 mm 1183 mm 180 in 32 5 in 32 in C Max Depth 3A2012B 4572 mm 826 mm 813 mm 77 Technical Data Pumpline Wall Mou
54. ine identification External mix proportioners only Connect the sup plied air tubing attached to air outlet 2 AF to atom ized air line on gun Internal mix proportioners only Connect the sup plied air tubing attached to air outlet 2 AF to sol vent pump air inlet See FIG 4 on page 17 Chop systems only Remove plug then connect the chop air line 0 375 in tube in the gun hose bundle to the chop air fitting AN on the air control panel Verify air shutoff valve AP is closed handle is ver tical then connect the air supply line to the air inlet AA on the air control panel REAR External Gel 3 8 tube 1 4 tube 3 8 tube 1 8 npt 3 8 tube 3 8 tube Plugged Plugged 23 Setup Resin Pump and Optional Heater Connections FiG 7 6 10 24 Verify the pressure relief recirculation valve P is set to pressure relief Place a waste container below the fluid outlet then remove the pump fluid inlet cap Drain the test oil then discard Connect resin suction hose to the resin pump 3 4 nptm fluid inlet S Place other end of suction hose in resin container For non heated systems only Connect resin hose from the gun hose bundle to the resin pump 1 4 fluid outlet R Reducer fitting comes with Graco hose bundle For heated systems only attach resin hose from the gun hose bundle to the heater outlet Verify fluid hose connecting resin pump outlet to heater inlet is installed and secur
55. ion immediately Do not use equipment until you identify and correct the problem Keep a working fire extinguisher in the work area SKIN INJECTION HAZARD High pressure fluid from dispensing device hose leaks or ruptured components will pierce skin This may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment Engage trigger lock when not dispensing Do not point dispensing device at anyone or at any part of the body Do not put your hand over the fluid outlet Do not stop or deflect leaks with your hand body glove or rag Follow the Pressure Relief Procedure when you stop dispensing and before cleaning checking or servicing equipment Tighten all fluid connections before operating the equipment Check hoses and couplings daily Replace worn or damaged parts immediately ELECTRIC SHOCK HAZARD This equipment must be grounded Improper grounding setup or usage of the system can cause electric shock Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment Connect only to grounded power source All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations 8 3A2012B Warnings 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 swallowed Head MSDSs to know the
56. k area Read the material manufacturer s warnings and mate rial MSDSs to know specific hazards and precautions related to polyester resins and gel coats To prevent contact with polyester resins and gel coats appropriate personal protective equipment including chemically impermeable gloves boots aprons and goggles are required for everyone in the work area Important Two Component Material Information Spraying and Lamination Operations Hemove all accumulations of overspray FRP sand ings etc from the building as they occur If this waste is allowed to build up spillage of catalyst is more likely to start a fire If cleaning solvents are required read material manu facture s warnings and material MSDS to know spe cific hazards and precautions Graco recommends that clean up solvents be nonflammable 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 Material Self ignition 22 Some materials may become self igniting if applied too thickly Read material manufacturer s warnings and material MSDS Keep Resin and Catalyst Components Separate Cross contamination can result in cured material in fluid lines which could cause serious injury or damage equipment To prevent cross contamination of the equipment s wetted parts never interchange catalyst usu
57. lf Never turn past 20 psi To reduce the risk of skin injection be careful to keep 0 14 MPa 1 4 bar See FiG 17 fingers away from front of gun To reduce the risk of fire and explosion use a Q grounded pail i dex NM 12 With a grounded bucket below the gun press the gun against the side of the bucket and pull the trig ger to dispense Continue dispensing until air free fluid is dispensed from both ports on the front of the gun See Fic 20 The pump air pressure may need FiG 17 to increase slightly until the material begins to flow 9 Turn the resin pump pressure relief recirculation valve to the dispense position Fic 20 18 30 3A2012B 13 Turn the main air supply ball valve to the closed position FIG 21 14 Turn the catalyst pump pressure relief recirculation valve to the pressure relief position This will relieve any built up pressure 22 15 Verify that the resin pressure relief recirculation fluid line is routed to a grounded container then turn the pressure relief recirculation valve to the pressure relief position FIG 23 16 Units with runaway protection only disable the prime flush function by pushing the prime flush but ton on the DataTrak 17 Engage gun trigger lock 18 If the front end of the gun was removed apply grease to o rings and front of gun to prevent mate rial from curing or sticking to it then install gun front end
58. mix chop with cuter 1 1 1 1 258858 GUN internal gel 1 1 me tt LII 1579 3A2012B 49 System Parts CO tks CC CC CC CC CC CC CC CC CC CC CC Cc cc cc oo Description TeNT69 WALL MOUNT KIT No Cay for use with boom ART 105 PUMP FRR TST mmm wcs PUMEFRRTZT 16 787 HARNESS stave linkage T06 119999 BOLT shoulder 107 quick release 153025 24E230 PUMP slave exemamx D LLL LLL LLLI 24450 PUMP slave memamx LLL 10 111040 Tock insert nylook 616 16 564 LABEL ratio T83 FRP ry rp ppt LTEM LABEL rato TI2e 994 mast ra PNELarame 2 2 55859 WASHER SW external woth pp 2222222222222222222 2 2 7 121141 imb elbow swivel 3 8t 111111111 111 E ms TUBING nyonoud 313 3131313 3 3 31313 TISe 25890 WIRE goudng 3 3 313131313 3 13131313 122 124077 PLUG fitting pushHo comect 123 16 588 bundle 25t externar ge 1 TL T LE LL I LE LE ELLE T6M587 H
59. n air line is connected to the air control panel air inlet AA For internal mix proportioners only check solvent line a Verify gun is ready to begin operation See gun manual b Turn shutoff valve AP on the air control panel to the open position Open the air valve on the solvent pump and adjust the solvent pressure to 90 psi 0 63 MPa 6 3 bar d Open the ball valve on the solvent pump e Open solvent knob on the gun to verify that sol vent will flow out of the front of the gun through the dispense tip then close the valve Oil left in the system the factory can react with cata lyst and create a fire or explosion e Flush before first use Do not add catalyst to the catalyst reservoir until the system has been flushed 4 fthis is the first startup of the machine perform the Flush procedure on page 32 28 As desired perform Prime Flush or Spray proce dures beginning on page 29 Make sure to flush the system before first use to flush out oil used to test the equipment at the factory 3A2012B Operation Prime 9 Oil left in the system at the factory can react with cata lyst and create a fire or explosion e Flush before first use Perform this procedure upon initial system setup when e Do not add catalyst to the catalyst reservoir until ever hoses are disconnected if the supply hose
60. nect the Displacement Pump 42 Disconnect the Air Motor 44 Reconnect the Air Motor 44 Replace Pumpline 46 Repair Catalyst Pump 46 System Parts NU dr uri 48 SVSIBITIS c Dos ier 48 ss xoa Qu 53 Wall Mount Kit 163169 54 BOOM ad p actin Mead 55 AIDE ael a 56 Resin Pumplines 57 Air Motor and Pump for Resin 58 Resin Fiter 5235 59 Resin Supply Hose 60 2101 61 Catalyst Slave Pumps 62 Catalyst Reservoir 64 Hose Bundles 66 Hose Bundles 67 2 52 5 22 2 68 Heater d TL T 68 Solvent Pressure Pot Kits 70 Solvent Diaphragm Pumps 72 DataTrak Upgrade Kit 73 Carts for 55 Gallon Barrel 74 Roving Box Bracket 75 Extension Hoses 76 DIMENSIONS 77 Wall Mounting Bracket Dimensions 78 Technical Data 78 Graco Standard Warranty 80 3A2012B Related Manuals Related Manuals Manuals are available at www gr
61. not shown 3A2012B 69 Accessory Parts Solvent Pressure Pot Kits ASME Pressure Pots 16M893 and 16M894 Ref 1301 1302 1303 1304 1305 1306 1307 1308 1309 1310 1311 1312 1313 70 20324 00 20324 01 160939 11021 23 18470 05 856 04 20655 04 103347 21035 00 21462 01 3165 17440 00 121307 1311 1306 1310 2 1309 f 1303 To assemble strainer 1311 remove the dip tube from tank 1301 Slide strainer onto bottom end of dip tube Hold strainer in place while positioning dip tube Strainer should be secure on ube and pressed to bottom of tank Tighten dip tube in place Strainer not shown A Apply pipe sealant A Clamp ground cable 1311 to handle on tank 1101 Ground cable not shown Description TANK solvent 2 gallon assembly 16M893 only TANK solvent 5 gallon assembly 16M894 only FITTING nipple reducing PLUG pipe 1 4 VALVE ball 2 way 1 4nptf FITTING elbow 1 4 nptm x 1 4 nptm FITTING elbow 3 8 nptm x 3 8 tube VALVE safety 100 psi STRAINER pick up material FITTING adapter 1 4 nptm x 3 8 nptf VALVE ball 2 way 3 8 female 3 8 male CLAMP grounding LABEL designation SEALANT pipe Qty 3A2012B ASME CE Approved Pressure Pots 16 874 16M875 N411 Apply pipe sealant A Clamp ground cable 1423 to handle on tank 1401 Ground cable not shown A Must be installed
62. nting Bracket Dimensions The pumpline bolts directly to this mounting plate Four 0 60 in 15 mm mounting holes Technical Data System Technical Data Maximum fluid working pressure Maximum air inlet Maximum air inlet pressure to ASME solvent pressure pots Typical flow rate of pattern Maximum fluid temperature A component catalyst inlet size B component resin inlet size Wetted Pumpline Technical Data Maximum fluid working pressure Maximum air inlet Minimum air inlet Maximum ambient air Maximum fluid temperature Stroke SOUNC P wees won ee Wetted 78 10 1 in 257 mm 13 1 Systems 1300 psi 9 MPa 90 bar 17 1 Systems 1700 psi 11 9 MPa 119 bar 100 psi 0 7 MPa 7 0 bar 100 psi 0 7 MPa 7 0 bar Refer to RS Gun manual See Related Manuals page 3 110 F 43 1 4 in tube 1 5 16 12 UN 2A male Stainless steel carbide UHMWPE PTFE and acetal 13 1 Systems 1300 psi 9 MPa 90 bar 17 1 Systems 1700
63. omization air correct amount of air no air too little air 29 AAC Air Adjustment After all pressure adjustments are made spray a final test shot on a clean piece of paper This shot should be approximately 5 ft long Check desired gel times and uniformity of curing For internal mix proportioners only When finished spraying engage trigger lock then point the gun into a waste container and use the solvent knob on the gun to move solvent through the gun to flush the gun For external mix proportioners only When finished spraying wipe the tip of the gun with a clean rag with solvent to remove any mixed material If necessary use a brush to remove cured material from front of the gun If finished spraying for an extended period of time Follow Pressure Relief Procedure and Shutdown on page 26 3A2012B DataTrak Operation For DataTrak installation instructions see NXT Air motor for manual Controls and Indicators NOTE See FiG 30 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 DataTrak will continue to count cycles when display is off Run Mode GT BT t OF min CF TI8622b Setup Mode RT UT a min 8 acc CF See Details at right rur CTRONIC MONITORING SYSTEM ST CD RK 220 cc E2 v
64. on the outlet side The outlet is the port without the cross hole Ref 1401 1402 1403 1404 1405 1406 1407 1408 1409 1410 1411 1412 1413 1414 Part Description Qty 236086 TANK pressure assy 2 gal 1 assembly 16M874 only 236087 TANK pressure assy 5 gal 1 assembly 16M875 only 165053 PACKING o ring 1 188880 PLUG lid 1 188784 NUT jam hex 1 171976 TUBE 1 assembly 16M875 only 185531 TUBE siphon assembly 1 16M874 only 125214 BUSHING hex 3 8npt x 1 4 2 male female 111763 FITTING elbow 1 4 npt 1 18470 05 VALVE ball 2 way 1 4 2 160939 FITTING nipple reducing 1 108673 street 1 103347 VALVE safety 100 psi 1 121140 FITTING connector male 1 3 8 npt 210575 filler assembly 16 875 1 only not shown 176347 LABEL identification 1 3A2012B Ref 1415 Part 14164 175078 1417 1418 1421 1423 1424 308370 17440 00 171988 1403 1408 Description LABEL designation LABEL warning SEALANT pipe SEALANT anaerobic MANUAL CLAMP grounding O RING for filler cap item 1413 not shown Accessory Parts Qty Ll Danger and Warning labels tags cards are available at no cost 71 Accessory Parts Solvent Di aphragm Pumps 16M560 and 16M561 1502 1503 1504 1501 1503 Base System shown for reference only Ref Part 1501 16M559 1502 16M652 16M651 150
65. q A Heplacement Danger and Warning labels tags and cards are available at no cost 2012 67 Accessory Parts Accessory Parts Heater Kits 1205 1204 E Aai 1202 1209 1201 2 1206 LU 8 1207 1208 0 0 1215 1213 1210 lt lt a Kit 15NO14 shown Cart not included in kit shown for reference only 68 3A2012B Accessory Parts Heater Kits Quantity 16N014 16 015 siti dean 120v FM 240v FM hazardous hazardous hazardous hazardous mor fenos BRACKET neater T T T T 1 1202 19891 60 2 2 2 2 2 2 1203 1989200 PLATE 2 2 2 2 2 2 1204 100018 WASHER Tock spring 4 NUT a 1206 15217 SCREW hexhead 4 1207 100003 ISCREW cap hexhead 4 DE ae oat NUT full hex full hex E LUN uU I NM elbow male 90 deg 1211 _ 100081 BUSHING pipe me 24C406 coupled 213 1159239 FITTING nipple pipe fs ptfe 1 2 in wide 245848 viscon HP 245863 HEATER viscon HP HE A RB BR SA A 245867 viscon HP 245869 HEATER viscon HP 226819 HEATER viscon 240 E 226816 viscon 120 ee Son Items are available in heater hardware 16 1 19 ltem
66. shown Air Water Separator customer supplied Grounding Wire not shown L Hook support for resin hose coil H Air Control Panel J Pressure Pot Options also available F Catalyst Reservoir E Solvent Flush Diaphragm Pump Option Shown G Boom not shown C Displacement Pump Key A B Air Motor D Catalyst Pump Internal mix systems only 2012 Component Identification Air Control Panel Air pressure gauge 2 AG indicates regulator 2 air pressure Air inlet AA from air line Air regulator 3 AH controls Air Assist Containment Air regulator 1 AB controls air to resin pump AAC air to spray gun Air outlet 1 AC air line to resin pump Air pressure gauge 3 AK indicates AAC air pres sure Air pressure gauge 1 AD indicates air pressure to resin pump Air outlet 3 AM AAC air line to spray gun Air regulator 2 AE for external mix guns only con trols catalyst atomization air For internal mix guns only controls solvent flush pressure Air outlet 4 AN Chop air supply to spray gun This outlet is plugged at the factory Plug must be removed to install chop air Air outlet 2 AF for external mix guns only catalyst air line to spray gun For internal mix guns only to solvent pump Air Shutoff valve AP shuts off air to entire system FRONT REAR AB AP AG AE 1 Air Control Panel Components Air Outlet Fitting Details Int
67. specific hazards of the fluids you are using Store hazardous fluid in approved containers and dispose of it according to applicable guidelines 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 hearing loss inhalation of toxic fumes and burns This equipment includes but is not limited to Protective eyewear and hearing protection Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer MOVING PARTS HAZARD Moving parts can pinch cut or amputate fingers and other body parts Keep clear of moving parts Do not operate equipment with protective guards or covers removed Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure and disconnect all power sources 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
68. suction tube speed High viscosity fluid Reduce viscosity increase fluid temperature reduce flow rate by using smaller tip Open or worn piston valve or seal Clear piston valve replace seal Open or worn intake valve Clear or service intake valve Runs sluggishly Possible icing See air motor manual for instructions Filler material clumping causing extra friction on Flush pump and replace packings rods and seals Cycles or fails to hold Worn check valves or seals Service lower See lower manual for instructions pressure at stall Air bubbles in fluid Loose suction line Tighten Use compatible liquid thread sealant or PTFE tape on connections Poor finish or irregular Incorrect fluid pressure at gun See gun manual read fluid manufacturer s recom spray pattern mendations Fluid is too thin or too thick Adjust fluid viscosity read fluid manufacturer s rec ommendations Dirty worn or damaged spray gun Service spray gun See spray gun manual To determine if fluid hose or gun is obstructed follow Pressure Relief Procedure and Shutdown page 26 Dis connect fluid hose and place a container at pump fluid outlet to catch any fluid Turn on air power just enough to start pump If pump starts the obstruction 15 in fluid hose or gun 2012 39 Troubleshooting DataTrak Diagnostics DataTrak can diagnose several problems with the pump When the monitor detects a problem the LED CD FIG 30 will flash an
69. t 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 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 nonconductive sur face such as paper or cardboard which interrupts grounding continuity 22 FRP Proportioner Grounding NOTE All external mix proportioners come with one grounding clamp to ground the proportioner to a true earth ground All accessories for internal mix systems come with a second grounding clamp to ground the sol vent flush system to the cart 1 Verify that the ground screw is attached and tight ened securely to the air motor Connect the other end of the ground wire to a true earth ground Ground screw Grounding wire 222 Br ZL EP 118454 5 Ground Wire 2 For internal mix systems only ground the solvent flush system a For solvent flush diaphragm pumps only con nect one end of the second grounding clamp to the solvent pump grounding strip See the dia phragm pump manual listed on page 3 for grounding details b Connect the other end of the grounding clamp to the cart 3 Use an ohmmeter to verify all components are grounded to the earth
70. tainers used with the resin pump fluid lines inserted in one and the catalyst pump fluid lines inserted in the other 3 With the fluid lines in the two separate solvent con tainers perform the Prime procedure at the lowest pressure possible While performing this procedure leave the fluid supply recirculation and supply lines in the solvent containers 32 3A2012B Spray NOTE If using an NXT air motor with DataTrak see DataTrak Operation page 35 for instructions on using the DataTrak counter totalizer 2 A Prior to production use spray onto a clean piece of paper until all system settings are adjusted to optimize the spray pattern Perform this full procedure whenever the gun has been unused for an extended period of time such as over night After performing this full procedure spraying can be performed intermittently as desired by simply pulling the trigger and utilizing the trigger lock to prevent acci dental triggering 1 this is the first time starting up the system if fluid lines have been disconnected if the fluid supply line has been removed from the supply container or if either pump has been run dry perform Prime proce dure on page 29 2 Turn the main air supply ball valve to the closed position 3 Turn the main air supply pressure regulator fully counterclockwise FIG 24 3A2012B Operation 4 Turn the resin pump pressure relief re
71. tween pump and heater Viscon Heater Shown i ti18529a b Connect heater electrical connections See heater manual listed on page 3 for detailed instructions 3A2012B 3 Install solvent flush diaphragm pump or pressure pot if ordered a Use the supplied hardware to install the dia phragm pump or pressure pot onto the base of the cart in the mounting holes provided 9 7 a gt 0 YA erate Solvent Flush Dia phragm Pump shown bd b Use supplied hardware to install solvent supply tank onto the base of the cart 4 Install DataTrak Upgrade Kit if ordered Follow the detailed instructions in DataTrak manual listed on page 3 5 Assemble the boom as shown below then slide the boom onto the system pole if ordered Guides Deflector Plates 18532 2012 Setup Use the supplied hardware to install the roving box bracket onto the pole Install the top pole clamp above the lower arm of the boom as shown below if ordered 118525 21 Setup Grounding AMA The equipment must be grounded to reduce the risk of static sparking and electric shock Electric or static sparking can cause fumes to ignite or explode Improper grounding can cause electric shock Grounding provides an escape wire for the electric current General Grounding Guidelines Pump use ground wire and clamp supplied Connec
72. undle 35 ft chop OSE bundle 50 ft external gel OSE bundle 50 ft internal gel OSE bundle 50 ft chop 258970 UN external mix chop with cutte 258840 UN external mix gel 258971 UN internal mix chop with cutter 258853 UN internal gel 16M736 SUPPLY HOSE 55 gallon 16M810 tie strap amp quick start amp TSL 124 m uu T 5 m 25 26 h h h lI h h l zi um X e pe pee n lle psc p p ere SRS p px Ce R m pes Ee pee ce ee e T a esce ce ceo RG Ce sero e ERC ER 519A 160136 LABEL warnings 5 Q h 5 Heplacement Danger Warning labels tags and cards are available at no cost 2 3A2012B Carts 201 203 v 204

3A2012B - FRP Proportioner, Instructions - Parts

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