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Graco 3A0420T User's Manual

1. r 571100 3a0420 101a 58 0420 Dimensions Floor Mounting Dimensions Top View y SS O 5 i RS SE E SN Se SR ee RES Ww f Sy O N 812 8 mm s N 22 in 558 8 mm 16 90 429 26 mm 15 25 in 387 35 mm 6 75 in 171 45 mm 40 in 1016 mm A 0420 59 Dimensions Bare Proportioner Mounting Hole Dimensions The dimensions below is the minimum opening size for mounting a bare proportioner 10 125 in 257 175 mm 3 8 16 4x 5 06 in 128 52 mm 10 375 in 263 525 mm 2 25 in 150 4x 57 15 mm 9 25 in 4 05 in 234 95 mm 102 87 mm 3 75 in 95 25 mm 190 5 mm 14 35 in 364 49 mm 0420 Dimensions Wall Mount Bracket 262812 Dimensions 15 0 in 381 mm 119046 0420 61 Dimensions Floor Stand 24M281 Dimensions 21 2 in 538 mm 7 30 3 in 770 mm t119047a Hydraulic Unit Dimensions Shown installed on floor stand 53 in 1346 mm 119048 3in 17 8 in our 51 62 0420
2. Falling Rising Rising Falling r 258914 3a0420a 10a r 258914 3a0420a 10a 34 0420 Repair To avoid serious injury due to the pump assembly falling secure a hoist to the lift ring Follow Shutdown procedure on page 30 which includes flushing if service time may exceed pot life time before servicing fluid components and before transporting system to a service area Pump Assembly The displacement pumps and air motor may be removed and serviced separately or the entire pump and motor assembly can be removed with a hoist Remove Pump Assembly 1 Stop the pumps near the bottom of their stroke Fol low Shutdown page 30 Disconnect all hoses from the pump assembly If hoppers are installed disconnect the hopper fluid lines from the pump fluid inlet See Hoppers page 40 NOTE The hopper and hopper bracket do not need to be removed from the cart 4 5 screws 6 and washers 5 under the tie plate 101 Use hoist to remove the pump assembly by the lift ring and carefully lift out of cart 1 Remove Displacement Pump Js 2 Follow Shutdown page 30 If hoppers are installed remove the hopper and hopper bracket from the cart See Hoppers page 40 If feed pumps are installed close the inlet ball valve Remove inlet union 61 0420 Hepair 4 Remove the
3. ER HORE IN AI A JE 27 Hr SE ESE CEN 12 22 LT B 26 HRR UE 262 7 SIF 4 211 E F LER r 571101 3A0420A 1a 2 FiG 10 Air Control Assembly 258983 0420 37 Repair Mix Manifold Assembly 1 2 Follow Pressure Relief Procedure page 22 Disconnect the fluid hose 25 and the flush hose from the mix manifold 36 Loosen the union fittings 306 that connect to the mix manifold adapter fittings Hemove the mix manifold assembly 36 mix manifold manual for service and repair instructions 36 r 571101 3a0420a 38a Fluid Circulation Manifold with Over Pressure Relief Valves See FiG 11 1 38 Flush before repairing equipment if possible See Empty and Flush Entire System new system or end of job page 29 Follow Pressure Relief Procedure page 22 Disconnect all fluid hoses from the fluid circulation manifold 35 Remove the mix manifold if it is assembled to the fluid circulation manifold See Mix Manifold Assembly for instructions Loosen the two screws 37 that secure the manifold 35 to the cart 1 Remove the two screws 37 and fluid circulation manifold 35 from the cart 1 r 571101 3a0420a 39a FIG 11 Fluid Circulation Manifold Replace Over Pressure
4. ro o4cc ma maa ma pS N SURE 072 0 PUMP LOWER 72cc 1097 0 PUMP PUMP LOWER 97cc 97cc 244819 COUPLING for 2 2 2 1 mi C uo dd DA 247167 COUPLING for 212 ve COVER motor rod motor rod cover motored as EARE ovem EE rr riese eer gemete rr rr rr rr errie ee ier 180029 JLABEL XP O A iic 929 1 EA Eee Lr NM 122 1314 15 108 LABEL pinch point 111111111111111111111111111 2121212 21212 12 21212 21212121111111 1111 185 74225 TRIM edge protection 38133138132 TERTE ETTER ETE TEE ETE SEE Te ETE TE TE T 133 140 141 238905 grounding ase 1 41 4444 16396 LABELXPh XP h aa warning multi lingual me E Edd tsl FLUID tsl 186 rese hoor we ere E EET EIE DEE EE EDE EE EE A Replacement Danger and Warning labels tags and cards are available at Not shown no cost Includes rupture disc 258962 1 Included with new pump assemblies 117 118 0420 51 Parts Air Controls 258983 17433 1 Apply anaerobic pipe sealant to all non swiveling pipe threads A Connect hose 214 to fitting 206 and air distribution manifold 213 Ref No Part No Description 201 202 203 204 205 206 207 208 209 21
5. 55 24872 BRACKET hopper NEE 2 O 72272727 56 262479 HOPPER blue NES NEE 57 262480 HOPPER green NE AE MEE E N 11152506 HOSE coupled 5600 psi 0 25 1D MEN MAN N gt gt gt gt gt E coupled 5600 psi 0 25 ID 2 212 2 2 52 gt gt 552 2 N N _61 160376 FI TING swivel 1 1 4 with plug EEN MEE EE EE 62 171192 SCREW cap tange head I I a lt a B 114055 VALVE safety 105 PSI 16 190 VALVE safety 202482 hopper galon EEN gt gt 22 gt gt 66A 151468 ADEL warning WMM M NM M M M M M M 2122 1010 USUS 9971369059 UM hele gades A Heplacement Danger and Warning labels tags and cards are available at no cost A 6 0420 Parts Parts Varying By Model 282xxx XP50 Systems 9 e S 95555029 EE Description 2 N N ANNA 4 282100 PUMP PACKAGE fixed ratio 1 0 1 NG 282150 PACKAGE fixed ratio 1 5 1 W 282200 PUMP PACKAGE fixed ratio 2 0 1 BOMB 282250 PUMP PACKAGE fixed ratio 2 5 1 1111111 282300 PUMP PACKAGE fixed ratio 3 0 1 a 282330 282400 24 423 100133 100131 512519 158491 5 987 UMP PACKAGE fixed ratio 3 3 1 UMP PACKAGE fixed ratio 4 0 1 UMP PACKAGE no lowers
6. MOT r 571101 3A0420A 9a 2 3 Ensure the recirculation hoses U are in the correct hoppers U 4 Open the circulation valve handle AC 0420 Prime Empty System 5 Turn down the air pressure regulator CB and then open the main air shutoff valve CA Use the air pressure regulator to slowly increase the air pres sure to the pumps until they start running slowly 6 Run the pumps for a few minutes or until the mate rial has reached the desired temperature See Heat Fluid 7 Close the main air shutoff valve CA CA Lr 571100 3A0420A 11 1 8 See Spray page 26 Heat Fluid To heat fluid evenly throughout the system 1 Circulate the fluid at approximately 1 2 gpm 10 20 cycles min to raise the temperature of the hoppers to 80 90 F 27 32 C 2 Decrease the circulation rate to approximately 0 25 gpm 5 cycles min to increase the heater out let temperature to match the spray temperature NOTE Circulating the fluid too quickly without decreasing the circulation rate will increase only the hopper temperature Similarly circulating fluid too slowly will increase only the heater outlet tempera ture 25 Spray Spray 7 7 9 Wear gloves when using flush solvents and or if fluid temperatu
7. 15 Main Air Controls 15 45 1 Solvent Flush Pump Kit 262393 optional 16 OE OR RC UR ee 17 Fluid Line Accessories 17 Flush Before Using Equipment 17 SETUD cla rn E ee es Sel 18 e i os a ate 18 Groundin ss ves Ad RE ER 18 Wire Systems with Explosion Proof Heaters 19 Motor Position 20 Connect Air Supply 21 Connect Static Mixers Gun and Hoses 21 Connect Fluid Hose Bundles Remote Mix Manifold doe act 21 Pressure Relief Procedure 22 Prime Empty System 23 Prime A and B Fluids 23 Prime Solvent Flush Pump 24 Recirculate Prior to Spraying or Re Prime After a Pump Runs 25 AN icu BE A 26 B Side Mix Manifold Restriction 27 Flush Mixed Material 28 Flush Mix Manifold Hose and Spray Gun 28 Empty and Flush Entire System new system or end of job 29 Sh tdOWN xou o oo c oce de cols 30 PAK eas ae ws bar ETE 30 System Verification 31 Maintenance 32 Hose Electrical Resistance 32 MOIS tic cp 6 te GAS o a UA 32 AR OE diu dad 32 Cleaning Procedure 32 Recommended Spare
8. Description XTR 5 and XTR 7 Spray Guns Instructions Parts Pump Package Components 312145 307158 Viscount Hydraulic Motor Instruc tions Parts NXT Air Motor Instructions Parts Xtreme Displacement Pumps Instructions Parts Hopper Kits 20 Gallon Double Wall Hopper Kit Instructions Parts 7 Gallon Hopper Installation Kit Instruc tions Parts 311238 311762 312747 406860 309524 Viscon HP Heater Instructions Parts 309525 313259 Heated Hose Kit Instructions Parts Hopper or Hose Heat Circulation Kit Viscon HP Heater Adapter Kit Instruc tions Parts Solvent Flush Feed and Solvent Flush Kits 406861 310863 312794 Merkur Pump Assembly Instructions Parts Accessories and Kits Polyurethane Circulation and Return Tube Kits Instructions Parts 309852 311486 DataTrak Conversion Kit Instruc tions Parts Feed Pump and Agitator Kits Instructions Parts High Pressure Hose and Accessories Brochure Hatio Check Kit Instructions Parts Mix Manifold Quickset Mix Manifold Instructions Parts Gun Splitter Valve with Independent Flush Instructions Parts 406739 Desiccant Kit Instructions Parts 312769 339361 3A0421 3A0590 3A2573 0420 Helated Manuals 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 symbol
9. 0 7 7 EJ MM 47 469 100 0 7 7 7250 50 500 100 0 7 7 9 O gt O O LO E gt lt 2 O N oO gt lt 571401 5713071 571400 4 011 12 0420 Models Bare Proportioning Pump Packages Packages include motor pump lowers and all connec NOTE All pump packages are Ex rated except for the tion hardware XP h pump packages 284xxx 2G 2 Building systems with bare proportioning pump Hydraulically powered pump packages XP h are not packages available as complete systems Refer to manual 307158 for hydraulic application information e Over Pressure Protection must be used see y PP EE SE A TO Pump sizes are marked on the pump cylinder sizes are pressure relief valves to use with your system nominal See technical data in manual 311762 for actual All components must meet or exceed maximum displacement working pressures Over Combined Maximum Fluid Maximum Air Pressure Fluid Fluid Flow Working Hydraulic Oil Relief Pump A Side Side Output Pressure at 40 cpm Pressure Working Pressure Ex Valve To Type Pump Pump Ratio cc cycle gpm Ipm psi MPa bar psi MPa bar Rated Use 281100 1090 0 LO90CO 1 9 7 2 3500 24 241 95 0 65 6 5 5 8 281200 1115 0 1058 0 1 8 6 8 3500 24 241 85 0 59 5 9 is 262803 114 0 1058 0 2 1 7 9 3500 24 241 100 0 7 7 Purp
10. Controls pump speed and outlet pressure Air line filter C 40 micron filter removes harmful dirt and moisture from compressed air supply Accu mulated water is automatically drained from the fil ter Fluid Line Accessories Fluid Manifold AA Controls circulation and pump priming Mix Manifold AB Combines A and B fluid into one fluid line Circulation Handle AC Directs fluid flow for cir culation or mixing Move to open position to relieve fluid pressure prime pumps and circulate material in hoppers Move to closed position to spray mixed material Dual Shutoff Handle AE Controls A and B fluid flow for mixing and dispensing Close before flush ing Solvent Flush Valve AD Controls solvent flow to the mix manifold hose and spray gun Static mixer gun hose kit Thoroughly mixes the two fluids and delivers the mixed fluid to the spray gun Includes static mixer and hoses to the spray gun 0420 Component Identification Optional Accessories e Optional Fluid Heaters Heats the resin and hardener before mixing Improves the chemical reaction and lowers viscosity to improve the spray pattern e Optional Solvent Flush Kit G Flushes the mix manifold Includes a solvent pump mounting hard ware and solvent supply hose Flush Before Using Equipment The equipment was tested with lightweight oil which is left in the fluid passages to protect parts To avoid con taminating your f
11. Dimensions 0420 63 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
12. Optional 3rd gun port does not have independent flush See manual 3A2573 for more information DataTrak Conversion Kit NXT606 Intrinsically safe battery operated NXT air motor acces sory for material tracking system diagnostics and run away control See manual 311486 for more information 55 Accessories and Kits Not Approved For Explosive Atmospheres These kits do not carry the EX mark 2 1 Feed Pump Kit 256275 For supplying viscous materials from a drum to XP sys tem See manual 312769 for more information 2 1 Drum Feed Kit 256232 One T2 pump feed kit and one Twistork agitator kit for mixing and supplying viscous materials from a 55 gallon drum to XP system See manual 312769 for more infor mation Wall Powered Pressure Monitor Kit 262940 Air Powered Pressure Monitor Kit 262942 Automatically monitors difference between A and B pressures when at spray pressure and shuts down the system if there is a problem 56 0420 Technical Data Technical Data XP Proportioners Maximum Fluid Working Pressure Maximum Air Hydraulic Oil Working Pressure Combined Fluid Output cc cycle See Models section beginning on page 11 See Models section beginning on page 11 See Models section beginning on page 11 Pressure Ratio See Models section beginning on page 11 Fluid Flow at 40 cpm See Models section beginning on page 11 Hydraulic Fluid Consumption XP h models only 0 2 gallons per cycle 0 76 liter
13. Pump operates but hardener output Dirty worn or damaged hardener Clean repair pump see 311762 pressure drops on downstroke 3 pump intake valve Pump operates but hardener output Resin output restriction Clean unplug resin side pressure drops on both strokes Fluid supply low Refill or change container Fluid leak in packing nut Loose packing nut or worn throat Tighten replace see 311762 packings Fluid leak under packing nut Packing cartridge o ring Replace o ring see 311762 Relief valve AM leaks back to sup Relief valve is dirty or damaged over pressure relief ply opens too soon or will not close valve 302 No pressure on hardener side fluid Overpressure rupture disk blown Determine cause of overpressuriza leaking from hardener pump outlet tion and correct Replace rupture disk rupture disc fitting assembly 258962 see page 51 and over pressure relief valve 302 Pressure and flow surges on Feed pressure too high Every 1 psi Reduce feed pressure See Techni upstroke of feed pressure adds 2 psi during cal Data page 57 upstroke 0420 33 Troubleshooting Problem Fluid outlet pressure gauges split Not fully loading one side on Increase feed pressure on side that only at the top changeover if one upstroke dropped gauge drops the other will rise Increase feed hose size Clean inlet strainer or hopper screen Air mixed in fluid from excessive agi
14. WASHER lock 3 8 NUT full hex 3 1 2 12 element IT TING nipple IT TING elbow 60 degree 2 m mi m m EE B POE EA E Hd POS REM 2 He EE EE lf ea N N EN 2 2 JI I I NENNEN AN 252101 Mo o o MAAR 282102 NO NO N gu JERE DODE p RIDE EN AENA H53825 HOSE coupled 5600 psi 0 375 ID 1 1 25 ft 11155 1155 11552105 355 2 HU UN UN BU UN 268 gt EE ERE 5T 124450 CLAMP spring constantiension 2 12 12 pel 28122121 2 2828 52 UN uN E 55 248872 BRACKET hopper 2 28 1712 ee 882 1 56 282479 HOPPER Bee 57 282480 HOPPER geen 222 222 2 22222 2 22 2 10 ft 6T 16076 FITTING swivel 1 74 with pag 2 EHI 282 Df HEBES 752 111192 SCREW capTangemead 15 45 5 15 15 15 15 15 14 15 15 150 13 64 108347 VALVE 00 E 1117 EL reos RR 1 5
15. 1115 0 L058CO 4 39 1 1 8 6 8 7200 50 496 1650 11 114 284251 129 0 1115 0 1 88 1 4 3 16 3 3400 23 234 1800 12 124 20 284252 118 0 1072 0 2 5 1 3 02 1 2 7 10 2 5000 34 345 1650 11 114 EE 2 5 284253 114 0 1058 0 3 77 1 2 1 7 9 6800 47 469 1800 12 124 284301 L29ACO L097CO 1 97 1 4 1 15 5 3500 24 241 1800 12 124 284302 122 0 1072 0 3 0 1 2 631 3 1 11 7 4700 32 324 1800 12 124 284303 L14ACO LO48CO 3 95 1 2 0 7 6 7100 49 490 1800 12 124 284401 L29ACO L072CO 2 10 1 3 8 14 4 3800 26 262 1800 12 124 284402 122 0 1054 0 4 0 1 2 801 2 9 11 0 5000 34 345 1800 12 124 284403 114 0 1036 0 4 21 1 1 9 7 2 7150 49 493 1700 12 117 0420 13 Component Identification Component Identification 0 9 B 3 amp a U W FiG 1 XP70 system with optional accessories Key A Air Supply Hose for Motor B Main Air Controls see page 15 C Air Inlet 3 4 npsm f D High Pressure Fluid Pump E Motor F Fluid Heater optional G Solvent Flush Pump optional see page 16 H Solvent Flush Pump Air Controls see page 16 J 7 Gallon Hoppers op
16. 2 UE 1386 _ SCREW button head 10 32 8 AO 137 124172 WASHER retaining nylon 10 32 8 110 262470 BRACKET ratio indicator 1 138 124665 NUT captive 10 32 4 111 262471 YOKE pump assembly 1 139A 157468 LABEL warning 2 112 15H392 ROD adapter Xtreme 2 113 262472 SLEEVE with bearing 2 A Replacement Danger and Warning labels tags and cards are available at no cost Kit NXT102 de ice knob 5 pack also available Parts Varying by Pump Package Quantity By Pump ee lO T e 5 el O IN re T S N ee vm IN Description EE 104 117 118 119T 121 262466 tie 4 001010 tie 4 00 long 3 3 313131 31 3 FODE OOR 2 te 500 eng foso EAM AAS PEE EH LE 4 494 MOTOR hydraulic N34DNO MOTOR 3400 de icing EN o ENE NesDNO MOTOR 6500 d9 cing_ NE C o Cl ls 262467 adapter Tig LTT Li VII NN 16M654 motor E 108500 PUMP LOWER 8502 109000 PUMP LOWER 1 0 4 LI4ACO PUMP LOWER 145 HE MEE 18 LOWER 180 AE LZ2ACO LOWER 22002 NM MEE EE EE NN M n 03600 PUMP LOWER 36 MAER
17. 72 T T T T a T TIED LT 41 158683 FITTING elbow 90 degrees ______ 2 21 2 2 2 2 21 2 2 212 2 2 748 101566 NUT look 1222722 5T 124450 CLAMP spring constanttension ____ 21712 52 124293 BOLT u bolt 3 8 16 1 00 dia 11111 755 24 872 BRACKET hopper 22221112 756 262479 HOPPER bue 1111 2 2 mm E 2 4 4 EN _ mU 2 2 2 010110110 1117 317 313 414 111 111 313 111 111 111 111 222222 111 212 Bs X 2 EN 2 E 2 4 2 2 2 TO ks 317 3 31313 a 414 21272 31313 2 2 i i 21212 ik BEA ENE AAR 57 282480 HOPPER green H52506 HOSE coupled 5600 psi 0 25 Toen 2 H52510 HOSE coupled 5600 psi 0 251 2 2 2 2 61 160376 FITTING swivel 1 174 with plug 2 88 62 111192 SCREW capfangehead 64 113498 VALVE safety TTT 21217 116643 VALVE safety relief 90 ps E 65 262482 STRAINER hopper 7gallon 1 127421202 157465 LABEL warning EI ERENS ER Ee 68 114858 STRAP We 10101011 101010 90 164688 PLUG hole gauge 111117 TITIT A Heplacement Danger and Warning labels tags and cards are available at no cost ED 317 71317 31313 4 14 414 4 2 1 2 1 8 111 11111 111 11111 3 3 31313 111 11111 111 11111 111 11111 111 11111 212 2 12 2 111 11
18. Flush and add new fluid tation or circulation Pump Troubleshooting This chart uses proportioning fluid gauges to determine pump malfunctions Observe the gauge readings during the stroke direction indicated by the bold arrow and immediately after closing the gun or mix manifold Refer to other manuals to troubleshoot individual components TROUBLE AREA TROUBLE AREA A Resin Pump Leakage A a Hardener Pump Leakage lt Jan 1 Throat packing 1 Throat packing 2 Piston packing af 2 Piston packing 3 Piston ball check HEP 3 Piston ball check E E Resin La H Hardener pua au Pump Resin my Hardener nae a Pump Falling 2 d Rising Falling r 258914 3a0420a 11a r 258914 3a0420a 11a TROUBLE AREA Resin Pump Leakage TROUBLE AREA Hardener Pump Leakage 1 Throat packing 1 Throat packing 2 Intake ball check 2 Intake ball check Resin Pump Hardener Resin Pump Pump Hardener Pump
19. H Flush the mix manifold when any of the following situa tions occur e breaks in spraying e overnight shutdown e mixed material in system approaching end of potlife To flush the entire system see Empty and Flush Entire System new system or end of job page 29 Flush Mix Manifold Hose and Spray Gun If your system doesn t include a solvent flush pump see step 2 of Empty and Flush Entire System new sys tem or end of job page 29 Turn off heaters Allow heater and heated hoses to cool Use Optional Solvent Pump 1 Close the main air shutoff valve CA to turn off the system Engage trigger lock Remove the spray tip and soak in solvent emo EES Us ac il A GF P 223 1949 r 571100 3A0420A 11a 1 2 Close the dual shutoff handle AE 3 Open the solvent pump air valve DA Slowly turn the solvent pump air regulator DB clockwise to increase air pressure DB r 571101 3A0420A 5a 2 28 5 Disengage the trigger lock and trigger gun into a grounded pail Use a pail lid with a hole to dispense through Seal around the hole and gun with a rag to prevent splash back Be careful to keep fingers away from the front of the gun Continue flushing until clean solvent dispenses 1950 T11953a 6 Close the solvent pump air valve DA Trigger the gun
20. if the base model all accessories all kits and all wiring meet local state and national codes Cart Mounted Systems NOTE cart mounted systems listed are Ex rated E 2G T2 See Accessories and Kits on page 55 for a list of all optional accessories NOTE The Standard mix manifold selection means the mix manifold is mounted on the cart and comes with mix ers 25 ft of 3 8 in mix hose and 10 ft of 1 4 in whip hose The Quickset mix manifold selection means the manifold has dual flush valves is mounted on a remote carriage and comes with mixers and 10 ft of 1 4 in whip hose When ordering the Quickset configuration A and B hoses from the sprayer to the mix manifold must be ordered separately Volume Max Fluid Max Air Pump Mix 7 Gallon Mix Working Pressure Pressure Pressure Package Ratio oppers Manifold Zu E MPa bar MPa bar Ratio 281000 I 281101 XTR5 281102 281100 3500 24 241 95 0 65 6 5 281105 281106 281201 35 ft AE XTR5 281202 281200 aa 10 7 3500 24 241 85 0 59 5 9 281205 281206 o 262804 35 ft Standard 5 581592 262803 2 5 3500 24 241 0 0 62 6 2 281256 N 9 O 2 lt c gt lt 2 z LO c A 281301 35 fi Standard XTR5 581302 281300 o1 LY Hie Ein 3500 24 241 100 0 7 7 281306 Er y Standar
21. included 30 mesh 60 mesh Environmental Rating Indoor outdoor Hazardous Areas EX II 2 G c IIA T2 NOTE XP h pump packages 284xxx are not Ex rated Ambient Temperature Range Operating 40 130 F 4 54 C Storage 30 160 F 1 71 C Maximum Fluid Temperature 160 F 71 C Wetted materials Housings and manifolds Miscellaneous parts Carbon steel with electroless nickel plating Plated carbon steel stainless steels carbide acetal UHM WPE nylon PTFE solvent resistant plastics Carbon filled PTFE proprietary UHMWPE Aluminum Nylon core Pump packings Flush pump suction tube Hoses 0420 5 N Dimensions Full XP35 XP50 or XP70 System with heaters solvent 575 261 kg flush pump and hoppers 425 lb 193 kg 286 Ib 130 kg 290 Ib 132 kg Dimensions Top View Bare System E Full System AS kK ib 32 in 4 gt BT 35 in 813 mm a WE A d ll 889 78 Y amp 52in 1321 mm 571100 0420 100a Side View
22. isocyanates appropriate personal protective equipment including chemically impermeable gloves boots aprons and goggles is also required for everyone in the work area Material Self ignition 2 Some materials may become self igniting if applied too thick Read material manufacturer s warnings and material MSDS Keep Components A and B Separate AR 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 component A isocyanate and component B resin parts 0420 Moisture Sensitivity of Isocyanates Isocyanates ISO are catalysts used in two component foam and polyurea coatings ISO will react with moisture such as humidity to form small hard abrasive crystals which become suspended in the fluid Eventually a film will form on the surface and the ISO will begin to gel increasing in viscosity If used this partially cured ISO will reduce performance and the life of all wetted parts NOTE The amount of film formation and rate of crystal lization varies depending on the blend of ISO the humidity and the temperature To prevent exposing ISO to moisture e Always use a sealed container with a desiccant dryer in the vent or a nitrogen atmosphere Never store ISO in an open container e Keep the ISO pump wetcup or rese
23. pot life at your fluid temperature Flush mixed fluid out of the mix manifold hose and gun before pot life time expires or before a rise in viscosity affects the spray pattern Ratio Check Check the ratio at the mix manifold after any changes to the proportioning system Use Ratio Check Kit 24F375 to check the ratio at the mix manifold See manual ratio check kit manual for instructions and parts NOTE To prevent an inaccurate ratio check when feed pumps are used in your system the feed pres sure cannot be more than a maximum of 25 of the proportioner outlet pressure High feed pressure can float the proportioner pump check balls result ing in an inaccurate ratio check There must be back pressure on both sides of the mix manifold when checking the ratio 31 Maintenance Maintenance Hose Electrical Resistance Check electrical resistance of hoses regularly If total resistance to ground exceeds 29 megohms replace hose immediately Filters Once a week check clean and replace if needed the following filters e Both pump filters see lower manual for instructions e Main air inlet manifold filter see Replace Air Filter Element page 36 e Spray gun handle filter see spray gun manual Seals Once a week check and tighten throat seals on both pumps See table for torque specifications Be sure to follow the Pressure Relief Procedure page 22 prior to tightening seals There must be zero pressure on t
24. service or repair the air motor 9 Follow the steps in reverse order to reinstall the air motor NOTE Position air motor for correct mix ratio See Motor Position on page 20 for instructions Torque nuts 108 to 50 60 ft Ib 68 81 Nem Air Controls 10 on page 37 Replace Air Control Assembly 1 Close the main air shutoff valve on the air supply line and on the system Depressurize the air line 2 Disconnect the air motor air lines and system air line 3 Remove the nut 8 and washer 5 Remove the bottom air control manifold assembly from the cart 4 Loosen the upper air control assembly from the air motor 5 Follow the steps in reverse order to reinstall the new air control assembly Replace Air Filter Element 1 Close the main air shutoff valve on the air supply line and on the system Depressurize the air line 2 Unscrew the serrated ring on filter bowl 210 3 Remove and replace the filter element 210a See Air Controls 258983 page 52 Replace System Air Regulator 1 Close the main air shutoff valve on the air supply line and on the system 2 Disconnect air motor air lines and system air line 3 Remove the regulator assembly 201 and replace with new regulator See Air Controls 258983 page 52 4 Follow the steps in reverse order to reassemble 0420 Repair
25. the fluid temperature exceeds 110 F 43 C NOTE The equipment is tested with mineral oil at the factory If necessary flush out the oil with a compatible solvent before spraying See Empty and Flush Entire System new system or end of job page 29 Do not install the gun spray tip yet To avoid splash ing use the lowest pressure possible to prime 1 Condition the materials prior to adding to the hop pers J Ensure that the resin materials are thor oughly mixed homogenous and pourable prior to adding to the hopper Stir the hardeners back into suspension prior to adding material to hopper 2 Fill the A and B reservoirs with proper materials Fill the A side blue with major volume of material fill the B side green with minor volume of material unless 1 1 mix ratio A Ee 0 0420 Prime Empty System 3 Move the recirculation lines U to empty containers 7 26 2 2 Be jfi 25 Tu s4 veil U 4 Close the dual shutoff handle AE and open the culation handle AC AC CET AE 155 d 1 r 571101 3A0420A 9a 2 5 Open the main air shutoff valve CA 6 Slowly open the air regulator CB 7 Dispense fluid into the containers until clean fluid comes out of the A and B recirculation line
26. the A side and B side flush solvent separate Shutdown Follow Pressure Relief Procedure page 22 Flush mix manifold hoses and gun See Flush Mix Manifold Hose and Spray Gun page 28 Close the main air shutoff valve CA Park Open the circulation handle AC and adjust the air regulator CB so that the pump runs slowly Close the circulation handle AC when the pump is at the bottom of the stroke Close the air regulator CB and open the circulation handle AC 0420 System Verification Graco recommends running the following tests daily Check for Normal Operation Every time you start spraying e Watch the fluid gauges AF A pressure drop occurs during pump stroke changeover It should be quick and synchronous e Stop the pumps on the upstroke Check that both gauges hold pressure for at least 20 seconds See Pump Troubleshooting on page 34 NOTE If one gauge drops the others will rise e Stop the pumps on the downstroke Check that all gauges hold pressure e f using feed pumps check that both feed pumps run during the proportioner upstroke Mix and Integration Tests Use the following tests to check for proper mix and inte gration Butterfly Test ZA At low pressure and with the spray tip reversed dis pense a 1 2 in 12 7 mm bead of material onto foil until multiple changeovers of each pump have occurred Fold the sheet of foil over the fluid then peel it back and l
27. the chart on page 39 Initial System Setup Initial System Setup 1 Check the shipment for accuracy Ensure you have received everything you ordered See Component Identification page 14 Check for loose fittings and fasteners Install optional solvent flush pump kit 262393 if ordered See manual 310863 for instructions Mount and connect optional heaters if ordered See the heater adapter kit manual 406861 for instruc tions and the heater manual 309524 Install desiccant kits if using polyurethane isocya nates in hoppers See manual 406739 for instruc tions Install circulation and return tube kits if you are feed ing material from drums or remote hoppers See manual 309852 if you are feeding urethane mate rial Install hopper or hose heat circulation kit 24M224 if ordered See 313259 for instructions NOTE Supply return lines must be used 8 10 11 10 Connect the feed pumps fluid strainers and air hoses as necessary If your system does not use hoppers then see manual 312769 Connect the air supply line See Connect Air Sup ply page 21 Connect the fluid hose assembly including the static mixers whip hose and gun See Pressure Relief Procedure page 22 Flush test oil from system as needed See Empty and Flush Entire System new system or end of job page 29 0420 Models Models WAN The XP systems are approved for use in hazardous locations only
28. to relieve pressure Close the solvent flush valve AD after relieving the pressure AD IX r 571101 0420 12 2 r 571101 3A0420A 12a 7 Follow Pressure Relief Procedure page 22 8 Engage the trigger lock Disassemble and clean the spray tip with solvent by hand Reinstall on the gun A TI1949a mossa 1948 0420 Empty and Flush Entire System new system or end of job Empty and Flush Entire System new system or end of job r 1 h a 2 3 e If the system includes heaters and heated hose turn them off and allow to cool before flushing Do not turn on the heaters until the fluid lines are clear of solvent e Cover fluid containers and use the lowest possi ble pressure when flushing to avoid splashing e Before color change or shutdown for storage circulate the solvent at a higher flow rate and for a longer time Change the solvent when it gets dirty e To only flush the fluid manifold see Flush Mix Manifold Hose and Spray Gun page 28 e If the machine is inoperable use drain plugs on the pump inlet fittings Guidelines Flush new systems if the coating materials will be con taminated by mineral oil Flushing will help prevent materials from settling or gell ing in the pumps lines and valves Flush the syste
29. 0 16F014 207675 113218 100509 100403 160327 101689 155699 119992 117628 210a 106204 52 REGULATOR air T handle MANIFOLD air VALVE ball PLUG 1 4 npt PLUG 1 8 npt FITTING union 90 3 4 male x female GAUGE pressure air FITTING elbow street 3 8 npt FITTING pipe nipple 3 4 x 3 4 npt FITLTER air auto drain 3 4 npt ELEMENT filter 3 4 npt Qty ld mk mk NO Ref No Part No 211 157785 213 15E145 214 16004 215 157350 216 115781 Not shown IRI 10 ay Op ob r 571100 3A0420A 1 1 Description FITTING union 3 4 male x female MANIFOLD air distribution HOSE coupled air 26 in 660 mm NIPPLE 3 8 x 1 4 npt CAP PLUG 1 4 Qty 0420 Fluid Circulation Manifold with Over Pressure Relief Valve Assembly 262784 XP35 262783 XP50 262806 XP70 1 Apply anaerobic pipe sealant to all non swiveling pipe 312 threads A Torque to 28 32 ft lb 38 43 Nem A Apply blue anaerobic adhesive to threads Ref Part 301 16D693 3021 262520 262809 262808 303 156684 304 112309 305 198241 30719 114434 113654 308 100840 309 156971 310 557349 311 16 34 312 16 2 313 124859 0420 Description BLOCK manifold recirculation VALVE over pressure relief silver XP70 VA
30. 0004444 114055 VALVE safety 105p II 65 252482 STRAINER hopper 7 galon 2 12 12 122122 2828 121122 gt 564 151468 LABEL warning 00 72 2 272121272722 22 12 72 68 11458 600000 1090010107010107010101010701070107010707070710101070 Proe hole g A Heplacement Danger and Warning labels tags and cards are available at no cost 0420 47 Parts Parts Varying By Model 283xxx XP50 Quickset gt dE 282100 PUMP PACKAGE fixed ratio 1 01 PACKAGE ratio 1 0 1 Eds 282300 PUMP PACKAGE Tied ato 80 7 m T 282400 PUMP PACKAGE fixed ratio 401 T 11 5 100133 WASHER Took 38 7 7 1 7 1 ISTE a 158491 FITTIN hipple 19M987 FITTING elbow 60 degree KIT mixer element 25 pack 248844 GUN Flex 32 162024 COUPLING 35 262783 MANIFOLD recirculation U2vaves 1 7 TT MANIFOLD Quickset o gh FITTING elbow 90 degree 5T 124450 CLAMP spring constanttension __ 2 BRACKET hopper 96 262479 HOPPER blue 9 262480 HOPPER green 52506 HOSE coupled 5600 psi 0 25 1D ER 2 510 KOS coupled 5600 pa 028 0 3 1 3 ST 160376 FITTING swivel 1 14 win pug 12 2 12 62 111182 SCREW pa 64 113488 VALVE safety TT 65 262482 STRAINER hopper 7galo
31. 01 3a0420a 2a 2 4 Loosen the three nuts P2 below the motor tie rods 2 2 258914 0420 5 Air Motor shown FiG 7 5 Grab the piston rod and slide the position of the motor E until the indicator lines are aligned with your ratio See 6 and FIG 7 NOTICE Do not hit tie rods P with a steel hammer Damage to the air motor base may result 6 Tighten the three nuts P2 and yoke nut V 7 Use supplied tool to tighten the yoke nut 8 Install the pump guards 0420 Connect Air Supply 1 Connect the air supply hose to the 3 4 npt f air filter inlet C NOTE Use a 3 4 in 19 1 mm ID minimum air hose Air consumption is 75 cfm per gallon per minute spraying Do not use pin fitting type quick discon nects plug r 571100 3a0420a 10a 1 FIG 8 2 Remove plugs as necessary for solvent pump and feed supply pump air hoses See pump manuals for setup instructions See FIG 8 Connect Static Mixers Gun and Hoses To prevent creating a flare on the mixer tube do not use a union swivel end on the mix tube inlet 1 Connect the outlet of the two primary static mixer tubes with mixer elements W to the fluid mix hose 25 cleanup mixer 27 28 whip hose 30 and spray gun 31 See FIG 9 2 Add
32. 111 111 11111 212 2 12 2 BEBE EJEDES 2 EB KN _ m EN EN _ EN gt 4 4 4 ESEE ee EN 2 2542 2 2 2 13 0420 Parts 49 Parts Bare Proportioning Pump Package 123 Model 571100 shown 122 EL 117 or 118 gt B E SA 116 9 d 120 gt B 130 _258914_3 0420 _ r 258914 3A0420A 2a IN Torque together to 50 60 ft lb 68 81 Nem A Torque to 145 155 ft Ib 196 210 Nem A Apply blue thread sealant Insert lanyard from locking pin onto pumps 17 18 as shown A Do not apply lubricant A Torque to 70 80 ft lb 95 108 Nem ZN Apply lithium grease to mating tapered surfaces 50 0420 Parts Parts Common to Pump Packages Ref Part Description Qty 2 116 123976 RING snap external 2 Ref Part Description Qty 122 262474 COVER pump 2 Ma 128 151277 CONTROL de ice 1 ie 2406 ong shoulder 130 124078 CLAMP spring constant tension 2 106 5007 Deus 1 along 5 134 2624755 BRACKET ratio indicator 1 107 once 135 162882 STRAP lowers
33. 4a 1 r 571101 3a0420a 45a A be ME EI EE Ee aa Lu ums ha 4 49 90 57 65 inside hopper TI17434a 3A0420T 43 Parts Cart Mounted System Continued LO 5 mm S PRAG Quickset Mix Manifold Models FIDA Ww 1L _ i Y EZRA EEN MAN SAA 19233 0420 44 Parts Common to All Systems J min O ON OWN 12 13 14 15 16 17 19 21 24 37 38 47 49 50 53 54 58 59 67 69 71 89 91 Part 258913 262476 111841 100101 113362 154628 113436 124410 124664 15A913 191824 113807 258982 101242 258983 16F206 111218 H75003 106212 116139 206995 15U654 555357 124259 124291 116704 15V421 16E336 16F615 16F359 16F536 16G819 126786 Description CART weldment AXLE WASHER plain 5 8 SCREW cap hex head WHEEL semi pneumatic WASHER RING retaining BEARING sleeve 1 00 x 1 25 x 1 5 WASHER 1 in ID stainless steel AXLE WASHER space WHEEL flat free urethane HANDLE cart RING retaining ext MODULE air controls inlet LABEL handles CAP tube square HOSE coupled 7250 psi 0 50 ID 3 ft SCREW cap hex head GRIP handle FLUID TSL 1 qt LABEL identification A B SCHEW BRAKE plunger clamp PIN spring ADAPTER 9 16 18 JIC x 1 4 npt TUBE recirculation GUIDE quick start TOOL wrench Xtreme LABEL w
34. 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 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 For patent information see www graco com patents Original instructions This manual contains English MM 3A0420 Graco Headquarters Minneapolis Inter
35. 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
36. Instructions Parts gt g XP Proportioners Mechanically linked fixed ratio plural component system used for proportioning mixing and spraying two component coatings For professional use only Important Safety Instructions Read all warnings and instructions in this manual Save these instructions See page 11 for maximum working pressure and model information XP70 system shown with hoppers and optional solvent flush pump and heaters r_571100_3A0420A_1a 2 4 PROVEN QUALITY LEADING TECHNOLOGY Contents Related Manuals 3 ler ae dex ux m Des di e mos els 4 Important Two Component Material Information 7 Isocyanate 7 Material Self ignition 7 Keep Components A and B Separate 7 Moisture Sensitivity of Isocyanates 7 Foam Resins with 245 fa Blowing Agents 7 Changing Materials 8 A and B Component Designations 8 DIERE MEES EE aUa E EE en Ec 9 UA ese 9 Over Pressure Protection 9 Initial System Setup 10 15 M cC 11 Cart Mounted Systems 11 Bare Proportioning Pump Packages 13 Component Identification 14 Fluid Control Assembly
37. LVE over pressure relief gold XP50 VALVE over pressure relief purple XP35 UNION 1 2 in male x female NUT hex jam PLUG port pressure 11 16 24 GAUGE pressure fluid sst 10k psi GAUGE pressure fluid sst 5k psi FITTING elbow street 1 4 npt FITTING nipple 1 4 npt x npsm PLUG dry seal 1 8 npt HANDLE manifold ROD connecting handle SCREW button head Qty N N NNN ANNNDNNN 316 302 A AN AN r 258988 3a0420a 1c Further tighten either valve 302 as required to line up handle straight across A Apply grease to spring ends A Torque to 70 90 in Ib 7 9 9 Nem Ref 316 317 318 320 351 352 Part 156684 121399 124676 150829 159239 156173 Description FITTING nipple 1 2 npt x 1 2 npt O RING solvent resistant RING snap external SPRING compression FITTING nipple pipe reducing UNION swivel Not shown Shipped loose For XP35 systems only For XP50 systems only T For XP70 systems only Parts 304 AN NOTE Loose fittings are supplied with replacement manifold to also fit Series A XP Proportioners with 3 8 in mix manifold ball valves 53 Recommended Spare Parts Recommended Spare Parts Keep these spare parts on hand to reduce downtime Pump Repair Kits See page 13 to see what pumps are used on your sys tem See lower manual for repair kits Pump Filter O rings packs of 10 262483 Top o ring 244895 Mid
38. Parts 32 Change the Mix Ratio 32 Troubleshooting 33 Pump Troubleshooting 34 TP 35 Pump 35 Air Controls 36 Mix Manifold Assembly 38 Fluid Circulation Manifold with Over Pressure Relief as 38 gloei EE 40 Optional Solvent Pump 40 Optional Fluid Heaters 41 RR ET Sues 42 Cart Mounted System 42 Bare Proportioning Pump Package 50 Air Controls 258983 52 Fluid Circulation Manifold with Over Pressure Relief 53 Recommended Spare Parts 54 Accessories and Kits 55 Acceptable For Use in Explosive Atmospheres 55 Not Approved For Explosive Atmospheres 56 Technical Data 57 DIMENSIONS 58 Bare Proportioner Mounting Hole Dimensions 60 Wall Mount Bracket 262812 Dimensions 61 Floor Stand 24M281 Dimensions 62 Hydraulic Unit Dimensions 62 Graco Standard Warranty 64 0420 Related Manuals Manuals are available at www graco com Component manuals in English
39. Relief Valves 1 Flush before repairing equipment if possible See Empty and Flush Entire System new system or end of job page 29 2 Follow Pressure Relief Procedure page 22 3 Ensure handle 312 is in the down position Remove the screws 313 jam nut 304 handles 311 handle rod 312 clips 318 and springs 320 311 ec 313 2 302 A AA 311 4 as GO N 313 304 A DS NA id Axe Go 302 gt 318 320 A S Yl A 302 NO C MAS 318 r 258988 3a0420a 2b 4 Unscrew both over pressure relief valves 302 from the manifold NOTE The correct over pressure relief valve must be used on all systems Choose the correct color coded valve from the chart on page 39 5 Apply blue threadlock to new over pressure relief valves 302 and install in the manifold Torque to 28 32 ft Ib 38 43 Nem Place a spring 320 over each valve stem Place a clip 318 in each valve stem groove to retain the springs 0420 Hepair 7 Slide handle 311 onto valve stem and rotate 12 Install two screws 313 in handles 311 approximately 90 until you feel it fully lock against the valve seat Repeat for opposite side 13 Check operation of the handle and valves 8 Remove handle then place handle 311 on valve 14 Operate the handle in and out of the spray and cir stem 302 at the vertical or near vertical position culate positions 9 Apply blue thread
40. XP70 to XP35 remove the existing over pressure relief valves 302 and install the cor rect valves for the new system type See Replace Over Pressure Relief Valves on page 38 5 Change air pressure relief valve as required depending on ratio See air relief valve 64 in tables starting on page 46 0420 Troubleshooting Troubleshooting Fluid ratio will be wrong A N W 7 7 fluids all air from system before proportioning Problem Cause System stops or will not start Air pressure or volume too low Increase check air compressor Closed or restricted air line or air Open or clean valve Repair air motor see 311238 Displacement pump parts worn or Repair pump see 311762 damaged Pump operates but resin output Dirty worn or damaged resin pump Clean repair pump see 311762 pressure drops on upstroke 3 piston valve or piston packings Pump operates but resin output Dirty worn or damaged resin pump Clean repair pump see 311762 pressure drops on downstroke intake valve Pump operates but resin output Hardener output restriction Clean unplug hardener side Open pressure drops on both strokes 3 manifold restrictor Fluid supply low Refill or change container Pump operates but hardener output Dirty worn or damaged hardener Clean repair pump see 311762 pressure drops on upstroke 3 pump piston valve or piston pack ings
41. age 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 4 0420 Warnings SKIN INJECTION HAZARD High pressure fluid from gun 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 Do not spray without tip guard and trigger guard installed Engage trigger lock when not spraying Do not point gun at anyone or at any part of the body Do not put your hand over the spray tip Do not stop or deflect leaks with your hand body glove or rag Follow the Pressure Relief Procedure when you stop spraying 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 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 com ponent See Technical Data in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts See Tech
42. arning fire and explo sion hazard LABEL arrow TOOL wrench Xtreme filter TOOL wrench restrictor valve N ANNNADaa lt MAA AP ADP A a ap DPD A Heplacement Danger and Warning labels tags and cards are available at no cost 0420 Parts 45 Parts Varying By Model XP35 Systems SS 5 5 SES A EEE 7 4 281100 PUMP PACKAGE fixed ratio 1 01 EN 262803 PUMP PACKAGE fixed ratio 251 1 1 1 281300 PUMP PACKAGE fixed ratio 3 0 1 261400 PUMP PACKAGE fixed ratio 40 1 i 240422 PACKAGE nolowers Coona 20 512519 MIXER 1 2 12 element 339535555 25 43825 HOSE coupled 4500 psi 0 375 ID 25 ft 1711 1 26 158 29 COUPLING 27 262478 HOUSING mixer ___ 3333 E EN EE 28 248927 mixer element 25 pack 171717 1 EE NN 29 150287 COUPLING Ci mE NU 30 H42510 HOSE coupled 4500 psi 0 25 ID 171717 NAME ANM 31 XIRS EE EE 32 162024 GOUFLING ___ _ _ 12222225 2 EE 2 2 2 36 262807 MANIFOLD mix 1 2 valves 1 117 1 agg 1 NN 48 101566 1222287 2 25542 2 91 124450 ULAMP spring constant tension 2 2 2 27 2 2 7 gt gt 52 124293 DOLI u bolt 3 8 16 1 00 dia 11111171 ANM
43. below summarizes the differ ent designations for the components used in various machines Machine Left Machine Right Designations Side Side er E T BT Color Blue oam and Polyurea and All Reactors ISO Hardener Polyol Resin Component Names Catalyst Base Major or Minor Component Low Volume High Volume when not 1 1 mix Side Side A Letter Color Blue Green Urethane Pour and VRM Epoxy and Urethane Xtreme Eas ardener Cata Protective Coatings and xP omponent Names lyst Major or Minor Component High Volume Low Volume when not 1 1 mix oide Side Letter Epoxy Silicone Ure coor thanes and other mate PR70 and PR Component Names i c a ISO Hardener rale Catalyst Major or Minor Component High Volume Low Volume when not 1 1 mix Side Side 8 0420 Overview Usage The XP is a mechanically linked fixed ratio system that can mix and spray most two component epoxy and ure thane protective coatings When using quick setting material less than 10 minute pot life a remote mix man ifold must be used or materials must mix at the gun Quickset manifold 24M398 is recommended for quick setting material The two pumps are carbide seat severe duty positive displacement pumps that displace fluid on both strokes WAN The XP systems are not approved for use in hazard ous locations unless the base model all accessories a
44. bu tion panel all meet flame proof explosion proof requirements to the Viscon HP heater manual for electrical con nection instructions and guidelines in hazardous loca tions 0420 19 Setup Motor Position The motor position must be set for the volume mix ratio of the system NOTE Changing the motor position does not change the mix ratio Check Motor Position 1 Verify that the correct pumps are mounted for your mix ratio by volume See chart in Bare Proportion ing Pump Packages on page 13 indicator line Li indicator line 2 Motor r 258914 3a0420a 10b FiG 6 Ratio indicators 2 Verify that the motor position is adjusted correctly for that mix ratio See 6 If not perform the fol lowing Change Motor Position procedure Change Motor Position There are specific motor positions for each mix ratio set ting To adjust the position of the air motor 1 Perform Check Motor Position procedure If posi tion is incorrect continue to next step 2 Loosen the eight fasteners and remove the two pump guards Air Motor shown fastener pump gua 20 3 Place wrench on adapter rod 104 then use sup plied tool to loosen the serrated yoke nut V above the yoke T 104 Air Motor shown V E r 5711
45. d 102 my XTRS Standard XTR5 581405 281400 4 0 Y 10 7 m 3500 24 241 95 0 65 6 5 EA 281406 0420 11 Models Volume Max Fluid Max Air Typ Pump Mix 7 Gallon Mix Working Pressure Pressure Pressure e Package Ratio Manifold B MPa bar E 282000 35 uS 282101 Ee Standard 282102 E34 282100 4500 31 310 100 0 7 7 282106 IE Rem 282150 5000 34 344 O 0 62 6 2 ET EI RA ER XTR5 282502 282200 a 4500 31 310 100 0 7 7 282205 ES ECM XTR5 282252 289250 TREES 5000 34 344 95 0 65 6 5 282255 282256 282301 35 XTR5 282305 282300 4500 31 310 100 0 7 7 45 1 282306 282531 282330 EE 5000 34 344 90 0 62 6 2 282401 EE Standard 1 e XTR5 585202 282400 4 0 4800 33 331 100 07 7 48 22 282406 283101 280100 an 4500 31 310 31 310 100 0 7 7 E 282200 EA 33 331 100 0 7 7 283202 Quickset ue FlexPlus XP50 with 6500 Air Motor NO 2 O NO 283301 283302 282300 4500 31 310 31 310 100 0 7 7 283401 5834051 282400 EI 33 331 100 0 7 7 EE 57110 DEE 571162 571100 103 Erg 50 500 6 5 871151 571150 154 7250 50 500 0 0 5 5 5 EN 57120 571501 571200 2 01 Standard ft 7250 50 500 95 0 65 6 5 Lol NN 6500 45 448 45 448 100
46. dle o ring 262484 Bottom o ring Recirculation Overpressure valve see page 39 XP35 262808 purple also for use with XP h 284x01 assemblies XP50 262809 gold also for use with XP h 284x02 assemblies XP70 262520 silver also for use with XP h 284x03 assemblies 15K692 Seal Mix Manifold Check Valve Cartridge NOTE 15K692 must be replaced when cleaning the check valves 1 2 in Mix Manifold Inlet Ball Valves 24M601 Ball valve repair kit 262740 Spare valve no handle 262739 Spare valve single handle 248927 Spare Mix Elements pack of 25 1 2 in OD x 12 element acetal plastic 248837 XTR Spray Gun Repair Kit 010 Seat Seal Kit for XHD Tips b pack XHDxxx spray tips See spray gun manual for tips 54 0420 Accessories and Kits Acceptable For Use in Explosive Atmospheres Blue 7 Gallon Hopper Kit 24F376 Green 7 Gallon Hopper Kit 24F377 Mount to the sides of the XP system See manual 406860 for more information Solvent Pump Kit 262393 For supplying solvent to the mix manifold See manual 310863 for more information Desiccant Dryer Kit 262454 For use with polyurethane isocyanates in 7 gallon hop pers See manual 406739 for more information Desiccant Dryer Filter 2 Pack 24K984 Heater Adapter Kit 262450 Hose and fittings for connecting Viscon HP heaters to XP system See manual 406861 for parts Purchase heaters separately see heater manual for
47. he pumps when adjusting PumpSize Torque Specification All 25 30 ft lb 34 41 Nem Cleaning Procedure A N M 7 7 1 Ensure all equipment is grounded See Grounding page 18 2 Ensure the area where the system will be cleaned is well ventilated and remove all ignition sources 3 Turn off all heaters and allow equipment to cool 4 Flush mixed material See Flush Mixed Material page 28 5 Relieve pressure See Pressure Relief Procedure page 22 32 6 Shutdown the sprayer and turn off all power See Shutdown page 30 7 Clean the external surfaces only using a rag soaked in solvent that is compatible with the spray material and surfaces being cleaned 8 Allow enough time for the solvent to dry before using the system Recommended Spare Parts Keep these spare parts on hand to reduce downtime See Recommended Spare Parts page 54 Change the Mix Ratio In order to change the mix ratio one or both pumps need to be replaced the air motor needs to be re posi tioned and the over pressure relief valves may need to be installed NOTE Only Xtreme XP lower pumps come with a rod coupling 1 Check the Varying Parts table on page 51 for the correct pump sizes 2 Remove and replace pump See page 35 3 Adjust the position of the air motor See page 20 4 from one type of XP system to another for example changing from 5 to XP70 or from
48. hoppers J are empty Salvage the material in separate clean con tainers Close the main air shutoff valve CA 1 YUL 9 acum 571100 3A0420A 11 1 Wipe the hoppers J clean then add solvent to each Move the circulation lines U to waste con tainers and push out the dirty fluids Move the recirculation lines U back to the hoppers Continue recirculating until the system is thoroughly flushed Close the circulation handle AC and open the dual shutoff handle AE Dispense fresh solvent through the mix manifold valves and out the gun Turn off the air motors and follow Pressure Relief Procedure page 22 8 AD 14 Close the dual shutoff handle AE 15 Remove pump fluid filters if installed and soak in solvent Clean and replace the filter cap Always replace the filter o rings NOTE Fill the A and B pump packing nuts with TSL Also always leave some type of fluid such as solvent or oil in the system to prevent scale build up This build up can flake off later Do not use water If machine is set up with a remote mix manifold the A and B hose can be disconnected from the mix manifold and secured in back of each hop per for circulation of flush solvent Change the flush solvent at least once until it circulates clean Always keep
49. l wiring Replace 1 Follow steps 1 through 2 in the Fluid Heaters Ser vice and Repair section 2 Loosen the four mounting screws lock washers and plain washers on back of the heater Slide the heater up and remove from the cart 3 Replace the heater Follow the steps in reverse order to install a new heater r 571101 3a0420a 42a 0420 Hepair 41 Parts Parts Cart Mounted System 1 Apply anaerobic pipe sealant to all non swiveling pipe threads 17 J r_571101_3a0420a_30a oL t6 IL LL Wu 4 7 r 571101 3a0420a 30a 42 0420 Parts Cart Mounted System Continued a vaal Is EE 18 Standard Mix Manifold Models 5 41 35 dad 4 9 pa C dE C esl NS N e ac 23 24 5 cdi 6 r 571101 3a0420a 4
50. le 0 281300 L14ACO LO48CO 2 0 7 6 3400 23 234 95 0 65 6 5 281400 114 0 1036 0 1 9 7 2 3500 24 241 90 0 62 6 2 282100 L14ACO L14ACO 1 001 288 45 1 3 1 11 7 4500 31 310 100 0 7 7 282150 L14ACO LO97CO 1 5 1 240 55 1 2 6 9 8 5000 34 345 90 0 62 6 2 ES S 282200 L18ACO LO90CO 2 9 11 0 4800 33 331 100 0 7 7 E 282250 L18ACO L072CO 2 7 10 2 5000 34 345 95 0 65 6 5 Gold e 282300 L22ACO 1072 0 3 1 11 7 4500 31 310 100 0 7 7 282330 L18ACO LO54CO 3 31 234 561 2 5 9 5 5000 34 345 95 0 65 6 5 282400 L22ACO LO54CO 401 270 48 1 2 9 11 0 4800 33 331 100 0 7 7 571100 1090 0 LO90CO 1 9 7 2 7250 50 500 100 0 7 7 se 571150 085 0 LO58CO 1 5 5 6 7250 50 500 80 0 55 5 5 PE smassuacoec 251 303 e1 2109 wonzn 2 571250 L14ACO LOS8CO 2 51 208 65 Q Z lt 571300 L14ACO L048CO 2 0 7 5 6500 45 448 100 0 7 7 571400 114 0 1036 0 1 9 7 2 7250 50 500 100 0 7 7 284101 L22ACO L22ACO 1 75 1 4 6 17 4 3150 22 217 1800 12 124 284102 14 14 1 0 1 2 631 3 1 11 7 4700 32 324 1800 12 124 284103 1090 0 1090 0 4 21 1 1 9 7 2 7150 49 493 1700 12 117 284201 L29ACO L14ACO 1 75 1 4 6 17 4 3150 22 217 1800 12 124 284202 L18ACO LO90CO 2 0 1 2 81 1 2 9 11 0 5050 35 348 1800 12 124 S 284203
51. ll kits and all wiring meet local state and national codes See Important Two Component Material Information page 7 to determine the appropriate location for your particular XP model 0420 Overview Over Pressure Protection CF Mechanically linked pumps can create excessive fluid pressure if the full motor force is applied to only one of the fluid pumps e Cart Mounted Systems Only Maximum air pres sure set point blow off valves are provided to limit maximum fluid pressure Do not remove these valves e Color coded automatic over pressure relief valves are used on cart mounted systems to dump excess fluid pressure back to the supply Never plug these return hoses See Fluid Circu lation Manifold with Over Pressure Relief Valves on page 38 e When using an XP bare pump package to build a system use the over pressure relief valves refer enced above Never install individual shut off valves on the A and lines On cart mounted systems com mon handles link the fluid control valves e On models other than 1 1 mix ratio a rupture disc is provided on the small side fluid pump pumps 72 and smaller as a back up to the over pres sure relief valve If the rupture disc ever opens do not operate the machine until the over pres sure valve and the rupture disc have been replaced e fchanging pump lowers or motor on your sys tem use the correct over pressure relief valves from
52. lock on the nut 304 threads and 15 Check for clearance with fittings tighten the handle against the spring 320 and clip 318 Torque to 70 80 in lb 7 9 9 Nem NOTE e Both valves should settle firmly into the spray 10 Place the rod 312 and the second handle 311 on position inward against the seats in the valve second valve stem aligned with the opposite handle e Both valve stems should rotate out to their most 11 Repeat step 9 extended positions when the handle is pulled down to the circulate position Fluid Circulation Manifold Replacement Guide ti19168a Circulation Relief Target Opening Manifold 35 Valve 302 Valve Sleeve Pressure Part No Part No Color psi MPa bar All XP35 models 262784 262808 Purple 5300 37 365 XP h models 284101 284201 284301 284401 All XP50 models 262783 262809 Gold 7100 49 490 XP h models 284102 284202 284302 284402 All XP70 models 262806 262520 Silver 9250 64 638 XP h models 284103 284203 284303 284403 NOTE Original XP70 valves did not include a silver valve sleeve When replacing these original valves replace with the current valves that have the silver valve sleeve 0420 39 Repair Hoppers Optional Solvent Pump 1 If material is in the hopper pump out the remaining 1 Follow Pressure Relief Procedure page 22 material 2 Disconnect the fluid line and air lines from the sol 2 If the pump has failed vent pump a Place a was
53. luid with oil flush the equipment with a compatible solvent before using the equipment See Empty and Flush Entire System new system or end of job page 29 17 Setup Setup Location WAN The XP35 XP50 and XP70 systems are approved for use in hazardous locations only if the base model all accessories all kits and all wiring meet local state and national codes 1 Locate the proportioner on a level surface 2 Position the proportioner for convenient operator access and maintenance safe routing of air and fluid lines and easy connection of components and accessories 3 For permanent mounting remove wheels and mount the frame to the floor See Dimensions page 58 4 Ensure that the cart brake L is in the locked posi tion Grounding Aue The equipment must be grounded Grounding reduces the risk of static and electric shock by pro viding an escape wire for the electrical current due to static build up 18 Pump use ground wire and clamp supplied Loosen grounding lug locknut W and washer X Insert ground wire end Y into lug Z slot and tighten locknut securely Connect ground clamp to a true earth ground Solvent Pump use ground wire and clamp supplied with solvent pump Follow instructions in pump manual Air and fluid hoses use only static dissipation type hoses with a maximum of 500 f
54. m when any of the following situations occur e anytime the system will not be used for more than one week depending on materials used e if the materials used have fillers that will settle e if using materials that are moisture sensitive e before servicing e if the machine is going into storage replace the flush solvent with light oil Never leave the equipment empty of any fluid Procedure 1 Follow Prime Empty System page 23 and Flush Mix Manifold Hose and Spray Gun page 28 as required 0420 2 Engage the trigger lock Turn the main pump air regulator CB fully counter clockwise to shut off CB m lt 9 UZ 11949 Qo r 571100 3A0420A 11 1 2 3 Move the recirculation lines U to separate fluid containers to pump remaining fluid out of the sys tem 6 CMM 4 Openthe circulation handle AC See 2 on page 15 5 Increase the main pump air regulator CB pressure to 20 psi 138 kPa 1 38 bar 6 Openthe main air shutoff valve CA V 1 go ES NOTE If the system does not start with static pres sure increase the air pressure by 5 psi 35 kPa 0 35 bar increments To avoid splashing do not exceed 35 psi 241 kPa 2 4 bar 29 Shutdown 10 11 12 13 30 Run the pumps until the A and B
55. mixed material hose as necessary between the mix hose 25 and cleanup mixer 27 28 0420 Setup Connect Fluid Hose Bundles Remote Mix Manifold Only Connect additional fluid hoses to the fluid manifold AA when the mix manifold AB is remote Hoses must be properly sized and balanced for your mix ratio See mix manifold manual for details 1 Connect the resin and hardener hoses to the resin and hardener outlets on the proportioner fluid mani fold and resin and hardener inlets on the mix mani fold 9 2 UJ 31 r 571100 3a0420a 43a Standard Mix Manifold shown FiG 9 21 Pressure Relief Procedure Pressure Relief Procedure m 8 Engage the trigger lock N UA 9 Close the dual shutoff handle AE and open the cir culation handle AC Follow Flush Mixed Material page 28 when you stop spraying or dispensing and before cleaning AC checking servicing or transporting equipment 2 2 Relieve A and B Fluid Pressure 11 1 Engage the trigger lock 1 a cau N I r 571101 3A0420A 9a 2 A 10 Always flush the mix hose after relieving A and B TI1949a fluid pressure through the mix manifold See Flush Mi M ial 28 2 Close the main air shutoff valve CA Material page 28 EE 11 Shutoff the solvent supply pum
56. n 22 2 21 27 ER EN E 68 TOS 10 1010 o 10110 10 50 167688 PLUG noe gewe T T T T T A Heplacement Danger and Warning labels tags and cards are available at no cost 48 0420 Parts Varying By Model XP70 Systems Quantity By System IN IN D e o e CN m Description 311 311335 571100 PUMP PACKAGE fixed ratio 1 0 1 fixed ratio 1 2 1 577150 PUMP PACKAGE fed rato 5 1 unum Em Tum 571200 PUMP PACKAGE fixed ratio 01 571250 PUMP PACKAGE fixed ratio 2 5 1 a 9 1900 PUMP PACKAGE fixed ratio 307 PUMP newer II rr a 5 100133 WASHER look 381717 720 512519 MIXER 2 i2deme 23222 22 158491 FITTING nipple FITTING elbow 60 degree FITTING elbow 60 degree 2 H 3825 HOSE coupled 7250 psi 0 375 ID 25 ft COUPLING 0 26 158729 COUPLING 3 3 4 2 727 262478 HOUSING mixer 2 2 57115 57130 571401 57140 5711 Pr AOS ete eae ese 3 3 4 2 T 1 3 1 30 72510 HOSE coupled 7250 psi 0 25 10 108 731 704 GUN 7 732 162024 COUPLING 2 EE 1 2 TT IT 7 7 3 3 4 4 2 Em 1 1 1 3 3 1 1 1 1 EN 1 1 1 COUPLING 12 2 2 2 2 rn 736 262807 MANIFOLD mix
57. national Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2010 Graco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com Revision T April 2014
58. nical Data in all equipment manuals Read fluid and solvent manufacturer s warnings For complete information 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 manufac turer s replacement parts only Do not alter or modify equipment Use equipment only for its intended purpose Call your 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 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 0420 5 Warnings 7 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 swal lowed e Read MSDSs to know the specific hazards of the fluids you are using St
59. ook for unmixed material appears marble like or color changes Curing Test Spray a single continuous pattern on foil at typical pres sure setting flow rate and tip size until multiple change overs of each pump have occurred Trigger and de trigger at typical intervals for the application Do not overlap or cross over your spray pattern Check curing at various time intervals listed on the material data sheet For example check for dry to touch by running your finger along the test pattern s entire length at the time listed on the data sheet 0420 System Verification NOTE Spots that take longer to cure indicate insuf ficient pump loading leakage or lead lag errors at a remote mix manifold Appearance Test opray material onto foil Look for variations in color gloss or texture that may indicate improperly catalyzed material Monitor Fluid Supply To prevent pumping air into the system which causes incorrect proportioning never allow the feed pump or solvent pump containers to run dry An empty pump will quickly accelerate to a high speed and may damage itself and the other displacement pump because it causes a pressure rise in the other pump If a supply container runs dry stop the pump immediately refill the container and prime the system Be sure to eliminate all air from the system Check Pot Life Check the fluid manufacturer s instructions for fluid
60. ore hazardous fluid in approved containers and dispose of it according to applicable guidelines e Always wear chemically impermeable gloves when spraying dispensing or cleaning equipment 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 e Protective eyewear and hearing protection e Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer BURN HAZARD Equipment surfaces and fluid that s heated can become very hot during operation To avoid severe burns e Do not touch hot fluid or equipment 0420 Important Two Component Material Information Important Two Component Material Information Isocyanate Conditions opraying or dispensing materials containing isocyanates creates potentially harmful mists vapors and atomized particulates Read material manufacturer s warnings and material MSDS to know specific hazards and precautions related to isocyanates Prevent inhalation of isocyanate mists vapors and atomized particulates by providing sufficient ventilation in the work area If sufficient ventilation is not available a supplied air respirator is required for everyone in the work area To prevent contact with
61. p and repeat steps 6 8 to relieve solvent pressure 1 If the mixed material has already been flushed but lt pressure remains on the A and B pumps pressure 7 can be relieved back to the hoppers J gt 2 a Close the main air shutoff valve o 1 571100 420 11 1 b circulation handle 3 Shut off heaters if used NOTE For longer valve life in abrasive fluids it is advisable to relieve high pressure out through the gun when possible 12 If you suspect the spray tip or hose is clogged or 6 Disengage the trigger lock that pressure has not been fully relieved after follow ing the steps above very slowly loosen tip guard retaining nut or hose end coupling to relieve pres sure gradually then loosen completely Clear hose or tip obstruction 4 Shutoff feed pumps if used 5 Remove the spray tip and clean 13 If static mixer whip hose and gun cannot be flushed because of mixed and cured material very slowly loosen static mixer tube from mix manifold outlet to relieve pressure gradually then loosen completely Replace or clean clogged components 1950 7 Hold a metal part of the gun firmly to a grounded metal pail Trigger the gun to relieve pressure 22 0420 Prime Empty System Prime A and B Fluids N W uh 2 777 Wear gloves when using flush solvents and or if
62. part numbers Twistork Agitator Kit 256274 For mixing viscous materials held within a 55 gallon drum See manual 312769 for more information 5 1 Feed Pump Kit 256276 For supplying viscous materials from a drum to XP system See manual 312769 for more information 5 1 Drum Feed Kit 256255 One 5 1 pump feed kit and one Twistork agitator kit for mixing and supplying viscous materials from a 55 gallon drum to XP system See manual 312769 for more information 10 1 Drum Feed Kit 256433 For supplying highly viscous material from a 55 gallon drum to XP system See manual 312769 for more infor mation 0420 Accessories and Kits 20 Gallon Hopper Kit 255963 Floor Stand for 20 Gal Hopper 262824 1 1 2 in ID Hose Flex Feed Kit 262820 XP Wall Mount Bracket 262812 Works with air or hydraulic XP systems Leg Stand 24M281 Includes wall bracket 262812 1 2 in Ball Valve Upgrade Kit for Mix Manifold 24M593 Quickset Mix Manifold 24M398 Mix manifold with independent A and B flushing for use with quick hardening materials See mix manifold man ual 3A0590 for more information Remote Mix Manifold Carriage 262522 A protective guard to mount mix manifold remote See mix manifold manual 3A0590 for more information Mix Manifold Restrictor Wrench 126786 Gun Splitter with Carriage 262826 One splitter valve to use one two or three spray guns with the system Provides independent flush for two guns
63. r valve DA Slowly turn the solvent pump air regulator DB clockwise to prime the solvent pump and push air out of the mix hose and gun Trigger the gun until all air is purged Close the solvent pump air valve DA and trigger the gun to relieve pressure Engage the trigger lock AS V N 22 TI1949a 222 LL DA 10 Close the solvent flush valve AD NOTE Solvent pump air and pressure may be left on while spraying Never spray mixed material with out the solvent pump and hose primed with solvent 0420 Recirculate Prior to Spraying or Re Prime After a Pump Runs Dry NOTE Agitate recirculate and heat the material only as necessary to avoid mixing air into the fluid Use the recirculation mode when heating the material is required Note the temperature at the top of the heater outgoing or back to the hopper When the thermome ter reaches operating temperature the material is ready to spray If using a system that does not require heat recircula tion is still required prior to spraying Recirculation ensures that any settled fillers are mixed in the pump lines are fully primed and the pump check valves are operating smoothly Recirculation also allows you to re prime one side that has run dry 1 Follow Prime Empty System page 23 2 Close the dual shutoff handle AE 2 2 AE
64. re exceeds 110 F 43 C NOTE After the first day of spraying follow Pres sure Relief Procedure page 22 and tighten the throat packing nuts on both pumps 1 If heaters are used turn them on To adjust the heater temperature refer to the Viscon HP manual for instructions and the Heat Fluid section page 25 Circulate as necessary 2 Close the circulation handle AC and the solvent flush valve AD Open the dual shutoff handle AE 9 bio D tw 448 AP AD 3 Adjust the main air regulator CB to 30 psi 0 21 MPa 2 1 bar 4 Remove tip Disengage the trigger lock and trigger the gun into a grounded metal pail Use a metal pail lid with a hole to dispense through to avoid splash ing Dispense out of the mix hose until a well mixed coating flows from the gun 1950 TI1953a 26 5 Engage the trigger lock Install the tip on the gun 4l SE 6 Adjust the main pump air regulator CB to the nec essary spraying pressure and apply a coating to a test panel lt 2 TI1949a NOTE Run system verification tests everyday See page 31 7 Excess pressure increases overspray and pump wear 8 Checkand record gauge readings frequently during operation A change in gauge readings indicates a change in system performance NOTE e pressure drop occurs during pump stroke changeover It should be quick and s
65. rvoir if installed filled with Graco Throat Seal Liquid TSL Part 206995 The lubricant creates a barrier between the ISO and the atmosphere e Use moisture proof hoses specifically designed for ISO Never use reclaimed solvents which may contain moisture Always keep solvent containers closed when not in use e Never use solvent on one side if it has been con taminated from the other side e Always lubricate threaded parts with TSL or grease when reassembling Foam Resins with 245 fa Blowing Agents Some foam blowing agents will froth at temperatures above 90 F 33 when not under pressure especially if agitated To reduce frothing minimize preheating in a circulation system Important Two Component Material Information Changing Materials e Changing material types used in your system requires special attention to avoid equipment dam age and downtime e Always clean the fluid inlet strainers after flushing e When changing between epoxies and urethanes or polyureas disassemble and clean all fluid compo nents and changes hose sets e Check with your material manufacturer for chemical compatibility e Most materials use ISO on the A side but some use ISO on the B side e Epoxies often have amines on the B hardener side Polyureas often have amines on the B resin side A and B Component Designations Material suppliers and markets refer to plural component materials differently The table
66. s 8 Decrease air pressure Close the main air shutoff valve CA 9 Move the recirculation lines U back to the correct hopper 10 If using heaters heat fluid throughout system before spraying See Recirculate Prior to Spraying or Re Prime After a Pump Runs Dry page 25 23 Prime Empty System Prime Solvent Flush Pump Follow instructions if the optional solvent flush pump kit is used 1 Connect the flush pail ground wire to a metal pail of solvent 2 Place the siphon tube and the solvent circulation hose BG in the pail of solvent r 571101 3A0420A 5b 2 3 Open the solvent prime valve BE on the solvent pump BA outlet 4 Open the solvent pump air valve DA Slowly turn the solvent pump air regulator DB clockwise to prime the solvent pump and route solvent back to the pail Close the solvent pump fluid valve BE and air valve DA fold AE closed 24 6 Ensure the trigger lock is engaged Remove the spray tip lt ye s 111949 111948 7 Disengage the trigger lock and trigger the gun into a grounded pail Use a pail lid with a hole to dispense through Seal around the hole and gun with a rag to prevent splash back Be careful to keep fingers away from the front of the gun 8 Open the solvent pump ai
67. s B Component Adjustable Fluid Restrictor see page 27 A and B Mix Manifold Check Valves Solvent Inlet Check Valve Automatic Spring Loaded Color Coded Over Pressure Relief Valves with grease fittings see page 39 A and B Combined Outlet 3 8 npt m CA Key CA Main Motor Shutoff Valve Relieving CB Main Motor Air Pressure Regulator CC Air Filter with Auto Drain CD Main Motor Air Pressure Gauge CE Filtered Air Distribution Manifold 15 Component ldentification 45 1 Solvent Flush Pump Kit 262393 optional Pump FiG 4 Air Controls DA FiG 5 16 Solvent flush pump Merkur Pump Fluid Inlet Muffler Prime Flush Sample valve Fluid Outlet Hose Circulation hose BB suction hose not shown r 571100 3a0420a 4a 2 Key DA Solvent Pump Air Shutoff Valve Relieving DB Solvent Pump Air Pressure Regulator DC Solvent Pump Air Pressure Gauge DD Air Outlet DE Air Inlet r 571101 3a0420a 5a 2 0420 Air Line Bleed type master air valve CA Required in your system to relieve air trapped between it and the air motor when the valve is closed Be sure the valve is easily accessible from the pump and located downstream from the air regulator Trapped air can cause the pump to cycle unexpect edly which could result in serious injury from splash ing or moving parts Pump air regulator CB
68. s per cycle Air inlet size 4 npsm f Maximum air pressure supply to the system 75 psi Fluid pump inlets without hoppers 1 4 in npsm m Fluid gauge manifold outlets 2 in npt f Fluid mix manifold inlets 2 in npt f ball valves Mix manifold material outlet 2 in npt f Maximum feed pressure from remote source 50 psi 17 bar 1 7 MPa Sound pressure 86 dBA at 100 psi 7 bar 0 7 MPa Sound power 98 at 100 psi 7 bar 0 7 MPa Maximum Storage Time 5 years To maintain original performance replace soft seals after 5 years of inactivity Indefinite with recommended maintenance and periodic rebuilds for critical parts 75 cu ft compressed air 1 gallon sprayed material at 100 psi 12 1 L Il 5 mk Maximum Lifetime Maximum feed pressure from remote source 12 P XP70 ower Efficiency Factor 2 12 m compressed air 1 liter sprayed material at 7 bar 0 7 MPa Air consumption 1 gallon 3 78 1 of flow XP70 75 scfm at 100 psi gpm 2 12 m min at 7 bar 0 7 MPa XP50 60 scfm at 100 psi gpm 1 7 m min at 7 bar 0 7 MPa 50 scfm at 100 psi gpm 1 42 m min at 7 bar 0 7 MPa C Air inlet filtration XP pump outlets XTR Spray Gun Fluid Viscosity Range Gravity feed with 7 gallon 26 liter hoppers 200 to 20 000 cps pourable Pressure feed Any viscosity that will not require feed pressure more than 1596 of outlet pressure 40 micron filter separator
69. s 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 operation immediately Do not use equipment until you identify and correct the problem Keep a working fire extinguisher in the work area SPECIAL CONDITIONS FOR SAFE USE To prevent the risk of electrostatic sparking the equipment s non metallic parts must be cleaned with only a damp cloth Refer to the Viscon HP Heater manual for special conditions for safe use ELECTRIC SHOCK HAZARD This equipment must be grounded Improper grounding setup or us
70. spring clamp 130 and coupling 119 or 120 108 r 258914 3a0420a 5a 5 Usea wrench to hold the tie rod 105 106 flats to keep the rods from turning Unscrew the nuts 108 from the tie rods and carefully remove the displace ment pump 117 or 118 and lower straps 135 6 Refer to the Xtreme Displacement Pump manual to service or repair the displacement pump 7 Follow the steps in reverse order to reinstall the dis placement pump NOTE Torque nuts 108 to 50 60 ft lb 68 81 Nem 35 Repair Remove Motor 1 Stop the pumps near the bottom of their stroke Fol low Shutdown page 30 2 Disconnect the air line from the air motor 103 3 Remove the air motor rod cover 121 and pump guards 122 Air Motor shown T 103 121 P r 258914 3a0420a 7a NN 22 4 Usea wrench to hold the tie rod 102 flats to keep the rods from turning Unscrew the nuts 108 and washers 107 from the tie rods 20 Air Motor shown c G lift ring 2 r 258914 0420 8 5 Place a wrench adapter rod 104 Use tool 70 to loosen the serrated yoke nut 109 that holds the air motor 103 above the yoke 111 6 Facethe front of the machine and slide the air motor 103 to the opening in the yoke 111 7 Use a hoist to remove the air motor by the lift ring 36 8 Refer to the air motor manual to
71. t 150 m combined hose length to ensure grounding continuity Check electrical resistance of hoses regularly If total resistance to ground exceeds 29 megohms replace hose immedi ately Air compressor follow manufacturer s recommenda tions 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 To maintain grounding continuity when flushing or relieving pressure hold metal part of the spray gun firmly to the side of a grounded metal pail then trigger the gun 0420 Setup Wire Systems with Explosion Proof Heaters Hazardous location systems only If your system is rated for hazardous areas and you have explosion proof heaters you must have a quali fied electrician connect heater wiring Ensure wiring and installation comply with local electrical codes for hazardous areas Improperly installed or connected equipment will create a hazardous condition and cause fire explosion or electric shock Follow local regulations When explosion proof heaters are used ensure the wir ing wiring connections switches and electrical distri
72. te container beneath the plug on fit 3 Loosen the four screws that attach the solvent pump ting 61 Remove the plug to the cart 1 Lift and pull pump from the slots b Drain all material from hopper into the waste container c Install plug after material is no longer draining from fitting 61 x 5 gt i plug 61 screw 3 Follow Pressure Relief Procedure page 22 4 Refer to the Merkur Pump Assembly manual to ser 4 Loosen fitting 61 and disconnect hopper from vice or repair the solvent pump pump 5 Follow the steps in reverse order to reinstall the sol 5 Remove the recirculation line from the hopper and vent pump J ie r 571101 3a0420a 18a 6 Liftthe hopper off of the mounting bracket 7 Repeat for second hopper 40 3A0420T Optional Fluid Heaters NOTE Wiring for heaters is not provided See the Vis con HP heater manual for wiring repair and parts infor mation for explosion proof heaters Service and Repair 1 Follow Pressure Relief Procedure page 22 2 Disconnect the fluid lines and electrical wiring from the fluid heater 3 Refer to the Viscon HP heater manual to service or repair Refer to the heater adapter kit manual 406861 for installation instructions 4 Reconnect the fluid lines and electrica
73. tional K Cart L Brake M Handle lift to release ob eb ob e3 of A j G Mounting Components for Pump Package p U 5 gt gt J D K xXxE lt CANDUZ lt r 571101 3a0420a 1a 2 Fluid Control Assembly see page 15 Tie Rods Motor Adapter Plate Adjustable Packing Nuts with Wet Cups Yoke With Rod Bearings Recirculation Lines Yoke Position Nut Static Mixer Tubes with Replacement Plastic Elements Motor Position Indicator Lines see Motor Position on page 20 Over Pressure Rupture Disc only 38cc 48cc 54cc 58cc and 72 pumps 0420 Fluid Control Assembly Standard Mix Manifold shown AA AH AF AJ a AN ti19167a FiG 2 Main Air Controls CE CB CC FIG 3 0420 Component Identification Fluid Manifold Mix Manifold Circulation Handle Solvent Flush Valve Dual Shutoff Handle Fluid Pressure Gauges Fluid Supply Inlet Behind Fluid Manifold Fluid Circulation Fitting
74. ynchro nous e Flush the mix manifold as necessary during the day s operation 9 Follow Flush Mixed Material page 28 when you are finished spraying or before potlife expires NOTE Mixed material potlife or working time decreases with increased temperature Pot life in the hose is much shorter than the dry time of the coating 0420 B Side Mix Manifold Restriction The B side restrictor AJ controls lead lag ratio errors of the A and B flow into the static mixer tubes These errors occur momentarily when the gun opens The error is caused by differences in viscosity volume and hose expansion The restrictor is used primarily when the mix manifold is positioned remote from the machine with a short mix hose to the spray gun It can also be used in the ratio check procedure If the mix manifold AB is mounted on the machine you do not need to adjust the restrictor Leave open two turns minimum To Adjust the Restrictor Adjust the restrictor stem clockwise while spraying until you see a slight rise in the B side pressure gauge The point where the pressure starts to rise is a good adjust ment setting NOTE Unless you are dispensing directly out of the mix manifold and mixer this is an approximate adjustment See the mix manifold manual for more information 0420 B Side Mix Manifold Restriction 27 Flush Mixed Material Flush Mixed Material rupe

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