Graco 3A6283F, XPs-hf Proportioners Owner's Manual

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Graco 3A6283F, XPs-hf Proportioners Owner's Manual | Manualzz

Operation, Repair, and Parts

XPs-hf

Proportioners

3A6283F

EN

Mechanically linked, fixed ratio, plural-component system used for proportioning, mixing, and spraying two component coatings.

For professional use only.

See page 10 for model information and working pressures.

See page 11 for component approvals.

Important Safety Instructions

Read all warnings and instructions in this manual and in related manuals before using the equipment. Save these instructions.

WLD

2

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Important Isocyanate (ISO) Information . . . . . . . . . . . . . . 7

Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . . . . . 7

Keep Components A and B Separate . . . . . . . . . . . . . . 7

Moisture Sensitivity of Isocyanates . . . . . . . . . . . . . . . . 8

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Over Pressure Protection . . . . . . . . . . . . . . . . . . . . . . . . . 9

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

XPs-hf Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Component Identification . . . . . . . . . . . . . . . . . . . . . . . . 15

XPs-hf Proportioners (Model 577101 shown) . . . . . . . 15

Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Fluid Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . 18

Main Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Solvent Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Heated Hopper Assembly . . . . . . . . . . . . . . . . . . . . . . 20

System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Air Control Components . . . . . . . . . . . . . . . . . . . . . . . 21

Fluid Line Components . . . . . . . . . . . . . . . . . . . . . . . . 21

Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Initial System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Proper Lifting of Sprayer . . . . . . . . . . . . . . . . . . . . . . . 23

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Connect Power Source . . . . . . . . . . . . . . . . . . . . . . . . 25

Connect Explosion-Proof Heaters . . . . . . . . . . . . . . . . 27

Motor Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Connect Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Connecting Heated Hose to Proportioner . . . . . . . . . . 29

Connect Static Mixers, Gun, and Hoses . . . . . . . . . . . 30

Add Heating Fluid to Heated Hoppers . . . . . . . . . . . . 30

Agitators (ED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Feed Pumps (EE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Solvent Pump (BA) . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

XP Displacement Pumps (D) . . . . . . . . . . . . . . . . . . . 33

Add Heating Fluid to Hoses . . . . . . . . . . . . . . . . . . . . 33

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Flush Before Using Equipment . . . . . . . . . . . . . . . . . . 34

Prime the Empty System . . . . . . . . . . . . . . . . . . . . . . 34

Startup/Recirculate . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Prime Solvent Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Prime the Material Lines . . . . . . . . . . . . . . . . . . . . . . . 40

Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Adjust the Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . 43

Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Overnight Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 48

System Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Mix and Integration Tests . . . . . . . . . . . . . . . . . . . . . . 49

Appearance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Monitor Fluid Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Check Pot Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Ratio Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Hose Electrical Resistance . . . . . . . . . . . . . . . . . . . . . 50

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Change the Mix Ratio . . . . . . . . . . . . . . . . . . . . . . . . . 50

Clean Inlet Strainer Screen . . . . . . . . . . . . . . . . . . . . 51

Check Heating Fluid Level . . . . . . . . . . . . . . . . . . . . . 51

Drain Heating Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Feed Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Solvent Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

XP Displacement Pumps . . . . . . . . . . . . . . . . . . . . . . 52

Agitators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Pump Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 55

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Pump Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . 56

Recirculation Manifold with Over Pressure Relief Valves

57

Replace Over Pressure Relief Valves . . . . . . . . . . . . 58

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

XP50s-hf and XP70s-hf Proportioner . . . . . . . . . . . . . 60

XP50s-hf and XP70s-hf Proportioners (Continued) . . 61

XP50s-hf and XP70s-hf Proportioners (Continued) . . 62

Water Jacketed Heated Hose Packages . . . . . . . . . . 64

Non-Heated Hose Packages . . . . . . . . . . . . . . . . . . . 66

Non-Hazardous Location Electric Heated Hose Packages

68

Hazardous Location Electric Heated Hose Packages 69

Air Control Filter 25N583 Parts . . . . . . . . . . . . . . . . . . 71

Air Control Regulator 25N575 Parts . . . . . . . . . . . . . . 72

Solvent Pump 262392 Parts . . . . . . . . . . . . . . . . . . . . 73

Solvent Air Control 24F126 Parts . . . . . . . . . . . . . . . . 74

Heater Block Remote Manifold Kit . . . . . . . . . . . . . . . 75

Material Recirculation Manifold with Over Pressure Relief

Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Diaphragm Pump 273093 Parts . . . . . . . . . . . . . . . . . 77

XP-hf Pump Assembly Parts . . . . . . . . . . . . . . . . . . . 78

Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . 80

Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

System Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 83

Recycling and Disposal . . . . . . . . . . . . . . . . . . . . . . . . . 85

End of Product Life . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

California Proposition 65 . . . . . . . . . . . . . . . . . . . . . . . . 85

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . 86

3A6283F

Related Manuals

Manuals are available at www.graco.com.

Manuals in English

Description

3A7469

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XP-hf Pump Package Components

334644

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Hopper Kits

3A6110

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Xtreme ® XL Air Motor, Instructions - Parts

Xtreme ® Displacement Pumps, Instructions - Parts

25 Gallon Double-Wall Hopper Kit, Instructions - Parts

Xtreme-Duty ™ Agitator and Packages, Operation - Parts

Monark ® Air Motor, Instructions - Parts 307043

Heating

3A2954

3A7523

Viscon ® HF Heater, Instructions - Parts

XP ™ Junction Box, Installation - Parts

Solvent Flush

310863 Feed and Solvent Flush Kits, Instructions Parts

312794 Merkur ® Pump Assembly, Instructions - Parts

Accessories and Kits

3A3320

3A1331

XP and XP-hf ™ PressureTrak ™ Kit, Instruction - Parts

XP Pressure Monitor Kit, Instructions - Parts

312769 Feed Pump and Agitator Kits, Instructions - Parts

3A0421 Ratio Check Kit, Instructions - Parts

3A2573 Gun Splitter Valve, Instructions - Parts

Water Heated Hose

309524 Viscon HP Heater, Instructions - Parts

3A5313 Xtreme-Wrap Water Heated Hose, Instructions - Parts

3A5314 Hose Heat Circulation XP and XP-hf Kit, Instructions - Parts

Electric Heated Hose

3A0590

3A7524

Mix Manifold, Quickset Mix Manifold, Instructions - Parts

Xtreme-Wrap Electric Heated Hose, Instructions - Parts

3A6283F

Related Manuals

3

4

Warnings

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks.

When these symbols appear in the body of this manual or on warning labels, 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.

DANGER

SEVERE ELECTRIC SHOCK HAZARD

This equipment can be powered by more than 240 V. Contact with this voltage will cause death or serious injury.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment.

• This equipment must be grounded. Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

• Do not expose to rain. Store indoors.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent flowing through the equipment can cause static sparking. 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 sparking).

Ground all equipment in the work area. See Grounding instructions.

• Never spray or flush solvent at high pressure.

• 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.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are anti-static or conductive.

• Stop operation immediately if static sparking occurs or you feel a shock .

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

• If using the Viscon HP and HF Heaters see manuals for special conditions for safe use.

• If using the PressureTrak, see the manual for special conditions for safe use.

3A6283F

3A6283F

Warnings

WARNING

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.

ENTANGLEMENT HAZARD

Rotating parts can cause serious injury.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Do not wear loose clothing, jewelry or long hair while operating equipment.

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.

• Equipment can start without warning. Before checking, moving, or servicing equipment, follow the

Pressure Relief Procedure and disconnect all power sources.

5

6

Warnings

WARNING

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 Specifications

in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See

Technical

Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For

complete information about your material, request Safety Data Sheet (SDS) 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.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• 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.

PERSONAL PROTECTIVE EQUIPMENT

Always wear appropriate personal protective equipment and cover all skin when spraying, servicing equipment, or when in the work area. Protective equipment helps prevent serious injury, including long-term exposure; inhalation of toxic fumes, mists or vapors; allergic reaction; burns; eye injury and hearing loss. This protective equipment includes but is not limited to:

• A properly fitting respirator, which may include a supplied-air respirator, chemically impermeable gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory authority.

• Protective eyewear and hearing protection.

BURN HAZARD

Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe burns:

• Do not touch hot fluid or equipment.

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.

• Read Safety Data Sheets (SDSs) for handling instructions and to know the specific hazards of the fluids you are using, including the effects of long-term exposure.

• When spraying, servicing equipment, or when in the work area, always keep work area well-ventilated and always wear appropriate personal protective equipment. See Personal

Protective Equipment warnings in this manual.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

3A6283F

Important Isocyanate (ISO) Information

Important Isocyanate (ISO) Information

Isocyanates (ISO) are catalysts used in two component materials.

Isocyanate Conditions Keep Components A and B

Separate

Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and atomized particulates.

• Read and understand the fluid manufacturer’s warnings and Safety Data Sheets (SDSs) to know specific hazards and precautions related to isocyanates.

• Use of isocyanates involves potentially hazardous procedures. Do not spray with this equipment unless you are trained, qualified, and have read and understood the information in this manual and in the fluid manufacturer’s application instructions and SDSs.

• Use of incorrectly maintained or mis-adjusted equipment may result in improperly cured material.

Equipment must be carefully maintained and adjusted according to instructions in the manual.

• To prevent inhalation of isocyanate mists, vapors, and atomized particulates, everyone in the work area must wear appropriate respiratory protection.

Always wear a properly fitting respirator, which may include a supplied-air respirator. Ventilate the work area according to instructions in the fluid manufacturer’s SDSs.

• Avoid all skin contact with isocyanates. Everyone in the work area must wear chemically impermeable gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory authority.

Follow all fluid manufacturer recommendations, including those regarding handling of contaminated clothing. After spraying, wash hands and face before eating or drinking.

Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination:

• Never interchange component A and component B wetted parts.

• Never use solvent on one side if it has been contaminated from the other side.

3A6283F 7

8

Important Isocyanate (ISO) Information

Moisture Sensitivity of

Isocyanates

Exposure to moisture (such as humidity) will cause ISO to partially cure, forming small, hard, abrasive crystal that become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity.

NOTICE

Partially cured ISO will reduce performance and the life of all wetted parts.

• Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere.

Never store ISO in an open container.

• Keep the ISO pump wet cup or reservoir (if installed) filled with appropriate lubricant. The lubricant creates a barrier between the ISO and the atmosphere.

• Use only moisture-proof hoses compatible with

ISO.

• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.

• Always lubricate threaded parts with an appropriate lubricant when reassembling.

NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature.

Changing Materials

NOTICE

Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime.

• When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical compatibility.

• When changing between epoxies and urethanes or polyureas, disassemble and clean all fluid components and change hoses.

Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the B

(resin) side.

3A6283F

Usage

Usage

The XPs-hf proportioner is a plural component sprayer that can mix and spray most two component epoxy and urethane protective coatings. It is a fixed-ratio system, where XP lowers can be changed to reconfigure the system to different volume mix ratios or spray

pressures. See details on page 15.

All models are mounted on a metal skid, and are equipped with heated hoppers where the resin (A material) and catalyst (B material) are heated and pressure fed to the XP-hf pump assembly.

The materials are pumped to the primary heaters, where the resin and hardener are heated to the required spray temperatures. Heat improves the chemical reaction and lowers viscosity to improve the spray pattern.

The materials then flow to the mix manifold assembly.

The mix manifold assembly consists of a recirculation manifold, mix manifold, and solvent flush valve. At the recirculation manifold, the materials either recirculate back to the heated hopper for continued heating, or combine at the mix manifold into one fluid line. The mixed material then flows through static mixers for continued mixing to the whip hose and out the spray gun.

The solvent flush system flushes the mixed material out of the manifold, static mixers, mixed material hoses, and spray gun.

When using quick-setting materials (less than 10 minute pot life) a remote mix manifold must be used. The mix manifold is separated from the recirculation manifold and mounted on a remote carriage. Heated hoses are used to prevent temperature loss in the materials while flowing to the remotely mounted mix manifold. Systems are configured to connect either a water heated hose, or an electric heated hose. Heated hoses are sold separately in various configurations and lengths depending on customer need.

Over Pressure Protection

Mechanically linked pumps can create excessive fluid pressure if the full motor force is applied to only one of the fluid pumps.

To reduce the risk of injury due to skin injections, perform the following:

• A maximum air pressure set point blow-off valve is provided to limit maximum fluid pressure. Do not remove these valves.

• Color-coded, automatic, over-pressure relief valves are used to transfer excess fluid pressure back to the supply. Never plug the return hoses. See

Fluid

Control Assembly , on page 18.

• Never install individual shut off valves on the “A” and “B” lines. Common handles link the fluid control valves.

• A rupture disk is provided on the “B” material pump

(pumps 145 cc and smaller) as a back-up to the over-pressure relief valve. If the rupture disk ever opens, do not operate the machine until the over-pressure valve and the rupture disc have been replaced.

• If changing pump lowers on your system, use the correct over-pressure relief valves from the chart on

page 58.

3A6283F 9

Models

Models

XPs-hf sprayers are not approved for use in hazardous locations unless all components, all accessories, all kits, and all wiring meet local, state, and national code.

NOTE: Not all configurations are available.

PART NUMBER CODE EXAMPLE:

First

Three Digits Fourth Digit

5

✠ System

Pressure Ratio

7 x

*Volume

Mix Ratio x

Fifth Digit

See X Power Type

(Fifth Digit of Part

Number); page 11.

x

System Pressure Ratio (First Three Digits of Part Number)

First Three

Digits

577 xxx

578 xxx

System Ratio

70 : 1

50 : 1

Maximum Fluid Working Pressure psi (MPa, bar)

7250 (50, 500)

5000 (34, 344)

Last Digit

See Heated Hose

Package (Last Digit of

Part Number); page 11.

x

*

Volume Mix Ratios - 70:1 (Fourth Digit of Part Number)

Fourth

Digit

Pump

Ratio

(A/B)

5771xx

5772xx

5773xx

5774xx

1 : 1

2 : 1

3 : 1

4 : 1

A Side

Pump

B Side

Pump

L14AC0 L14AC0

L18AC0 L090C0

L22XC0 L072C0

L22XC0 L054C0

Combined

Fluid Output

(cc/cycle)

290

270

292

274

Fluid Flow at 40 cpm gpm (lpm)

Over-

Pressure

Relief Valve

3.0 (11.3)

2.8 (10.6)

3.0 (11.3)

2.8 (10.6)

Silver

Silver

Silver

Silver

Maximum Air

Working

Pressure psi (MPa, bar)

100 (0.7, 7)

95 (0.65, 6.5)

100 (0.7, 7)

95 (0.65, 6.5)

Fluid to Air

Pressure

Ratio

71 : 1

76 : 1

71 : 1

76 : 1

Maximum Fluid

Working

Pressure psi (MPa, bar)

7100 (49, 490)

7250 (50, 500)

7100 (49, 490)

7250 (50, 500)

*

Volume Mix Ratios - 50:1 (Fourth Digit of Part Number)

Fourth

Digit

Pump

Ratio

(A/B)

5781xx

5782xx

5783xx

5784xx

1 : 1

2 : 1

3 : 1

4 : 1

A Side

Pump

B Side

Pump

L22AC0 L22AC0

L29AC0 L14AC0

L29AC0

L29AC0

L097C0

L072C0

Combined

Fluid

Output

(cc/cycle)

440

435

387

362

Fluid Flow at 40 cpm gpm (lpm)

Over-

Pressure

Relief Valve

Maximum Air

Working Pressure psi (MPa, bar)

4.6 (17.4)

4.6 (17.4)

4.0 (15.1)

3.8 (14.4)

Gold

Gold

Gold

Gold

100 (0.7, 7)

100 (0.7, 7)

95 (0.65, 6.5)

85 (0.59, 5.9)

Fluid to Air

Pressure

Ratio

Maximum Fluid

Working Pressure psi (MPa, bar)

48 : 1

48 : 1

53 : 1

59 : 1

4750 (33, 330)

4750 (33, 330)

5000 (35, 345)

5000 (35, 345)

10 3A6283F

XPs-hf Systems

Power Type (Fifth Digit of Part Number)

Fifth Digit xxxx0x xxxx1x xxxx2x xxxx3x

VAC

240

240

480

480

Environment

Non-Hazardous/Ordinary Locations

Class I, Division 1

Non-Hazardous/Ordinary Locations

Class I, Division 1

Heated Hose Package (Last Digit of Part Number)

Sixth Digit xxxxx1 xxxxx2 xxxxx3

Water Hose Heat with Circulation Pump

Electric Heated Hose

Approvals

XPs-hf System Approvals

System

57xx0x

57xx1x

57xx2x

57xx3x

Approvals

System is intended for hazardous locations with the classification of

Class I, Division 1, Group D T3 0 ° C to 54 ° C

System is intended for hazardous locations with the classification of

Class I, Division 1, Group D T3 0 ° C to 54 ° C

Models

3A6283F 11

Models

Component Level Approvals

Primary Heaters

North American

Location

Component Description Non-Hazardous Hazardous

European

Atmosphere

Non-Explosive Explosive

26C476 480V HF Ex ✓

24W248 240V HF Ex ✓

24P016

240V HF

Non-Hazardous

26C475

480V HF

Non-Hazardous

Approvals

9902471

Class 1, Division 1, Groups C, D (T3)

Ta = -20°C to 60°C

Certificate No:

18-KA4B0-0072X

ATEX

Ratings: II 2 G Ex db IIB T4 Gb

ATEX Certificate No.

ITS14ATEX18155X

IECEx Ratings EX db IIB T4 Gb

IECEx Certificate No. IECEx ETL

14.0046X

Ta = -20°C to 60°C

9902471

Certified to CAN/USA C22.2 No. 88

Conforms to UL499

12 3A6283F

Models

Component

Junction Box

Description

North American

Location

European

Atmosphere

Non-Hazardous Hazardous Non-Explosive Explosive

Explosion Proof

Electrical Enclosure

✓ ✓

26C583

26C906

26C581

26C905

26C582

26C904

26C580

26C899

480V Explosion Proof

Junction Box

480V Explosion Proof

Junction Box, Electric

Hose Heat

240V Explosion Proof

Junction Box

240V Explosion Proof

Junction Box, Electric

Hose Heat

Ordinary Location

Electrical Enclosure

480V Junction Box

480V Junction Box,

Electric Hose Heat

240V Junction Box

240V Junction Box,

Electric Hose Heat

Heated Hopper Assembly

Component Description

North American

Location

Non-Hazardous Hazardous

European

Atmosphere

Non-Explosive Explosive

Approvals

Class 1, Division 1, Groups B, C, & D

UL 1203/CSA C22.2 No. 25 & 30

Designed to Standards:

UL 60079-0

UL 60079-25

9902471

Conforms to UL STD 508A

Certified to CAN/CSA C22.2 No. 14

Approvals

25P239*

Immersion Heaters,

480V

✓ ✓

C US

For US/CAN:

Class 1, Division 1, Groups B, C, & D (T4)

25N577

Immersion Heaters,

240V

25N584

25N588

5:1 Monark Pump

Xtreme Duty Hopper

Agitator

C US

For US/CAN:

Class 1, Division 1, Groups B, C, & D (T4)

3A6283F 13

Models

Heated Hose

Component Description

North American

Location

Non-Hazardous

European

Atmosphere

Hazardous Non-Explosive Explosive

See your water heated hose manual for complete list of part numbers

Water Jacketed ✓ ✓ ✓

See your electric heated hose manual for complete list of part numbers

Electric ✓ ✓ ✓

Component

245864

Hot Water Heater

North American

Location

European

Atmosphere

Hazardous Non-Explosive Explosive Description Non-Hazardous

480V HP

Hazardous

✓ ✓ ✓ ✓

Approvals

II 2 G Ex h T5 Gb

Approvals

245863

240V HP

Hazardous

✓ ✓ ✓ ✓

9902471

Class 1, Division 1, Groups C, D (T3)

Ta = -20°C to 60°C

Certificate No:

18-KA4B0-0072X

ATEX

Ratings: II 2 G Ex db IIB T4 Gb

ATEX Certificate No.

ITS14ATEX18155X

IECEx Ratings EX db IIB T4 Gb

IECEx Certificate No. IECEx ETL

14.0046X

Ta = -20°C to 60°C

245869

245870

240V HP

Non-Hazardous

480V HP

Non-Hazardous

9902471

Certified to CAN/CSA C22.2 No.

161010-1-12 and 61010-2-010

Conforms to UL 61010-1 and

UL 61010-2-010

14 3A6283F

Component Identification

Component Identification

XPs-hf Proportioners (Model 577101 shown)

3A6283F

5

9

&

XP-hf Pump Assembly

+

$

8

&

%

1

=3

=8

=*

;

7

6

3

< .

-

(

$

=)

WLF

=&

%$

=7

-

15

Component Identification

Key:

A XP-hf Motor Air Supply Hose

B Stand

C

Main Air Controls , see page 18

D XP Displacement Pump

E Xtreme XL Air Motor

F Primary Heaters

H

Solvent Pump Controls; see page 19

J

Heated Hopper Assembly; see page 20

K Frame, Skid

N

Fluid Control Assembly; see page 18

P Pump Tie Rods

R Motor Adapter Plate

S Adjustable Packing Nuts with Wet Cups

T Yoke with Rod Bearings

U Recirculation Lines

X Motor Position Indicator Bracket

V Connecting Rod Nut

Y Over-Pressure Rupture Disk;

(for pumps that are 145cc or smaller)

BA Solvent Pump, see page 19

ZC Electrical Enclosure, see page 17

ZF Hot Water Reservoir (if equipped)

ZG Diaphragm Pump (if equipped)

ZP Diaphragm Pump Needle Valve (if equipped)

ZT Hot Water Heater (if equipped)

ZU Mixed Material Gun and Hose

16 3A6283F

Component Identification

Junction Box

=$ =&

=&

=$

03

=(

=(

03

=-

=5

=:

=+

WLE

=5

=/

Key:

MP Main Power Switch

ZA Power Indicator Light

ZB Primary Heater Switches

ZC Electrical Enclosure

ZE Hose Heater Switch

ZH Strain Relief (Non-hazardous locations only)

ZJ Electric Heated Hose Temperature Controller / Display

(Non-hazardous locations only)

=6

=/

=.

ZK Hose Heater Harness Entry Point

ZL Thermocouple Sensor Entry Point

ZM Fluid Heater and Hopper Heater Harness Entry Point

ZN Hopper Heater Switches

ZR Electric Heated Hose Temperature Controller (Hazardous locations only)

ZS Main Power Entry Point

ZW Temperature Display (Hazardous locations only)

3A6283F 17

Component Identification

Fluid Control Assembly

Shown with water-heated hose configuration

$& $+ $$

AV

$%

$:$1

$'

$-

$)

$(

$.

$8

WLE

$3

$5

$0

$/

0&

$1

Key:

AA Recirculation Manifold

AB Mix Manifold

AC Recirculation Handle (shown closed), see page 21.

AD Solvent Flush Valve

AE Dual Shutoff Handle (shown closed)

AF Fluid Pressure Gauges

AH Fluid Recirculation Fittings

AJ B Component Adjustable Fluid Restrictor;

see page 42

AK A and B Mix Manifold Check Valves

AL Solvent Inlet Check Valve

AM Automatic, Spring Loaded, Color-Coded, Over-Pressure

Relief Valves; with grease fittings

AN Static Mixer Tubes; 3/8 npt(m)

AP Recirculation Manifold Outlet

AR Mix Manifold Inlet

AW Primary Static Mixer Tubes

AV Cleanup Static Mixer Tube

AU Long Fasteners (shipped loose with Remote Manifold kit)

MC Remote Manifold Carriage

Main Air Controls

&$

&'

&*

&%

&)

Key:

AI Main Air Inlet

CA Motor Air Valve

CB Motor Air Pressure Regulator

CC Air Filter with Auto Drain

CD Main Motor Air Pressure Gauge

CE Filtered Air Distribution Manifold

CF Main Air Shutoff Valve

CG XP-hf Motor Air Pressure Relief Valve

&(

&&

$,

WLD

18 3A6283F

Solvent Pump

Pump

%$

%+

%%

Air Controls

DC

DE

DB

DD

WLD

WLE

%)

%(

%*

Key:

BA Solvent Pump

BB Siphon Tube

BE Solvent Prime Valve

BF Solvent Supply Hose

BG Solvent Prime Hose

BH Solvent Pump Wet Cup

Key:

DA Solvent Air Shutoff Valve (Relieving)

DB Solvent Air Pressure Regulator

DC Solvent Air Pressure Gauge

DD Solvent Air Outlet

DE Solvent Air Inlet

DA

Component Identification

3A6283F 19

Component Identification

Heated Hopper Assembly

(7

(.

('

($

(-

(%

Key:

EA Double-Wall Hopper

EB

EC

Hopper Lid

Hopper Heater

ED

EE

EF

EG

EH

EJ

Agitator

Feed Pump

Y-Strainer

Recirculation Tube

Material Drain

Heating Fluid Drain Valve

((

WLF

(3

(5

(*

(6

(/

()

(&

(+

EK

EL

EM

EN

Heating Fluid Fill Port

Heating Fluid Vent

Air Valve (Feed Pump)

Air Regulator (Feed Pump)

EP

ER

ES

ET

Air Valve (Agitator)

Air Regulator (Agitator)

Y-Strainer Valve

Fill Port Cap

EU Accessory Ports

(0

(1

20 3A6283F

System Components

System Components

Air Control Components

XP-hf Motor Air Valve (CA)

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

Air Valve (CA) to relieve trapped air.

Be sure the valve is easily accessible from the pump and located downstream from the air regulator (CB).

To relieve air trapped between the air motor when the valve is closed:

1. Open the valve to supply air to the motor.

2. Close the valve to shut off air to the motor, and bleed any trapped air from the motor.

XP-hf Motor Air Pressure Relief Valve (CG)

Automatically opens to relieve air pressure if supplied pressure exceeds preset limit. Use the correct air pressure relief valve for the system ratio:

Ratio

1:1

2:1

3:1

4:1

XP70s-hf

Valve Part

113498

114055

113498

114055

Ratio

1:1

2:1

3:1

4:1

XP50s-hf

Valve Part

113498

113498

114055

16M190

Main Air Filter (CC)

Removes harmful dirt from compressed air supply. A minimum 40 micron filter is used.

XP-hf Motor Air Pressure Regulator (CB)

Adjusts air pressure to the motor and fluid outlet pressure of pump. Locate the air regulator close to the pump. Read air pressure on the gauge.

Main Air Shutoff Valve (CF)

Controls the flow of inlet air. Close main air shutoff valve to stop all components and pumps.

Fluid Line Components

Recirculation Manifold (AA)

Controls recirculation and pump priming.

Mix Manifold (AB)

Combines A and B fluid into one fluid line.

Recirculation Handle (AC)

Directs fluid flow for recirculation 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 flushing.

Solvent Flush Valve (AD)

Controls solvent flow to the mix manifold, hose, and spray gun.

Static mixer (AV, AW)

Thoroughly mixes the two fluids and delivers the mixed fluid to the spray gun.

3A6283F 21

System Components

Heaters

Primary Heaters (F)

Viscon HF Fluid Heaters heat resin and hardener before the materials combine in the mix manifold assembly.

The heater improves chemical reaction and lowers viscosity of material to improve the spray pattern. There are two Viscon HF heater variants (hazardous location heaters, and non-hazardous location heaters). For approval rating, see

Approvals , page 11 regarding your

primary fluid heaters.

Hot Water Heater (ZT)

Viscon HP Fluid Heater is included in the water heated hose packages. Heating fluid is circulated by a diaphragm pump through the heater and into the water jacketed lines surrounding the material hoses. There are two Viscon HP heater variants (hazardous location heaters and non-hazardous location heaters). For approval rating, see

Approvals

, page 14, regarding

your primary fluid heaters.

Hopper Heaters (EC)

Immersion heaters used to heat the outer jacketed area of the double walled hoppers. The outer jacket is filled with heating fluid to condition the resin and hardener materials.

Pumps

XP-hf Pump Assembly

A mechanically linked, fixed-ratio system that consists of a singular air motor and two individual XP displacement pumps.

XP Displacement Pump (D)

Pump used to deliver the resin and hardener materials at high pressure to the mix manifold and spray gun.

Solvent Pump (BA)

Pump used to flush the mix manifold, hose, and gun.

Feed Pumps (EE)

Pumps that transfer conditioned resin and hardener materials to the primary pump. Using feed pumps is the preferred method to transfer viscous material compared to the gravity feed method.

Diaphragm Pump (ZG)

Pump equipped on water heated hose packages, used to circulate the heating fluid through the water heated hose.

22 3A6283F

Setup

Setup

Initial System Setup Proper Lifting of Sprayer

1. Check the shipment for accuracy. Ensure you have received everything you ordered. See

Component

Identification , page 15.

2. Check for loose fittings and fasteners.

3. If any accessories are added, refer to their Related

Manuals listed on page 3 for all warnings and

instructions.

4. Confirm air supply requirements. This system requires a 1.0 in. airline.

5. Confirm electric power requirements and a make sure a properly sized electrical cord is used.

NOTE: A minimum of 25 gallons (95 liters) of heating fluid is needed. Additional heating fluid is needed if water heated hose is used.

NOTE: A minimum of 10 gallons (39 liters) of “A” and “B” materials are needed to load the hoppers and prime the system.

NOTE: A minimum of 25 gallons (95 liters) of solvent is required for flushing.

NOTE: Empty metal pails for both “A” and “B” materials are required for flushing.

Location

1. Locate the proportioner on a level surface. Follow the

Proper Lifting of Sprayer

procedure.

2. Position the proportioner for convenient operator access and maintenance, proper routing of air and fluid lines, and easy connection of components and accessories.

Follow these instructions to help prevent serious injury or damage to equipment. Never lift while a hopper is filled.

NOTICE

To prevent spilling and to ensure even weight distribution, drain all fluid prior to lifting the proportioner.

Lift Using a Forklift

The proportioner can be raised and moved using a forklift. Disconnect power and air from the system.

Carefully lift the proportioner; make sure it balances evenly.

Lift Using a Hoist

• Lift the system with a lift apparatus rated appropriately for the weight of the system (see

Technical Specifications , page 83).

• Do not lift the system by the handle on the hoppers or air motor lift ring.

• Lift the system using the lift eyes shown in the lifting illustration.

WLD

3A6283F 23

Setup

Grounding

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.

System: Connect the supply ground wire in the

electrical compartment as shown in Connect Power

Source on page 25.

Pump: Connect ground wire 244524 (GW) to the ground stud (GS) on the air motor (E).

(

*:

WLD

*6

Connect the other end of the ground wire to a true earth ground for system without heaters, otherwise connect to

HF heater clamp bar.

Air and fluid hoses: Use only electrically conductive hoses with a maximum of 300 ft (91 m) combined hose length to ensure grounding continuity. Check electrical resistance of hoses regularly. If total resistance to ground exceeds 29 megohms, replace hose immediately.

Spray gun: Ground through connection to a properly grounded fluid hose and pump.

Solvent pails: Follow your local code. Use only metal pails, which are conductive, placed on a grounded surface. Do not place pail on a non-conductive surface, such as paper or cardboard, which interrupts grounding continuity.

To maintain grounding continuity when flushing or relieving pressure: Hold the metal part of the spray gun firmly to the side of a grounded metal pail, then trigger the gun.

Work area: Ground the object being sprayed, fluid supply container, and all other equipment in the work area.

Air compressor: Follow manufacturer’s recommendations.

Object being sprayed: Follow your local code.

Material supply container: Follow your local code.

24 3A6283F

Setup

Connect Power Source

NOTE: Required voltage and amperage is noted on the control panel label. See

Power Cord Guidelines

tables below.

To help prevent injury from electric shock, turn off and disconnect power at the main switch before connecting any cables and before servicing equipment. All electrical work must be done by a qualified electrician and comply with local codes and regulations.

Use the intended entry locations shown in

Junction

Box , page 17.

1. Turn the main power switch (MP) off.

2. Open the junction box door.

3.

Non-Hazardous Locations only: Route the power cord through the strain relief (ZH) into the electrical enclosure (ZC).

Hazardous Locations only: Follow local codes and regulations for routing the power through the main power entry point (ZS).

NOTE: The machine is provided with jumpers in the 380

Vac 3-Phase Wye position.

NOTE: Terminal jumpers are not used for 480V.

4. Connect the ground wire to the ground terminal (G).

5. Connect the power cord to the disconnect as shown in

XPs-hf Wiring Diagram , page 26. Gently pull on

all connections to verify that they are properly secured.

6.

Non-Hazardous Locations only: Tighten the strain relief (ZH).

Hazardous Locations: Follow local codes and regulations for sealing the power cable entering into the enclosure.

7. Install the supplied terminal jumpers in the positions

shown in the XPs-hf Wiring Diagram , page 26.

8. Verify that all items are connected properly as

shown in the XPs-hf Wiring Diagram , page 26,

then close the electrical enclosure (ZC) door.

Power Cord Guidelines

Use the guidelines listed in the table below to determine the power cord needed for your specific system.

Models with 240 Volt Viscon HF Fluid Heater

Junction Box

240 V, 1 Phase

240 V, 3 Phase

380 V, 3 Phase

480 V

Full Load Peak Amperes (A) xxxx01 xxxx11 xxxx02 xxxx12 xxxx03 xxxx13

87

76

48

87

76

48

71

65

48

71

65

48

84

73

48

84

73

48

Models with 480 Volt Viscon HF Fluid Heater

Junction Box

Full Load Peak Amperes (A) xxxx21 xxxx31 xxxx22 xxxx32 xxxx23 xxxx33

240 V, 1 Phase

240 V, 3 Phase

380 V, 3 Phase

480 V 28 28 26 26 27 27

3A6283F 25

Setup

XPs-hf Wiring Diagram

Disconnect

NON-HAZARDOUS LOCATIONS

Terminal

Jumpers

Terminal

Jumpers

HAZARDOUS LOCATIONS

MP

Disconnect

G

PJ

ZH

230 Vac

1-Phase Delta

Disconnect

8T4 1L1 3L2 5L3

L1 L2

7L4 2T1 4T2 6T3

230 Vac

3-Phase Delta

8T4 1L1 3L2 5L3

L1 L2 L3

7L4 2T1 4T2 6T3

380 Vac

3-Phase Wye

8T4 1L1 3L2 5L3

N L1 L2 L3

7L4 2T1 4T2 6T3 ti37278a

WLD

G

480 Vac

3-Phase Delta

1L1 3L2 5L3

L1 L2 L3

2T1 4T2 6T3

Terminal

Jumpers TB

11

TB

12

TB

13

TB

14

TB

15

TB

11

TB

12

TB

13

TB

14

TB

15

TB

11

TB

12

TB

13

TB

14

TB

15

26 3A6283F

Setup

Connect Explosion-Proof

Heaters

Hazardous location proportioners only

(xxx1x, xxxx3x)

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

volume mix ratio. See the Models chart on page 10.

Volume mix ratio indicator lines

If your sprayer is intended for hazardous locations, a qualified electrician must connect the explosion-proof heater wiring. Ensure wiring and installation comply with local electrical codes and regulations.

Improperly installed or connected equipment may result in fire, explosion, or electric shock. Follow all local codes and regulations.

Ensure wiring, wiring connections, switches, and electrical distribution panel all meet flame-proof

(explosion-proof) installation requirements.

Refer to your Junction Box manual for the wiring diagram for hazardous locations.

Refer to your Viscon HP heater manual for electrical connection instructions and guidelines in hazardous locations.

Refer to your Viscon HF heater manual for electrical connection instructions and guidelines in hazardous locations.

WLF

2. Verify that the motor position is adjusted correctly for that volume mix ratio. If not, perform the following Change Motor Position procedure.

Change Motor Position

There are specific motor positions for each mix ratio setting. To Adjust the position of the air motor:

1. Verify that the XP-hf motor air valve (CA) is closed.

2. Perform the Check Motor Position procedure. If the position is incorrect, continue to the next step.

3. Loosen the eight fasteners and remove the two pump guards. fastener pump guard fastener

WLD pump guard

3A6283F 27

Setup

4. Loosen the three nuts below the motor tie rods (P).

(

5. Slide the tie rods (P) and motor (E) until the indicator lines are aligned with your ratio.

NOTICE

Do not hit the tie rods (P) with a hammer. Damage to the air motor base may result.

6. Tighten the three nuts.

7. Install the pump guards.

3

Air Motor shown

WLD

28 3A6283F

Setup

Connect Air Supply

Connect the air supply hose to the main air inlet (AI).

Use a 1.0 in. (25.4 mm) ID minimum air hose. Do not use pin fitting type quick disconnect.

Connect any air-powered accessories to the accessory port (CM).

CM

Connecting Heated Hose to

Proportioner

1. Disconnect the solvent outlet hose (BF) and elbow fitting (BK) from the solvent flush valve (AD).

2. Loosen the union fittings (AR) on the mix manifold inlet that connect to the recirculation manifold (AA) to disconnect the mix manifold (AB).

$$

$5

AI

WLD

$%

WLE

%.

$'

%)

3.

For water jacketed heated hoses,

follow Connect

Static Mixers, Gun, and Hoses , page 29.

4.

For electric heated hoses , see your heated hose

manual for installation. See Related Manuals , page

3.

Connect Static Mixers, Gun, and

Hoses

1. Connect the outlet of the two primary static mixer tubes (AW) to the gun and hose assembly (ZU).

3A6283F 29

Setup

2. Check that all connections are tight.

Add Heating Fluid to Heated

Hoppers

=8

WLE

1. Use a 50/50 mixture of water and ethylene glycol

(engine coolant) for heating fluid in the outer cavity of the hopper. Approximately 12 gallons (45 liters) of heating fluid is needed for each hopper.

NOTICE

Other glycols (RV/Marine Antifreeze) are not recommended for use as a heating fluid. These materials are not rated for higher temperatures and could cause damage to the immersion heaters.

NOTE: The ethylene glycol mixture provides the fastest heat-up time and prevention of algae build-up regardless of ambient temperature. Oil can be used but heat-up time will increase and the hopper level needs to be lower to allow for thermal expansion.

Spray material temperature

NOTICE

To prevent creating a flare on the mixer tube, do not use a union swivel end on the mix tube inlet.

Oil ethylene glycol mixture

Time ti33983a

2. Remove fill port cap (ET) and pour heating fluid in the outer cavity through the fill port (EK).

(.

(7

30 3A6283F

Setup

3. Use approximately 12 gallons (53 liters) to fill the cavity. Stop filling when fluid is visible at the bottom of the port elbow.

NOTE: Thermal expansion may cause the heating fluid to overflow after it rises to temperature.

NOTE: If using water mix, the maximum fluid level must be 1 in. (2.5 cm) below side port level.

NOTE: If oil is the heating fluid, the maximum oil level must be 3 in. (7.6 cm) below the hopper side port level.

4. Replace the fill port cap (ET).

Below required minimum level

Maximum fill level

WLE

NOTICE

Any portion of the heating element exposed to air will lead to overheating and premature burnout. Ensure that the element is completely submerged.

WLE

3A6283F 31

Setup

Agitators (ED)

The Xtreme-Duty Agitator is provided with an airline lubricator to aid in proper maintenance. Fill the lubricator with Air Motor Oil 202659 (do not fill past the maximum level shown in the oil fill sight glass). Set the lubricator feed rate at one drop of oil per minute. Do not overfeed the oil, or the exhaust air may become contaminated.

Adjusting Knob

Feed Pumps (EE)

Fill the wet-cup half full with Graco Throat Seal (TSL ™ ) or a compatible solvent.

WLD ti34269a

WLE

Fill Port

Oil Fill

Sight

Glass

32 3A6283F

Solvent Pump (BA)

Before starting, fill wet cup (BH) 1/3 full with Graco

Throat Seal Liquid (TSL) or compatible solvent.

BH

WLD

XP Displacement Pumps (D)

Make sure the A and B pump packing nuts are tightened. Fill the A and B pump packing nuts with TSL.

Setup

Add Heating Fluid to Hoses

(Water jacket heated hose packages only)

1. Add a 50/50 mixture of water and ethylene glycol to the reservoir (ZF) of the diaphragm pump (ZG).

2. Slowly open the needle valve (ZP) to circulate the fluid with the diaphragm pump (ZG) to remove air from the system.

3. Continue adding heating fluid to the reservoir (ZF) as air continues to bleed from the system.

4. Stop the pump when there is no more air in the system, fill the reservoir (ZF) halfway, then replace the cap.

=)

=3

WLD

WLD

3A6283F 33

Operation

Operation

Flush Before Using Equipment

The system was tested with lightweight oil, which is left in the fluid passages to protect parts. To avoid contaminating your fluid with oil, first flush the equipment with a compatible solvent before using the equipment. Follow the

Flushing procedure, page 44.

Prime the Empty System

3. Fill the “A” and “B” hoppers (J) with respective material, up to 25 gallons. Fill the “A” side (blue) with resin or base material. Fill the “B” side (green) with the hardener or catalyst.

To help prevent injury from burns, wear gloves when using solvents and/or if the fluid temperature exceeds

122 °F (50 °C).

1. Prepare your materials prior to adding to heated hoppers. Ensure resin materials are thoroughly agitated, homogeneous, and pourable prior to adding them to the hopper. Stir hardeners back into suspension prior to adding material to the hopper.

2. Move the recirculation lines (U) to grounded empty containers.

J

WLE

4. Open the main air valve.

5. Close the dual shutoff handle (AE).

AE

WLD

6. Open the recirculation handle (AC).

A

B

AC

U

WLD

WLD

34 3A6283F

Operation

7. Fully open the feed pump air regulator (EN) and turn the feed pump air valve (EM) to OPEN.

8. Slowly open the feed pump air regulator (EN) to start the feed pump.

12. Move the recirculation lines (U) back to the correct hopper.

EM

U

EN

WLD

NOTE: If the material is too thick, the XP-hf pump will

need to be used. See Startup/Recirculate on page 36.

9. Dispense fluid into the containers until clean fluid flows through the “A” and “B” recirculation lines.

10. Close the feed pump air regulator (EN).

11. Close the feed pump air valve (EM).

WLD

13. Repeat for the other side.

14. If running solvent through the system for the first

time, proceed to Flushing on page 44 to empty the

system of solvent, then repeat this process with “A” and “B” materials.

3A6283F 35

Operation

Startup/Recirculate

NOTE: Use recirculation mode to condition materials prior to spraying; agitating and heating materials evenly.

The hopper heaters are factory set to maintain temperatures of conditioned materials only. To bring spray material up to temperature, the material needs to circulate through the HF heaters while adjusting the heater set point to the desired temperature.

1. Ensure that the main power switch (MP) is ON at the junction box.

4. Slowly increase the agitator air regulator (ER) to turn the agitator until the desired speed is reached.

5. Ensure the feed pump air regulator (EN) is fully closed and open the feed pump air valve (EM) to the

OPEN position.

EM

EN

MP

2. Turn on the hopper heat switches (ZN).

ZB

ZE

ZN

WLD

6. Slowly open the feed pump air regulator (EN) until the pump starts. Cycle the feed pump slowly until the feed pump stalls.

7. Repeat steps 3-6 for the other heated hopper.

8. Open the recirculation valve handle (AC).

A

B

AC

3. Ensure the agitator air regulator is fully closed and open the agitator air valve (EP) to the OPEN position.

36

EP

ER

WLD

WLD

9. Fully open the XP-hf air pressure regulator (CB) then turn the air valve (CA) to OPEN. Use the XP-hf air pressure regulator (CB) to slowly increase the air pressure until the XP-hf pumps start running slowly.

10. Turn on the primary heater switches (ZB). To adjust the heater temperature, refer to your Viscon heater manual for instructions.

11. Recirculate the fluids to raise the temperature of the materials in the hoppers evenly. Continue running the pump until the material is uniform and reached the desired temperature.

NOTE: Begin circulating the XP-hf pump to run at approximately 10 cycles/min to evenly heat materials, increase or decrease the pump rate depending on material conditions.

3A6283F

12.

For systems with water-heated hose: Pump setting - Set the flow rate of the heating fluid by opening the diaphragm pump (ZG) needle valve

(ZP) 45°- 60° open until the pump cycles 60-80 cycles/min (0.7-1.0 gpm or 2.6-3.8 l/min).

Operation

13.

For systems with water-heated hose only:

Heater setting - Adjust the heater thermostat to the desired temperature. The setting at the heater output thermometer should be approximately 10 °F

(6 °C) higher than the desired paint temperature.

Never exceed the XP system 160 °F (71 °C) maximum fluid temperature rating. See your Viscon

HP heater manual for instructions.

As a general guideline, heater knob settings are #7 for 105 °F (40 °C), #8 for 135 °F (57 °C), and #8 1/2 for 150 °F (65 °C).

NOTE: If the hose heat is not being used for more than one hour, shut off the hot water heater (ZT) and diaphragm pump (ZG) to lengthen heater life.

14. On initial start-up, proceed to Flushing on page 44.

3A6283F 37

Operation

Prime Solvent Pump

5. Open the solvent flush valve (AD) on the mix manifold.

1. Connect a ground wire (not included) to a metal pail of solvent.

2. Place the siphon tube (BB) and the solvent circulation hose (BG) in the pail of solvent.

BE

BG

BB

AD WLD

6. Ensure the trigger lock (TL) is engaged. Remove the spray tip.

TL

WLD

3. Open the solvent prime valve (BE).

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 prime valve (BE) and air valve (DA).

TI1949a ti1948a

7. Disengage the trigger lock (TL) and trigger the gun into a grounded metal pail while holding the metal part of the gun firmly against the side of the 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.

TL ti1950a

DA

WLD

DB

WLD

38 3A6283F

Operation

8. Slowly turn the solvent pump air regulator (DB) clockwise to prime the solvent pump and push air out of the mix hose and gun. Continue to hold the metal part of the gun firmly against the side of the grounded metal pail and trigger the gun until all air is purged.

9. Close the solvent pump air valve (DA) and trigger the gun to relieve pressure. Engage the trigger lock

(TL). Replace the spray tip.

TL

DB

DA

WLD

10. Close the solvent flush valve (AD).

NOTE: Solvent pump may stay pressurized while spraying.

NOTICE

To prevent material from curing inside the system, never spray mixed material without the solvent pump and hose primed with solvent for proper flushing in time to clear the mixed material.

3A6283F 39

Operation

Prime the Material Lines

(Units with heated hose and remote mix manifold)

5. Engage the trigger lock (TL). Remove the spray tip.

TL

1. Follow the Prime the Empty System procedure on page 34.

2. Follow the

Startup/Recirculate procedure on page

36.

3. Close the recirculation handle (AC).

TI1949a ti1948a

6. Slowly increase the XP-hf motor air regulator (CB) enough to cycle the pumps.

7. Disengage the trigger lock (TL) and trigger the gun into a grounded metal pail while holding the metal part of the gun firmly against the side of the pail.

Use a pail lid with a hole to dispense through. Seal around the hole and gun with a rag to prevent splash-back. Keep fingers away from the front of the gun.

AC

WLD

4. Open the dual shutoff handles (AE).

AE

TL

8. Close the XP-hf motor air valve (CA).

WLD

WLD

40 3A6283F

Spray

Operation

4. Slowly increase the XP-hf air regulator (CB) to cycle the pumps.

1. Follow the Startup/Recirculate

procedure on page

36.

2. Ensure that the XP-hf air pressure regulator (CB) and is fully closed and open the XP-hf air valve

(CA).

WLD

CB

WLD

5. Engage the trigger lock (TL). Remove the spray tip.

TL

CB

3. Close the recirculation handle (AC) and the solvent flush valve (AD). Open the dual shutoff handle (AE).

AC

TI1949a ti1948a

6. Disengage the trigger lock (TL) and trigger the gun while holding against a grounded metal pail. Use a metal pail lid with a hole to dispense through to avoid splashing-back. Dispense out of the mix hose until a well mixed coating flows from the gun.

3A6283F

AE

AD

WLD

TL

WLD

7. Engage the trigger lock (TL). install the tip on the gun.

41

Operation

8. Adjust the XP-hf motor air regulator (CB) to the necessary spraying pressure and apply a coating to a test panel.

NOTE:

Run System Verification tests everyday (see page 49).

Adjust the Restrictor

The B side restrictor (AJ) reduces momentary “lead/lag” ratio imbalance of the A and B flow into the static mixer tubes (AN, AW) 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 remotely from the machine with a short mix hose to the spray gun. It can also be used in the ratio check procedure.

NOTE: Excess pressure increases overspray and pump wear.

9. Check and record gauge readings frequently during operation. A change in gauge readings indicates a change in system performance.

NOTE: A pressure drop occurs during pump stroke changeover. It should be quick and synchronous.

10. Flush the mix manifold as necessary during the day’s operation. Follow the

Flush Mixed Material on see page 44.

11. Follow the

Flushing procedure on page 44. 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

Restrictor

Stem

AJ

AB

If the mix manifold (AB) is mounted on the machine, you do not need to adjust the restrictor. Leave the restrictor stem open two turns minimum from fully closed.

Use the wrench restrictor (92) to balance the “B” pressure to the “A” pressure. Turn the restrictor clockwise to increase pressure, or counterclockwise to decrease pressure.

42 3A6283F

Operation

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

4. Close the dual shutoff handle (AE).

AE

This 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

Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

1. Close the XP-hf motor air valve (CA).

CA

WLD

5. Open the recirculation handle (AC) to relieve “A” and “B” fluid pressure.

A

B

AC

2. Hold a metal part of the gun firmly to a grounded metal pail. Trigger the gun to relieve pressure in material hoses.

6. Close both feed pump air valves (EM).

WLD

EM

WLD

3. Engage the trigger lock (TL), then remove the spray tip.

TL

TI1949a ti1948a

3A6283F

WLD

43

Operation

Flushing Flush Mixed Material

1. Follow the

Pressure Relief Procedure on page 43.

2. Ensure the solvent pump regulator (DB) is fully closed and open the solvent air valve (DA).

To avoid fire and explosion, always ground equipment and waste container. To avoid static sparking and injury from splashing, always flush at the lowest possible pressure. Hot solvent may ignite. To avoid fire and explosion:

• Flush equipment only in a well-ventilated area

• Ensure main power is off and heater is cool before flushing

• Do not turn on heater until fluid lines are clear of solvent

Guidelines

Flushing will help prevent materials from setting or gelling in the pumps, lines, and valves. Flush the system when any of the following situations occur:

• Any time the system will not be used for more than one week (depending on materials used)

• If the materials used have fillers that will settle

• If using materials that are moisture sensitive

• Before servicing

• If the machine is going into storage, replace the solvent with light oil. Never leave the equipment empty of any fluid.

Flush the mix manifold when any of the following situations occur:

• Breaks in spraying

• Overnight shutdown

Mixed material in system approaching end of pot life

DB

AD

DA

3. Open the solvent flush valve (AD).

4. Disengage the trigger lock (TL), hold the gun against a grounded metal pail, and trigger the gun into the 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.

TL

WLD

5. Close the solvent pump air valve (DA).

6. Hold a metal part of the gun against a grounded metal pail and trigger the gun to relieve pressure.

Close the solvent flush valve (AD) after relieving the pressure.

7. Engage the trigger lock (TL). Disassemble and clean the spray tip with solvent by hand. Reinstall spray tip on the gun.

44 3A6283F

Operation

Flush Hoppers Procedure

1. Follow the Flush Mixed Material

procedure on

page 44.

2. Turn off all heater switches (ZB, ZE, ZN) and the main power switch (MP). Allow the system to cool before flushing.

5. Open the recirculation handle (AC).

A

B

WLD

WLD

6. Move the recirculation lines (U) to separate grounded fluid containers and pump remaining spray material out of the system.

AC

ZB

ZE

MP

3. Engage the trigger lock (TL).

ZN

TL

U

WLE

7. Open the feed pump air valve (EM) and pump material out of the hopper.

TI1949a

4. Turn the XP-hf motor air pressure regulator (CB) fully counter-clockwise to shut off.

EM

CB

WLD

WLD

3A6283F 45

Operation

8. Run the feed pumps until they are dry. Turn off the feed pump air valve (EM) and agitator air valve

(EP).

10. Close the material drain (EH) and fill the hopper with solvent.

EM

EP

WLD

9. Place a small pail under the hopper and open the material drain (EH) to fully drain the spray material.

WLE

11. Return the recirculation lines (U) to their respective hoppers.

12. Open on the agitator air valve (EP) and pump air valve (EM). Circulate for two to three minutes.

EH EM

WLE EP

13. Repeat steps 4 - 10. Change the flushing solvent until it runs clean. To flush the remainder of the

system, follow Flush Material Lines Procedure

on

page 47.

46 3A6283F

Operation

Flush Material Lines Procedure

1. Follow the Flush Mixed Material

procedure on

page 44.

2. Follow the Flush Hoppers Procedure on page 45.

3. Close the recirculation handle (AC) and open the dual shutoff handle (AE).

CA

8. Close the main inlet air shutoff valve (CF).

WLD

CF

AC

(closed)

CB

9. Remove the filters of the XP displacement pumps and soak in solvent. Clean and replace the filter cap. Always replace the filter o-rings. See your

Xtreme lower pump manual.

10. Fill the pump packing nuts of the XP displacement pumps with TSL.

AE

(open)

WLD

4. Open the XP-hf motor air shutoff valve (CA) and increase the XP-hf motor air pressure regulator

(CB) to dispense fresh solvent from the hoppers through the mix manifold valves and out the gun.

5. Continue flushing solvent until it runs clean.

6. Close the motor air shutoff valve (CA).

7. Lift to close the dual shutoff handle (AE).

AE

WLD

NOTCE

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 and cause damage to the equipment.

NOTE: Always keep the A side and B side solvent containers separate to avoid cross-contamination.

WLD

3A6283F 47

Operation

Overnight Shutdown

5. Turn off all heater switches (ZB, ZE, ZN) and the main power switch (MP).

WLD

1. Follow the

Pressure Relief Procedure procedure on page 43.

2. Flush the mix manifold, hoses, and gun. Follow the

Flush Mixed Material procedure on page 44.

3. Open the recirculation handle (AC) and adjust the

XP-hf motor air regulator (CB) so that the pump runs slowly.

A

B ZB

ZE

MP

ZN

6. Close the feed pump air valve (EM) when the feed pump is at the bottom of the stroke.

AC

EM

CB WLD

4. When the pump is at the bottom of the stroke, close the XP-hf motor air valve (CA) and turn the air regulator (CB).

CA

WLD

NOTICE

If fluid is allowed to dry on the exposed displacement rod, damage to the throat packings may occur. To prevent damage, always stop the feed pump at the bottom of the stroke.

7. Close the agitator air valve (EP).

48

CB

WLD

EP

8. Turn off main air shutoff valve (CF).

3A6283F

Operation

System Verification

Graco recommends running the following tests daily.

Check for Normal Operation

Every time you start spraying:

• Watch the fluid gauges (AF). A pressure drop occurs during pump stroke changeover. It should be quick and synchronous.

• Stop the pumps on the upstroke. Check that both gauges hold pressure for at least 20 seconds.

If one gauge drops, the others will rise.

• Stop the pumps on the down stroke. Check that all gauges hold pressure.

• If using feed pumps, check that both feed pumps run during the proportioner upstroke.

Spots that take longer to cure indicate insufficient pump loading, leakage, or lead/lag errors at a remote mix manifold.

Appearance Test

Spray material onto foil. Look for variations in color, gloss, or texture that may indicate improperly catalyzed material.

Monitor Fluid Supply

NOTE: 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.

Mix and Integration Tests

Use the following tests to check for proper mix and integration.

Butterfly Test

At low pressure, and with the spray tip reversed, dispense 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 look for unmixed material (appears marble-like), or color changes.

Curing Test

Spray a single continuous pattern on foil at typical pressure setting, flow rate, and tip size until multiple changeovers 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.

Check Pot Life

Check the fluid manufacturer's instructions for fluid 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.

To prevent an inaccurate ratio check when feed pumps are used in your system, the feed pressure cannot be more than a maximum of 25% of the proportioner outlet pressure. High feed pressure can float the proportioner pump check balls, resulting in an inaccurate ratio check.

There must be back pressure on both sides of the mix manifold when checking the ratio.

3A6283F 49

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.

• Both pump filters; see your Xtreme lower pump manual for instructions.

• Spray gun handle filter; see your spray gun manual.

Seals

Once a week, check and tighten throat seals on both pumps (see table for torque specifications). Follow the

Pressure Relief Procedure procedure on page 43 prior

to tightening seals. There must be zero pressure on the pumps when adjusting.

Pump Size

All

Torque Specification

25-30 ft-lb (34-41 N•m)

Cleaning Procedure

1. Ensure all equipment is grounded. See

Grounding

,

page 24.

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. Follow the complete

Flushing procedure starting on page 44.

5. Follow the

Overnight Shutdown

procedure on

page 48. Turn off all power.

6. Clean the external surfaces only using a rag soaked in solvent that is compatible with the spray material and surfaces being cleaned.

7. Allow enough time for the solvent to dry before using the system.

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-positioned, and the over pressure relief valves may need to be changed.

1. Check the Models table on page 10 for the correct

pump sizes.

2. Remove and replace pump. See Remove XP

Displacement Pump page 56.

3. Adjust the position of the air motor. See

Recirculation Manifold with Over Pressure

Relief Valves page 57.

4.

If changing from one type of XPs-hf system to another (for example - changing from XP50s-hf to XP70s-hf or from XP70s-hf to XP50s-hf):

Remove the existing over pressure relief valves (702) and install the correct valves for the

new system type. See Replace Over Pressure

Relief Valves on page 58, and

Material

Recirculation Manifold Replacement Table on page 59.

5. Change the XP-hf Motor Air Pressure Relief

Valve (CG)

as required, depending on the ratio. See

page 21.

50 3A6283F

Maintenance

Clean Inlet Strainer Screen

The inlet strainers filter out particles that can plug the pump inlet check valves. Inspect the screens daily as part of the startup routine, and clean as required.

1. Follow the Startup/Recirculate on page 36.

2. Ensure that all pumps are shut off and close the

Y-strainer valve (ES).

3. Place a container under the strainer base to catch drain off when removing the strainer plug.

4. Remove the screen from the strainer manifold.

Thoroughly flush the mesh screen (MS) with compatible solvent and shake it dry.

Check Heating Fluid Level

Gradual fluid evaporation can occur. Check the level of heating fluid monthly. Add fluid as needed.

NOTICE

Freezing temperatures can cause damage that may result in the heating fluid leaking into the terminal enclosure. To avoid damage, do not expose the unit to freezing conditions.

Drain Heating Fluid

Replace heating fluid once a year to improve heating efficiency and increase heater element life. Keep the heating element above the sediment deposits. Sediment deposits will drain out from the coolant drain valve (EJ).

SP

SG

MS

ES

PP

WLD

5. Inspect the screen. No more than 25% of the mesh should be restricted. If more than 25% of the mesh is blocked, replace the screen. Inspect the gasket and replace as needed. See your heated hopper manual for replacement components.

6. Ensure that the pipe plug (PP) is screwed into the strainer plug (SP). Install the strainer plug (SP) with the mesh screen (MS) and gasket (SG) in place and tighten. Do not over tighten the strainer plug--let the gasket make the seal.

7. Open the Y-strainer valve (ES). Ensure that there are no leaks and wipe the equipment clean.

Maximum sediment level

WLE

EJ

NOTE: The heater will not operate in sediment deposits.

3A6283F 51

Maintenance

Feed Pumps XP Displacement Pumps

Check packing nut. Torque to 25-30 ft-lb (34-41 N•m).

Keep the wet cup half filled with Graco Throat Seal

Liquid (TSL ™ ).

Keep the packing nut/wet-cup half filled with Graco

Throat Seal Liquid (TSL ™ ) or compatible solvent to help prolong packing life.

Agitators

0.25 in. (6.3 mm)

Diameter Rod ti34523a

Adjust the packing nut weekly so it is just tight enough to prevent leakage. Use a spanner wrench or a 0.25 in.

(6.3 mm) diameter rod to tighten the nut. Do not over-tighten.

Never leave the pump or hoses filled with water or air.

To help prevent corrosion, flush the water and all air out of the system and leave it filed with mineral spirits or an oil-based solvent.

NOTICE

To prevent air motor failure and possible damage to equipment, always keep the air motor properly lubricated using Air Motor Lubricant.

After the first 100 hours, or two weeks of operation, change the gear reducer oil. After that, change the oil every 2500 hours, or six months (whichever comes first) of operation under normal conditions. More frequent oil changes are needed under severe operating conditions or in atmospheres containing excessive moisture or abrasives. See your agitator manual for the oil changing procedure.

If the air motor is operating sluggish or inefficiently, flush the air motor (see your agitator manual).

Every 2500 hours, or six months (whichever comes first) of operation, inspect the bearing block (see your agitator manual).

Solvent Pump

Keep the wet cup half filled with Graco Throat Seal

Liquid (TSL ™ ).

52 3A6283F

Troubleshooting

Troubleshooting

1. Follow Pressure Relief Procedure on page 43

before checking or repairing the system.

2. Check all possible problems and causes before disassembling the gun.

Problem

System stops or will not start.

System speeds up or runs erratically.

Pump operates, but resin output pressure drops on upstroke.

Pump operates, but resin output pressure drops on downstroke.

Pump operates, but resin output pressure drops on both strokes.

Pump operates, but hardener output pressure drops on upstroke.

Pump operates, but hardener output pressure drops on downstroke.

Pump operates, but hardener output pressure drops on both strokes.

Fluid leak in packing nut.

Fluid leak under packing nut

Relief valve (AM) leaks back to supply, opens too soon, or will not close.

Cause Solution

Air pressure or volume too low.

Increase; check air compressor.

Closed or restricted air line or air valve. Open or clean.

Fluid valves closed.

Clogged fluid hose.

Air motor worn or damaged.

Open.

Replace.

Displacement pump stuck.

Repair air motor; see your air motor manual.

Repair pump; see your Xtreme pump manual.

Fluid containers are empty.

Air in fluid lines.

Displacement pump parts worn or damaged.

Dirty, worn, or damaged resin pump piston valve or piston packings.

Dirty, worn, or damaged resin pump intake valve.

Hardener output restriction.

Fluid supply low.

Dirty, worn, or damaged hardener pump piston valve or piston packings.

Check often; keep filled.

Purge; check connections.

Repair pump; see your Xtreme pump manual.

Clean, repair pump; see your Xtreme pump manual.

Clean, repair pump; see your Xtreme pump manual.

Clean, unplug hardener side. Open manifold restrictor.

Refill or change container.

Clean, repair pump; see your Xtreme pump manual.

Dirty, worn, or damaged hardener pump intake valve.

Resin output restriction.

Fluid supply low.

Loose packing nut or worn throat packings.

Packing cartridge o-ring.

Relief valve is dirty or damaged.

Clean, repair pump; see your Xtreme pump manual.

Clean, unplug resin side.

Refill or change container.

Tighten; replace; see your Xtreme pump manual.

Replace o-ring; see your Xtreme pump manual.

Replace over pressure relief valve (302)

3A6283F 53

Troubleshooting

Problem

No pressure on hardener side; fluid leaking from hardener pump outlet rupture disk fitting.

Pressure and flow surges on upstroke.

Fluid outlet pressure gauges split only at the top changeover (if one gauge drops the other will rise).

Cause Solution

Overpressure rupture disk blown.

Determine cause of overpressurization and correct.

Replace rupture disk assembly

258962 (see page 15) and over

pressure relief valve (302).

Reduce feed pressure. See

Repair

,

page 56.

Feed pressure too high. Every 1 psi of feed pressure adds 2 psi during upstroke.

Not fully loading one side on upstroke.

Increase feed pressure on side that dropped.

Increase feed hose size.

Clean inlet strainer or hopper screen.

Air mixed in fluid from excessive agitation or circulation.

Flush and add new fluid.

✖ Fluid ratio will be wrong.

◆ Purge all air from system before proportioning fluids.

54 3A6283F

Troubleshooting

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:

Resin Pump Leakage

1. Throat packing

2. Piston packing

3. Piston ball check

TROUBLE AREA:

Hardener Pump Leakage

1. Throat packing

2. Piston packing

3. Piston ball check

Resin

Pump

Hardener

Pump

Resin

Pump

Hardener

Pump

Falling Rising

Rising Falling

TROUBLE AREA:

Resin Pump Leakage

1. Throat packing

2. Intake ball check

TROUBLE AREA:

Hardener Pump Leakage

1. Throat packing

2. Intake ball check

Resin

Pump

Hardener

Pump

Resin

Pump

Hardener

Pump

Falling Rising Rising Falling

3A6283F 55

Repair

Repair

Follow the complete

Flushing procedure starting on page 44, which includes pressure relief and full system

flushing if service time may exceed pot life time before servicing fluid components and before transporting the system to a service area.

Pump Assembly Repair

Remove XP Displacement Pump

1. Flush all system components. Follow the complete

Flushing procedure starting on page 44.

2. Disconnect the hopper fluid lines from the pump fluid inlet (228).

3. Disconnects the outlet hose (12 or 24). For parts

identification, see Parts starting on page 60.

4. Remove the spring clamp (930) and coupling (919).

To avoid serious injury due to the pump assembly falling, secure a hoist to the lift ring.

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.

Pump Assembly Removal

1. Flush all system components. Follow the complete

Flushing procedure starting on page 44.

2. Disconnect all hoses from the pump assembly.

3. Disconnect the hopper fluid lines from the pump fluid inlet (228).

4. Remove screws (6) and washers (5) under the tie plate (901). For additional parts identification, see

Parts starting on page 60.

901

935

917

902

930

919

918

901

5. Use hoist to remove the pump assembly by the lift ring and carefully lift out of stand (1).

908

WLD

5. Use a wrench to hold the tie rod (902) flats to keep the rods from turning. Unscrew the nuts (908) from the tie rods and carefully remove the displacement pump (917 or 918) and lower straps (935).

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 displacement pump.

NOTE: Torque nuts (908) to 95-105 ft-lb (129-142 N•m).

56 3A6283F

35

37

Repair

Remove Motor

1. Flush all system components. Follow the complete

Flushing procedure starting on page 44.

2. Disconnect the air line from the air motor.

3. Remove the air motor rod cover (921) and pump guards (922).

WLD

921

922

Recirculation Manifold with Over

Pressure Relief Valves

1. Flush all system components. Follow the complete

Flushing procedure starting on page 44.

2. Disconnect all fluid hoses from the material recirculation manifold (35).

3. Remove the mix manifold if it is assembled to the material recirculation manifold.

4. Loosen the two screws (37) that secure the manifold

(35) to the cart (1).

5. Remove the two screws (37) and material recirculation manifold (35) from the cart (1).

1

4. Use a wrench to hold the tie rod (902) flats to keep the rods from turning. Unscrew the nuts (908) from the tie rods.

WLD

902

HX

908

909

WLD

5. Place a wrench on the motor shaft hex flats (HX).

Loosen coupling nut (909).

6. Use a hoist to remove the air motor by the lift ring.

7. Refer to the air motor manual to service or repair the air motor.

3A6283F 57

Repair

Replace Over Pressure Relief

Valves

1. Flush all system components. Follow the complete

Flushing procedure starting on page 44.

2. Ensure handle (712) is in the down position.

Remove the screws (713), jam nut (704), handles

(711), handle rod (712), clips (718), and springs (720).

WLD

3. Unscrew both over pressure relief valves (702) from the manifold.

4. Apply blue threadlock to new over pressure relief valves (702) and install in the manifold. Torque to

28-32 ft-lb (38-43 N•m).

5. Place a spring (720) over each valve stem. Place a clip (718) in each valve stem groove to retain the springs.

6. Slide handle (711) onto valve stem and rotate approximately 90° until you feel it fully lock against the valve seat. Repeat for opposite side.

7. Remove handle then place handle (711) on valve stem (302) at the vertical, or near vertical, position.

8. Apply blue threadlock on the nut (704) threads and tighten the handle against the spring (720) and clip (718). Torque to 70-80 in-lb (7.9-9 N•m).

9. Place the rod (712) and the second handle (711) on second valve stem aligned with the opposite handle.

10. Repeat step 9.

11. Install two screws (713) in handles (711).

12. Check operation of the handle and valves.

13. Operate the handle in and out of the spray and circulate positions.

14. Check for clearance with fittings.

NOTE:

• Both valves should settle firmly into the spray position inward against the seats in the valve.

• Both valve stems should rotate out to their most extended positions when the handle is pulled down to the circulate position.

58 3A6283F

Material Recirculation Manifold Replacement Guide

Colored Valve Sleeve ti19169a

Circulation

Manifold (35)

Part

262783

262806 ti19168a

Material Recirculation Manifold Replacement Table

Relief

Valve (302)

Part

262809

Valve Sleeve

Color

Gold

Target Opening

Pressure psi (MPa, bar)

7100 (49, 490)

Use with:

All XPs50-hf models

262520 Silver 9250 (64, 638) All XPs70-hf models

Repair

3A6283F 59

Parts

Parts

XP50s-hf and XP70s-hf Proportioner

Label No.

16F359 C

Modifying this machine or adding

Non-approved accessories voids the

Hazardous Area Approvals.

La modificaci ón de esta máquina o adición de accesorios no autorizados anula la zona peligrosa de idoneidad.

Modification de cette machine ou de l ajout d accessoires non approuvés par les vides de la zone dangereuse approbations.

60

1. Apply anaerobic pipe sealant to all non-swiveling pipe threads.

WLF

3A6283F

XP50s-hf and XP70s-hf Proportioners (Continued)

Parts

3A6283F

WLF

61

Parts

XP50s-hf and XP70s-hf Proportioners (Continued)

223

208

230

214

225

215

214

225

215

220

219

215

225

218

217

WLF

62 3A6283F

Parts

XP50s-hf and XP70s-hf Proportioners Parts List

48

51

52

53

54

36

37

41

43

47

31

32

35

22

23

24

25

29

30

18

19

20

21

13

15

16

17

5

6

7

12

3

4

Ref. Part

1 25N579

Description

CART, painted, XPs,

2 25N583 MODULE, air controls, filter

(see page 72)

25N575 MODULE, air controls, regulator

- - - - -

PUMP (see page 79)

100133

100101

17V986

H75004

WASHER, lock, 3/8

SCREW, cap, hex head

HOSE, coupled, 1 in.

HOSE, 7250 psi, 4 ft

17N487

112958

100015

104429

100131

16F206

100016

111218

HOSE, XP-hf Air Motor supply

NUT, hex, flanged, 3/8-16

NUT, hex, flange head

SCREW, cap

NUT, hex

LABEL, XP, handles

WASHER, lock

CAP, tube, square

158491 FITTING, nipple

15M987 FITTING, elbow, 60°

H75002 HOSE, 7250 psi, 2 ft

110755 WASHER, plain

214037 VALVE, ball

156971 FITTING, nipple

104984 FITTING, tee

H42503 HOSE, solvent, outlet

MANIFOLD, recirculation

262783 XP50 (578xxx)

262806 XP70 (577xxx)

262807 MANIFOLD, mix, 1/2 in. valves

106212 SCREW, cap, hex head

158683 FITTING, elbow

16G819 TOOL, wrench, Xtreme, filter

206995 FLUID, TSL

126786 TOOL, restrictor

205447 COUPLING, hose

16F537 HOSE, air, inlet, solvent control

15B772 HOSE, air, solvent pump

061132 HOSE, circulation, solvent

Qty.

1

1

1

1

1

1

1

1

2

2

1

1

4

4

1

4

1

1

2

1

2

4

1

2

2

2

6

4

1

1

1

3

1

1

1

Ref. Part Description

55 ▲ 16F359 LABEL, warning, fire/exp hazard

56 - - - - -

VALVE, safety (see page 79)

58

59

16F615 TOOL, wrench, Xtreme

111192 SCREW, cap, hex head

60

61

24F126

262392

MODULE, air controls, solvent

PUMP, solvent (see page 79)

202 25N578 BASE, painted, XPs, pallet

206 17V987 TUBE, recirculation, material

207 116704 FITTING, adapter

208 H52506 HOSE, recirculation material

209 111192 SCREW, cap, socket head

210 108851 WASHER, plain

211 100133 WASHER,lock,3/8

212 123433 SCREW, cap, socket head

213 GUN, ovl, hnd

XTR522 XTR5 (578xxx)

Qty.

1

XTR722 XTR7 (577xxx)

214 162024 COUPLING

215 262478 HOUSING, mixer

217 HOSE, coupled

H53825 5600 psi (578xxx)

H73825 7250 psi (577xxx)

218 15B729 COUPLING

219 150287 COUPLING

220 HOSE, coupled

H52510 5600 psi (578xxx)

221

222

223

224

225

H72510 7250 psi (577xxx)

121620

15R424

101566

124293

248927

FITTING, reducer,

LABEL,A-B

NUT, lock

BOLT, u-bolt

KIT, mixer element, (25 pack)

227 214961 HOSE, coupled

228 121571 FITTING, elbow, female

229 203320 HOSE, coupled

230 114030 UNION, adapter, swivel

▲ Replacement safety labels, tags, and cards are available at no cost.

2

1

2

1

3

2

1

2

2

2

3

1

1

1

1

4

4

1

2

2

8

4

1

1

1

2

1

1

2

3A6283F 63

Parts

Water Jacketed Heated Hose Packages

+$=/2&

+$=/2&

64

+$=/2&

WLD

246 245 247

3A6283F

Parts

Water Jacketed Heated Hose Packages Parts List

Ref.

10

11

14

27

28

33

34

38

63

203

243

244

245

246

247

248

238

239

240

241

242

234

235

236

237

204

231

232

233

Part

25C962

26C471

26C476

166590

185065

110963

C19075

111841

26C482

26C479

17X398

16P608

117535

121603

126896

17N599

17N598

116171

26C580

26C581

26C582

26C583

25C961

126898

126900

17D306

113796

17P759

122032

273093

17X552

245869

245863

245870

245864

17N600

17P594

17S051

24Z934

113974

Description

HARNESS, B heater, non-hazardous

HARNESS, A heater, non-hazardous

BUSHING, strain relief

JUNCTION BOX, 240V, non-hazardous

JUNCTION BOX, 240V, hazardous

JUNCTION BOX, 480V, non-hazardous

JUNCTION BOX, 480V, hazardous

HEATER, hf, 240V, non-hazardous

HEATER, hf, 240V, hazardous

HEATER, hf, 480V, non-hazardous

HEATER, hf, 480V, hazardous

FITTING, bushing adapter

ADAPTER, cable

SCREW, cap, flanged head

SCREW, cap, hex head

WASHER

HOPPER, heated, 240V

HOPPER, heated, 480V

HARNESS, hopper

CLAMP, mounting, top, heater

SCREW, cap, socket head

GRIP, cord

FITTING, elbow

FITTING, elbow

FITTING, elbow

FITTING, coupler

SCREW, flanged

TUBE

NUT, wire (not shown)

PUMP, heated hose

BRACKET, recirc pump

HEATER, hose, 240V, non-hazardous

HEATER, hose 240V, hazardous

HEATER, hose 480V, non-hazardous

HEATER, hose, 480V, hazardous

HARNESS, WJ, hose heat

FITTING, house coupler

FITTING, hose nipple

KIT, heater block, remote manifold

SCREW, mach, slotted

1

10

1

1

1

1

1

1

8

Qty.

Ordinary

240V

Hazardous

Locations

XXXX01

Locations

XXXX11

Ordinary

480V

Hazardous

Locations

XXXX21

Locations

XXXX31

1 1

1 1

2

1

2

1

1

1

2

2

2

3

5

2

3

5

4 4

2

4

4

2

4

4

2

2

4

2

1

2

4

1

4

2

1

2

2

2

2

2

4

1

1

8

1

1

1

1

1

1

10

1

1

1

1

1

8

1

8

1

1

1

1

1

1

1

1

1

1

1

1

1 1

1

1

1

1

1

1

1

1 1

1

1

1

3A6283F 65

Parts

Non-Heated Hose Packages

+$=/2&

+$=/2&

WLD

66 3A6283F

Parts

Non-Heated Hose Packages Parts List

Ref. Part Description

10

11

14

27

17N599 HARNESS, B heater, non-hazardous

17N598 HARNESS, A heater, non-hazardous

116171 BUSHING, strain relief

26C580 JUNCTION BOX, 240V, non-hazardous

26C581 JUNCTION BOX, 240V, hazardous

26C582 JUNCTION BOX, 480V, non-hazardous

26C583 JUNCTION BOX, 480V, hazardous

28

25C961 HEATER, hf, 240V, non-hazardous

25C962 HEATER, hf, 240V, hazardous

26C471 HEATER, hf, 480V, non-hazardous

26C476 HEATER, hf, 480V, hazardous

33

34

166590 FITTING, bushing adapter

185065 ADAPTER, cable

38

110963 SCREW, cap, flanged head

C19075 SCREW, cap, hex head

63 111841 WASHER

203

26C482 HOPPER, heated, 240V

26C479 HOPPER, heated, 480V

204 17X398 HARNESS, hopper

233 121603 GRIP, cord

240 122032 NUT, wire (not shown)

Qty.

240 V

Ordinary Hazardous

480 V

Ordinary Hazardous

Locations

XXXX02

Locations

XXXX12

Locations

XXXX22

Locations

XXXX32

1 1

1

1

1

1

1

1

1

1

2

2

2

2

4

4

4

4

2

2

4 4

2

4

2

4

2

2

8

2

8

2

2

2

3A6283F 67

Parts

Non-Hazardous Location Electric Heated Hose Packages

240V

480V

68

WLD

3A6283F

9

3A6283F

Hazardous Location Electric Heated Hose Packages

Parts

9

WLD

69

Parts

Electric Heated Hose Packages Parts List

Ref. Part Description

10

11

14

27

28

33

34

38

17N599 HARNESS, B heater, non-hazardous

17N598 HARNESS, A heater, non-hazardous

116171 BUSHING, strain relief

26C899 JUNCTION BOX, 240V, non-hazardous

26C905 JUNCTION BOX, 240V, hazardous

26C904 JUNCTION BOX, 480V, non-hazardous

26C906 JUNCTION BOX, 480V, hazardous

25C961 HEATER, hf, 240V, non-hazardous

25C962 HEATER, hf, 240V, hazardous

26C471 HEATER, hf, 480V, non-hazardous

26C476 HEATER, hf, 480V, hazardous

166590 FITTING, bushing adapter

185065 ADAPTER, cable

110963 SCREW, cap, flanged head

C19075 SCREW, cap, hex head

63

64

65

66

111841 WASHER

18C158 SPLICE BOX

18B948 SPLICE BOX, explosion-proof

115942 NUT

112958 NUT

18C151 COVER, splice box

19B335 BRACKET, splice box

19Y807 BUSHING, strain relief 67

68

69

70

19B130 CORD, cable

128986 CONNECTOR, splice

26C791 TRANSFORMER

19B356 TRANSFORMER, 5kV, hazardous

71

72

73

19B359

132001

BRACKET, transformer

BOLT, flange, serrated

74

75

112395 SCREW, cap

112958

25T264

NUT, hex flanged

KIT, fittings (not shown)

203

26C482 HOPPER, heated, 240V

26C479 HOPPER, heated, 480V

204 17X398 HARNESS, hopper

233 121603 GRIP, cord

240 122032 NUT, wire (not shown)

Qty.

240 V

Ordinary Hazardous

480 V

Ordinary Hazardous

Locations

XXXX03

Locations Locations

XXXX13 XXXX23

Locations

XXXX33

1 1

1

1

1

1

1

1

1

1

2

2

2

2

5

4

4

4

2

2

4 8

4 4

1

2 2

3

4 4

1

1

1

1

2

1

1

1

1

1

2

4

4

1

2

4

4

1

1

4

1

2

2

8

2

8

2

2

2

70 3A6283F

Air Control Filter 25N583 Parts

Parts

WLE

Parts List

Ref. Part Description

302 116648 FITTING, swivel, 1 in. m x f

303 17N485 FITTING, tee, 1 x 1 x 1 npt(f), cs,

2.2k

304 158555 FITTING, nipple, 1 x 3/4 npt

305 15E145 MANIFOLD, air distribution

306 100615 BUSHING, hex steel

307 157350 ADAPTER

308 115781 CAP plug

309 17N486 FITTING, elbow, 1 in. npt

310 17N462 FILTER, air, 1 in. npt

311 113163 VALVE, ball, vented, 1

312 127784 COUPLING, universal,1 in. nptm

Qty.

2

1

1

1

2

2

1

1

3

1

1

Ref. Part Description

313 127785 COUPLING, universal, 1 in. nptf

314 16W586 CABLE, lanyard, whip check

315 113161 SCREW, flange, hex hd

316 16P338 SCREW, mach, serrated hex head

317 17X550 BRACKET, XPs, filter, mount, painted

318 17X551 BRACKET, XPs, filter, painted

319 114526 FITTING, tee

320 155665 UNION, adapter

321 156849 PIPE, nipple

322 111763 FITTING, elbow, 1/4 npt

Qty.

1

1

2

4

1

1

1

2

1

1

3A6283F 71

Parts

Air Control Regulator 25N575 Parts

Ref. Part Description

402 119363 FITTING, swivel, pipe

403 113163 VALVE, ball, vented, 1.0

404 17S719 FITTING, 1 in. npt x 3 in., nipple

405 17N463 REGULATOR, air, 1 in. npt

WLE

Qty.

1

1

1

1

Ref. Part Description

406 108638 FITTING, pipe, tee

407 100960 GAUGE, press air

408 116648 FITTING, swivel, 1 in. m x f

409 16P338 SCREW, mach, serrated hex head

410 17X553 BRACKET, XPs, regulator, painted

Qty.

1

4

1

1

1

72 3A6283F

Parts

Solvent Pump 262392 Parts

WLE

2 Torque to 50-55 ft-lb (68-75 N•m).

3 Torque to 50-60 ft-lb (68-81 N•m).

Ref. Part Description

501 24F079 MOTOR, air, 6 in., std, slvt only

503 111799 SCREW, cap, hex hd

504 244675 HOSE, coupled, suction

505 108143 STRAINER

506 116395 FITTING, swivel, elbow

507 100081 BUSHING, pipe

508 157350 ADAPTER

510 15M662 ROD, tie

511 16U431 ADAPTER, 50 cc, pump lower

(not shown)

512 15U606 NUT, lock, m16 x 2

4 Torque to 75-80 ft-lb (102-108 N•m).

Qty.

1

4

1

1

1

1

1

3

1

3

Ref. Part Description

513 LW050A LOWER, assy, 50 cc

514 15T337 RESERVOIR, tsl, 50 cc lwr 7 1/2 motor (not shown)

515 184128 COLLAR, coupling

516 15T311 NUT, coupler

517 277743 SHIELD, 6.0/7.5 in.

518 15V028 SHIELD, drip

528 156589 FITTING, union, adapter, 90 deg

529 100505 BUSHING, pipe

530 156849 PIPE, nipple

533 105335 SCREW, mach, pnh

Qty.

1

2

1

1

1

1

1

1

1

1

3A6283F 73

Parts

Solvent Air Control 24F126 Parts

Ref.

Part Description

551 - - - - - PANEL, air controls, slvt, painted

552 15T500 GAUGE, pressure, air, pl mnt, 1/8

553 15T536 REGULATOR, air, 3/8 npt

554 16F810 NUT, regulator, steel

555 114362 VALVE, ball, air

556 15T498 FITTING, 90, swvl, 5/32 t x 1/8 fnpt

558 113498 VALVE, safety, 110 psi

559 15T937 FITTING, elbow, swivel 1/4 npt x 5/32 t

560 155699 FITTING, elbow, street

561 164672 ADAPTER

563 054753 TUBE, nylon, rd, black

568 108296 SCREW, mach, hex wash hd

569 109544 FITTING, elbow, pipe, male

0.75

4

1

2

2

1

1

Qty.

1

1

1

1

1

1

WLE

74 3A6283F

Parts

Heater Block Remote Manifold Kit

(Water Jacketed Heated Hose Packages Only)

Kit 24Z934

[

WLD

[

[

1 Apply thread sealant to all non-swiveling pipe threads.

Ref. Part Description

601 24F834 CARRIAGE, weldment, remote manifold

602 16T294 PLATE, heater transfer, PFP 2k

603 110837 SCREW, flange, hex

604 110996 NUT, hex, flange head

605 126692 FITTING, tube, NPT x tube

606 100721 PLUG, pipe

608 ▲ 189285 LABEL, safety, burn

609 120736 SCREW, hex flange HD

610 126894 FITTING, union, 1/2 tube x 1/2 tube

611* 054960 TUBE, red, nylon, 0.375 (9.5 mm) ID (1.5 ft)

612* 054961 TUBE, blue, nylon, 0.375 (9.5 mm) ID (1.5 ft)

* Supplied loose, not installed.

▲ Replacement safety labels, tags, and cards are available at no cost.

Qty.

1

1

2

2

2

2

1

2

2

1

1

[

2 Supplied loose, not installed.

3A6283F 75

Parts

Material Recirculation Manifold with Over Pressure Relief Valve

Assembly 262783 (XP50s-hf); 262806 (XP70s-hf)

712

713

709

708

711

6 3

704

718

720

5

708*

709*

703 708

710

713

2 3

701

4

702

705

717

720

5

718

707

1. Apply anaerobic pipe sealant to all non-swiveling pipe threads.

2 Torque to 28-32 ft-lb (38-43 N•m).

3 Apply blue anaerobic adhesive to threads.

Ref Part Description

708

709

710

711

712

713

716

701 16D693 BLOCK, manifold, recirculation

702† 262520 VALVE, over pressure relief, silver,

XP70s-hf

◆ 262809 VALVE, over pressure relief, gold,

XP50s-hf

703

704

705

707

156684 UNION; 1/2 in. male x female

112309 NUT, hex, jam

198241 PLUG, port, pressure; 11/16-24

114434 GAUGE, pressure, fluid, sst; 10k psi

100840 FITTING, elbow, street; 1/4 npt

156971 FITTING, nipple; 1/4 npt x npsm

557349 PLUG, dry seal 1/8 npt

16E334 HANDLE, manifold

16E332 ROD, connecting, handle

124859 SCREW, button head

156684 FITTING, nipple, 1/2 npt x 1/2 npt

Qty

1

2

2

2

2

4

2

2

2

2

2

1

2

2

711

717

705

702

2 3 4

704

716 r_258988_3a0420a_1c

4

5

6

Further tighten either valve (302) as required to line up handle straight across.

Apply grease to spring ends.

Torque to 70-90 in-lb (7.9-9 N•m).

3 6

Ref Part Description

717

718

121399 O-RING, solvent resistant

124676 RING, snap, external

720 150829 SPRING, compression

751 ✖ 159239 FITTING, nipple, pipe, reducing

752 ✖ 156173 UNION, swivel

✖ Not shown. Shipped loose.

◆ For XP50s-hf systems only.

† For XP70s-hf systems only.

NOTE: Loose fittings are supplied with replacement manifold to also fit Series A (XP70s) Proportioners with 3/8 in. mix manifold ball valves.

* Fitting orientation can be modified to allow for easier routing of recirculation lines. Remove fitting (708) and reinstall fitting

(709).

Qty

2

2

2

2

2

76 3A6283F

Parts

Diaphragm Pump 273093 Parts

(Water Jacketed Heated Hose Packages Only)

WLD

D

1

Apply thread sealant to all non-swiveling pipe threads.

2

4

Orient fittings as shown.

Install two loose plugs and muffler provided with pump in the ports indicated.

Ref. Part Description

801 108126 FITTING, tee, street

802 126897 FITTING, elbow, 1/2 tube x 1/4 nptm

803 126898 FITTING, elbow, 1/2 tube x 1/2 nptm

804 126899 FITTING, 1/2 tube x 1/2 nptm

805 16D939 FITTING, nipple, reducing

806 16R871 BOTTLE, overflow, 1/2 npt

807 17P088 BRACKET, XP-hf, re-circ, painted

808 206264 VALVE, needle

Qty.

1

2

1

1

1

1

1

1

6 Orient fittings approximately 15 degrees away from pump.

8 Install ground wire between screw and washer.

The nut is held in the slot of the pump.

Ref. Part Description

809 24T761 PUMP, acetal, w/pvdf check, husky

810 113161 SCREW, flange, hex hd

811 17N910 TUBE, red, 0.5 o.d., nylon

812 17N911 TUBE, blue, 0.5 o.d., nylon

814 126900 FITTING,1/2 tube x 3/8 nptm

815 17D307 FITTING, nipple, quick coupling

818 17N595 WIRE, ground, door to enclosure

819 248208 HOSE, coupled

Qty.

1

1

1

1

1

1

2

2

3A6283F 77

Parts

XP-hf Pump Assembly Parts

E

D

F

E

G

D

78

2

3

4

5

6

Torque to 50-60 ft-lb (68-81 N•m).

Torque to 145-155 ft-lb (196-210 N•m).

Apply medium strength (blue) threadlock to top thread only.

Pins and lanyards must be positioned toward the outside of the pump as shown. Allow ends of lanyard to hang freely.

Remove ground screw and washer from the motor, then use to install ground wire.

12 Torque together to 230-250 ft-lb (312-339 N•m).

13 Torque together to 95-105 ft-lb (129-142 N•m).

WLE

3A6283F

Parts

XP-hf Pump Assembly Parts List

Ref.

Part

909

910

911

912

913

916

921

901

902

903

904

905

906

907

908

Description

273087 PLATE, XP-hf, motor

273086 ROD, tie, 4 in. long, 1 in. dia

273088 MOTOR, air, 13 in.

273085 ROD, adapter

262468 ROD, tie, 14.25 long, w/shoulder

262469 ROD, tie, 14.25 long, 1.25 dia

129383 NUT, 5/8-11, flanged, sst

101712 NUT, lock

184096 NUT, yoke

17R501 BRACKET, ratio indicator

273090 YOKE, pump assembly

273091 ROD, adapter, Xtreme, hf

262472 SLEEVE, bearing

123976 RING, snap, external

273089 BRACKET, XP-hf, finger guard

2

2

1

2

1

1

1

3

6

Qty.

1

3

1

1

4

2

Ref.

Part Description

921a 16P338 SCREW, mach, serrated hex hd

921b 17N312 PLATE, XP-hf, finger guard

922 273092 COVER, pump

922a 121803 SCREW, cap, button head

922b 124172 WASHER, retaining, nylon, 10-32

922c 124665 NUT, captive, 10-32

922d ▲ 15T468 LABEL, warning

930 124078 CLAMP, spring, constant-tension

931 ▲ 15H108 LABEL, safety, warning, pinch

932 111192 SCREW, cap flange hd

934

935

940

184130 BRACKET, ratio indicator

16E882 STRAP, lowers

244525 WIRE, grounding assembly

1

2

1

1

2

2

2

Qty.

2

1

8

4

2

8

▲ Replacement safety labels, tags, and cards are available at no cost.

Ref. Description

4 PUMP, assembly

917 PUMP, lower, A

918 PUMP, lower, B

919 COUPLING, A

920 COUPLING, B

929 LABEL, XP-hf

56 VALVE, safety

57710x 57720x 57730x 57740x 57810x 57820x 57830x 57840x Qty.

572100 572200 572300 572400 573100 573200 573300 573400 1

L14AC0 L18AC0 L22XC0 L22XC0 L22AC0 L29AC0 L29AC0 L29AC0 1

L14AC0 L090C0 L072C0 L054C0 L22AC0 L14AC0 L097C0 L072C0 1

244819 244819 244819 244819 244819 244819 244819 244819 1

244819 247167 247167 247167 244819 244819 247167 247167 1

17N281 17N281 17N281 17N281 17N282 17N282 17N282 17N282 4

113498 114055 113498 114055 113498 113498 114055 16M190 1

3A6283F 79

Recommended Spare Parts

Recommended Spare Parts

Keep these spare parts on hand to reduce downtime.

Pump Repair Kits

See

Models (page 10) to see what pumps are used on

your system. See lower manual for repair kits.

Pump Filter O-Rings (packs of 10)

262483, Top o-ring

244895, Middle o-ring

262484, Bottom o-ring

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

XHD010, Seat/Seal Kit for XHD RAC Tips

(5 pack)

Recirculation/Overpressure Valve

(see page 59)

XP50-hf: 262809, gold

XP70-hf: 262520, silver

15K692, Seal Mix Manifold Check Valve

Cartridge

NOTE: 15K692 must be replaced when cleaning the check valves.

XHDxxx, Spray Tips

See spray gun manual for tips.

80 3A6283F

Accessories and Kits

Accessories and Kits

PressureTrak

Kit, 25C452

Monitors pressures to provide ratio assurance on XP-hf plural component sprayers in hazardous and non-hazardous locations.

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-hf 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-hf 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-hf system. See manual 312769 for more information.

1-1/2 in. ID Hose Flex Feed Kit, 262820

XP Wall Mount Bracket, 262812

Works with air systems.

Leg Stand, 24M281

Includes wall bracket 262812.

1/2 in. Ball Valve Upgrade Kit for Mix

Manifold, 24M593

Remote Mix Manifold with Heater Block,

24Z934

A mounting carriage with a heater block to circulate water-jacketed hose heat to maintain heat on the mix manifold.

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. Optional 3rd gun port does not have independent flush. See manual 3A2573 for more information.

Filter Element, 116635

40 micron filter element.

Automatic Float Drain Kit, 17P521

Internal auto float drain for filter bowl.

2:1 Feed Pump Kit, 256275

For supplying viscous materials from a drum to XP-hf system. 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-hf system. See manual 312769 for more information.

Wall Line Powered Pressure

Monitor Kit, 26C008*

Air Turbine Powered Pressure

Monitor Kit, 26C009

Automatically monitors difference between A and B pressures when at spray pressure and shuts down the system if there is a problem.

* Not approved for Hazardous locations

3A6283F 81

Dimensions

Dimensions

System Dimensions

Top View

LQ

FP

Side View

LQ

FP

82

LQ

FP

WLD

3A6283F

Technical Specifications

Technical Specifications

XPs-hf System

U.S.

Metric

Output

Maximum Fluid Working Pressure

Combined Fluid Output (cc/cycle)

Pressure Ratio

Fluid Flow at 20 cpm

Maximum Storage Time

Air Specifications

Required Air Flow

Supply Pressure

Inlet Size

Inlet Filtration

Electrical Specifications

See Models section beginning on page 10.

See Models section beginning on page 10.

See Models section beginning on page 10.

See

Models section beginning on page 10.

5 years (To maintain original performance, replace soft seals after 5 years of inactivity)

185 cfm (minimum)

30-100 psi

1 in. npsm

5.23 m3/min (minimum)

2.0-6.7 bar, 0.2-0.67 MPa

2.54 cm npsm

40-micron filter/separator included

See XPs-hf Wiring Diagram , page 26

Filtration

Feed Pump Outlet/Y-Strainer

XP Pump Outlets

XTR Spray Gun

Viscosity

Gravity Feed

Pressure Feed

Temperature

Operating

Storage

Maximum Fluid Temperature

Wetted Materials

Housings and Manifold

Displacement Pump Packings

Solvent Pump

Hoses

Feed Pump

Agitator

Hopper

Miscellaneous Parts

Dry Weight (does not include stand alone transformer)

XXXX01

XXXX02

XXXX03

XXXX11

XXXX12

XXXX13

XXXX21

XXXX22

XXXX23

40-130 °F

30-160 °F

160 °F

20 mesh

30 mesh

60 mesh

200 - 20,000 cps (pourable)

Any viscosity that will not require feed pressure more than 15% of outlet pressure

Carbon steel with electroless nickel plating

Carbon filled PTFE, proprietary UHMWPE

Stainless steel, PTFE, UHMWPE, aluminum, tungsten carbide

Plated carbon steel, Nylon

Plated carbon steel, PTFE

Stainless steel

Stainless steel, brass, nickel plating

Carbide, acetal, solvent resistant plastics

1350 lb

1300 lb

1325 lb

1350 lb

1300 lb

1475 lb

1475 lb

1425 lb

1450 lb

4-54 °C

1-71 °C

71 °C

612 kg

590 kg

596 kg

612 kg

590 kg

700 kg

700 kg

646 kg

658 kg

3A6283F 83

Technical Specifications

XXXX31

XXXX32

XXXX33

Sound Data

Sound Power measured at 70 psi

(0.48 MPa, 4.8 bar), 20 cpm, per ISO-9614-2

Sound Pressure tested at

3.28 ft (1 m) from equipment

Proportioner

Input

Maximum air input

Air inlet size

Fluid pump inlets

Output

Fluid gauge manifold

Fluid mix manifold inlets (ball valves)

Mix manifold material outlet

Sound Data

Air consumption per 1 gpm (3.78 lpm) of flow

XPs70-hf

XPs50-hf

Double Wall Hopper

Temperature (set point)

Spray material capacity

Heating fluid capacity

Feed Pump

Input

Maximum air input

Air inlet size

Output

Maximum working pressure

Fluid outlet size

Flow at maximum pump speed: (66 cycles/min)

Air consumption per 1 gpm (3.78 lpm) of flow

Sound Data

1475 lb

1425 lb

1450 lb

Greater than 96 dBA

Greater than 86.8 dBA

700 kg

646 kg

658 kg

U.S.

100 psi

Metric

1 in. npsm

1-1/4 npt (m)

6.7 bar, 0.67 MPa

1/2 in. npt(f)

1/2 in. npsm

1/2 npt(f)

See XL 10k Air Motor manual for sound data.

75 cfm at 100 psi

60 cfm at 100 psi

2.12 m3/min at 6.7 bar, 0.67 MPa

1.7 m3/min at 6.7 bar, 0.67 MPa

U.S.

110 °F

25 gallons

12 gallons

Metric

43 ° C

94.6 liters

53 liters

U.S.

100 psi

Metric

3/8 in. npt(f)

6.7 bar, 0.67 MPa

500 psi 34.4 bar, 3.4 MPa

2.5 gallons per minute

3/4 in. npt(f)

9.5 liters per minute

8 cfm at 100 psi 0.23 m3/min at 6.7 bar, 0.67 MPa

See Monark Air Motor manual for sound data.

84 3A6283F

Technical Specifications

Xtreme Duty Agitator

Input

Maximum air input

Air inlet size

Air Consumption

30 rpm at 20 psi (1.4 bar, 0.14 MPa)

60 rpm at 80 psi (5.5 bar, 0.55 MPa)

Maximum free speed at 100 psi (6.7 bar, 0.67 MPa)

Speed

Maximum shaft speed

Gear ratio

Torque:

Stall torque at maximum pressure

Sound Data

Solvent Pump

Input

Air pressure

Air inlet size

Output

Maximum working pressure

Fluid outlet size

Flow at maximum pump speed (60 cpm)

Air Consumption

Per 0.5 gpm (1.89 lpm) of flow

Sound Data

U.S.

100 psi

7 cfm

30 cfm

60 cfm

Metric

3/8 in. npsm

6.7 bar, 0.67 MPa

0.198 m3/min

0.850 m3/min

1.70 m3/min

60 rpm

20:1

1120 in-lb 127 N•m

See XD Agitator manual for sound data.

U.S.

10 - 100 psi

Metric

1/2 in. npt(f)

0.67 MPa - 6.7 bar

4500 psi

0.9 gpm

3/8 in. npt

3.1 MPa, 31 bar

3.0 lpm

20 cfm @70 psi 0.57 m^3/min at

0.48 MPa, 4.83 bar

See your Merkur air motor manual.

Recycling and Disposal

End of Product Life

At the end of a product’s useful life, recycle it in a responsible manner.

California Proposition 65

CALIFORNIA RESIDENTS

WARNING: Cancer and reproductive harm – www.P65warnings.ca.gov.

3A6283F 85

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by

Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT

LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE .

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy

(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT

MANUFACTURED BY GRACO . These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com

.

For patent information, see www.graco.com/patents .

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 3A6283

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Copyright 2018, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revision F , April 2021

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