Graco 3A4381G, XP-hf Proportioner Owner's Manual

Operation, Repair and Parts

XP-hf

™

Proportioner

3A4381G

EN

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

For professional use only.

Not approved for use in explosive atmospheres or hazardous locations except where indicated in the Models section.

See page 12 for models numbers, descriptions

and agency approval designations.

Important Safety Instructions

Read all warnings and instructions in this manual and in related manuals.

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

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Over Pressure Protection . . . . . . . . . . . . . . . . . 10

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Component Identification . . . . . . . . . . . . . . . . . . . 14

XP-hf Proportioners (Model 572407 shown) . . . 14

XP-hf Proportioners (continued) . . . . . . . . . . . . 15

Fluid Control Assembly . . . . . . . . . . . . . . . . . . . 16

Main Air Controls . . . . . . . . . . . . . . . . . . . . . . . 17

45:1 Solvent Flush Pump . . . . . . . . . . . . . . . . . 18

System Components . . . . . . . . . . . . . . . . . . . . . . . 19

*Bleed Type Motor Air Valve (CA) . . . . . . . . . . 19

*Air Pressure Relief Valve (CG) . . . . . . . . . . . . 19

*Air Filter (CC) . . . . . . . . . . . . . . . . . . . . . . . . . . 19

*Air Regulator Adjustment (CB) . . . . . . . . . . . . 19

Fluid Line Components . . . . . . . . . . . . . . . . . . . 19

Initial System Setup . . . . . . . . . . . . . . . . . . . . . . . 20

Flush Before Using Equipment . . . . . . . . . . . . . 20

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Connect Power . . . . . . . . . . . . . . . . . . . . . . . . . 22

Power Cord Requirements . . . . . . . . . . . . . . . . 22

Wire Systems with Explosion-Proof Heaters . . . 23

Motor Position . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Connect Air Supply . . . . . . . . . . . . . . . . . . . . . . 24

Connect Static Mixers/Gun/Hoses . . . . . . . . . . 24

Connect Fluid Hose Bundles (Remote Mix Manifold

Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Connecting Additional Hose Lengths . . . . . . . . 25

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 27

Prime Empty System . . . . . . . . . . . . . . . . . . . . . . . 28

Prime A and B Fluids . . . . . . . . . . . . . . . . . . . . 28

Prime Solvent Flush Pump . . . . . . . . . . . . . . . . 30

Recirculate Prior to Spraying or

Re-Prime After a Pump Runs Dry . . . . . . . 31

Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

B Component Adjustable Fluid Restrictor . . . . . 34

Flush Mixed Material . . . . . . . . . . . . . . . . . . . . . . . 35

Flush Mix Manifold, Hose, and Spray Gun . . . . 35

Empty and Flush Entire System

(new system or end of job) . . . . . . . . . . . . . . . 37

Park . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

System Verification . . . . . . . . . . . . . . . . . . . . . . . . 41

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Hose Electrical Resistance . . . . . . . . . . . . . . . . 42

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . 42

Change the Mix Ratio . . . . . . . . . . . . . . . . . . . . 42

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 45

Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Mix Manifold Assembly . . . . . . . . . . . . . . . . . . . 48

Fluid Circulation Manifold with Over Pressure Relief

Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Hoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Solvent Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Fluid Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Complete System (572107 shown) . . . . . . . . . . 52

Complete System (continued) . . . . . . . . . . . . . . 53




Bare Proportioning Pump Package . . . . . . . . . . 60

Heated Hose Recirculation Pump . . . . . . . . . . . 63

Hose Heater (bracket mounted) . . . . . . . . . . . . 64

Enclosure Junction Box . . . . . . . . . . . . . . . . . . . 66

Enclosure Junction Box (continued) . . . . . . . . . 67

Heater Wiring Diagram . . . . . . . . . . . . . . . . . . . 69

Heater Block Remote Manifold Kit . . . . . . . . . . . 70

Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Recommended Spare Parts . . . . . . . . . . . . . . . . . 72

Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . . 73

Acceptable For Use in

Explosive Atmospheres . . . . . . . . . . . . . . . 73

Not Approved For

Explosive Atmospheres . . . . . . . . . . . . . . . 74

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Floor Mounting Dimensions, Top View . . . . . . . 76

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 82

3A4381G

Related Manuals

Manuals are available at www.graco.com.

Component manuals in English:

Manual

334644

311762

Description

312145 XTR 5 ™ and XTR 7 ™ Spray Guns, Instructions - Parts

Pump Package Components

Xtreme ® XL Air Motor, Instructions - Parts

Xtreme Displacement Pumps, Instructions - Parts

Hopper Kits

312747

406860

Heating

20 Gallon Double Wall Hopper Kit, Instructions - Parts

7 Gallon Hopper Installation Kit, Instructions - Parts

3A2954

309524

406861

3A5313

Viscon ® HF Heater, Instructions - Parts

Viscon HP Heater, Instructions - Parts

Viscon HP Heater Adapter Kit, Instructions - Parts

Xtreme-Wrap Water Heated Hose, Instructions - Parts

3A5314

Solvent Flush

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

310863

312794

Feed and Solvent Flush Kits, Instructions Parts

Merkur ® Pump Assembly, Instructions - Parts

Accessories and Kits

3A3320 XP and XP-hf PressureTrak Kit, Instruction - Parts

3A1331

312769

339361

3A0421

3A0590

3A2573

406739

XP Pressure Monitor Kit, Instructions - Parts

Feed Pump and Agitator Kits, Instructions - Parts

High Pressure Hose and Accessories Brochure

Ratio Check Kit, Instructions - Parts

Mix Manifold, Quickset Mix Manifold, Instructions - Parts

Gun Splitter Valve, Instructions - Parts

Desiccant Kit, Instructions - Parts

Related Manuals

3A4381G 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.

FIRE AND EXPLOSION HAZARD

WARNING

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.

Static charge may build up on plastic parts during cleaning and could discharge and ignite flammable vapors. To help prevent fire and explosion:

• Clean plastic parts only in well ventilated area.

• Do not clean with a dry cloth.

• Do not operate electrostatic guns in equipment 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.

3A4381G

3A4381G

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.

MOVING PARTS HAZARD

Moving parts can pinch, cut or amputate fingers and other body parts.

• Keep clear of moving parts.

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

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

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

• Connect only to grounded power source.

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

5

6

Warnings

EQUIPMENT MISUSE HAZARD

WARNING

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.

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.

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.

3A4381G

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.

3A4381G 7

8


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.

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.

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

3A4381G


A and B Component Designations

Material suppliers and markets refer to plural component materials differently. The table below summarizes the different designations for the components used in various machines.

Market Equipment

Foam and Polyurea, and Urethane

Pour

Epoxy and

Urethane Protective

Coatings

Epoxy, Silicone,

Urethanes, and other materials

All Reactors,

HFR ™ , and VRM

Hydra-Cat

XtremeMix

XM ™

PR70 ™

™

®

™

,

, and XP

,

and PR

Designations

Letter

Color

Component Names

Major or Minor Component

(when not 1:1 mix)

Letter

Color

Component Names


(when not 1:1 mix)

Letter

Color

Machine Left Side Machine Right Side

A

Red

ISO, Hardener,

Catalyst

B

Blue

Polyol, Resin, Base

Low Volume Side

A

Blue

Resin, Base

High Volume Side

A

Red

Component Names


(when not 1:1 mix)

Polyol, Resin, Base

High Volume Side

High Volume Side

B

Green

Hardener, Catalyst

Low Volume Side

B

Blue

ISO, Hardener,

Catalyst

Low Volume Side

3A4381G 9

Overview

Overview

Usage

The XP-hf is a mechanically linked fixed ratio system that can mix and spray most two-component epoxy and urethane protective coatings.

When using quick-setting material (less than 10 minute pot life), the Remote Manifold Heater Block Kit (24Z934) is recommended for use (included in complete systems).

The two pumps are carbide seat severe duty positive displacement pumps that displace fluid on both strokes.

Using an XP-hf system, or components on the system, not approved for hazardous locations or explosive atmospheres may result in a fire or explosion hazard.

The XP-hf systems are not approved for use in hazardous locations unless the base model, all accessories, all kits, and all wiring meet local, state, and national codes.

See Wire Systems with Explosion-Proof Heaters on

page 23.

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.

• Cart-Mounted Systems Only: Maximum air pressure set point blow off valves are provided to limit maximum fluid pressure. Do not remove these valves.

• Color coded automatic over pressure relief valves are used on cart-mounted systems to dump excess fluid pressure back to the supply. Never plug these return hoses. See Fluid Circulation Manifold with

Over Pressure Relief Valves

on page 48.

• When using an XP-hf bare pump package to build a system, use the over pressure relief valves referenced above.

• Never install individual shut off valves on the “A” and

“B” lines. On cart-mounted systems, common handles link the fluid control valves.

• A rupture disc is provided on the small side fluid pump (pumps 145 cc and smaller) as a back-up to the over pressure relief valve. If the rupture disc ever opens, do not operate the machine until the over pressure valve and the rupture disc have been replaced.

• If changing pump lowers or motor on your system, use the correct over pressure relief valves from the chart on page 49.

10 3A4381G

Models

Models

Bare Proportioning Pump Packages

Packages include motor, pump lowers, and connection components.




page 23.

NOTE: See special conditions for safe use in Viscon HF

Heater manual (3A2954) and Viscon HP Heater Manual

(309524).

Building systems with bare proportioning pump packages:

•

Over Pressure Protection must be used, see

page 10. See chart on page 19 to identify the over

pressure relief valves to use with your system.

• All components must meet or exceed maximum working pressures.

Pump sizes are marked on the pump cylinder; sizes are nominal. See technical data in manual 311762 for actual displacement.

These packages require additional components to make a complete system. See Fluid Control Assembly , page

16;

Main Air Controls

, page 17; and

System Components

, page 19.

3A4381G 11

Models

Models

PART NUMBER CODE EXAMPLE:

First

Three Digits

Fourth and

Fifth Digits

5

 System

Pressure Ratio

7 x x

*Volume

Mix Ratio x

Last Digit

#Components

(see page 13)

x



System Pressure Ratio (First Three Digits of Part Number)

First Three

Digits

572 xxx

573 xxx

System Ratio

70 : 1

50 : 1

Maximum Fluid Working Pressure psi (MPa, bar)

7250 (50, 500)

5000 (34, 344)

*

Volume Mix Ratios - 70:1 (Fourth and Fifth Digits of Part Number)

Fourth and

Fifth

Digits

Pump

Ratio

(A/B) xxx 10 x 1 : 1 xxx 15 x 1.5 : 1 xxx 20 x 2 : 1 xxx 25 x 2.5 : 1 xxx 30 x xxx 40 x

3 : 1

4 : 1

A Side

Pump

L14AC0

L14AC0

L18AC0

L18AC0

L22XC0

L22XC0

B Side

Pump

L14AC0

L097C0

L090C0

L072C0

L072C0

L054C0

Combined

Fluid

Output

(cc/cycle)

290

242

270

252

292

274

Fluid Flow at 40 cpm gpm (lpm)

3.0 (11.3)

2.6 (9.8)

2.8 (10.6)

2.6 (9.8)

3.0 (11.3)

2.8 (10.6)

Over

Pressure

Relief Valve

Silver

Silver

Silver

Silver

Silver

Silver

Maximum Air

Working

Pressure psi (MPa, bar)

100 (0.7, 7)

85 (0.59, 5.9)

95 (0.65, 6.5)

90 (0.62, 6.2)

100 (0.7, 7)

95 (0.65, 6.5)

*

Volume Mix Ratios - 50:1 (Fourth and Fifth Digits of Part Number)

Fluid to Air

Pressure

Ratio

73 : 1

86 : 1

76 : 1

81 : 1

71 : 1

76 : 1

Maximum Fluid

Working


7100 (49, 490)

7250 (50, 500)

7250 (50, 500)

7250 (50, 500)

7100 (49, 490)

7250 (50, 500)

Fourth and

Fifth

Digits

Pump

Ratio

(A/B)

A Side

Pump

B Side

Pump xxx 10 x 1 : 1 L22AC0 L22AC0 xxx 15 x 1.5 : 1 L22AC0 L14AC0 xxx 20 x 2 : 1 L29AC0 L14AC0 xxx 25 x 2.5 : 1 L29AC0 L115C0 xxx 30 x 3 : 1 L29AC0 L097C0 xxx 40 x 4 : 1 L29AC0 L072C0

Combined

Fluid

Output

(cc/cycle)

440

365

435

405

387

362

Fluid Flow at 40 cpm gpm (lpm)

Over

Pressure

Relief Valve

Maximum Air

Working Pressure psi (MPa, bar)

4.6 (17.4)

3.8 (14.4)

4.6 (17.4)

4.2 (15.9)

4.0 (15.1)

3.8 (14.4)

Gold

Gold

Gold

Gold

Gold

Gold

100 (0.7, 7)

90 (0.62, 6.2)

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

57 : 1

48 : 1

51 : 1

53 : 1

57 : 1

4750 (33, 330)

5000 (35, 345)

4750 (33, 330)

5000 (35, 345)

5000 (35, 345)

5000 (35, 345)

12 3A4381G

Approvals

#Components (Last Digit of Part Number)

 = Ex rated

Pump Assembly

(Air Motor and Pump Lowers)

Cart

Last Digit of Part Number

      xxxxx 0 (†) xxxxx 1 xxxxx 2 xxxxx 3 xxxxx 4 xxxxx 5 xxxxx 6 (  ) xxxxx 7 (‡) x x x x x x x x x x x x x x x

7 gallon hoppers x x x x x

Includes:

Solvent Pump

HF Hazardous Location

A/B Heaters (2)

HF Non-Hazardous Location

A/B Heaters (2)

Wiring Junction

Box (connected)

HP Hazardous Location Hose

Circulation Heater (1)

HP Non-Hazardous Location Hose

Circulation Heater (1)

Hose Heat

Circulation Pump

Pressure Trak

(Hazardous Location)

XTRxxx Spray Gun and 35 ft

(10.7m) Supply Hose (not attached) x x x x x x x x x x x x x x x x x x x x x x x x x

† Bare pump packages ending in zero require additional components to make a complete system, see Bare Proportioner Pump Packages

, page 11.

 Complete - All connected except for hazardous location heating wiring.

‡ Complete - All connected and wired for non-hazardous locations.

Pump Packages without Pump Lowers

Includes:

Part System Ratio

Maximum Fluid Working

Pressure psi (MPa, bar)

7250 (50, 500)

Cart

XTRxxx Spray Gun and 35 ft (10.7 m)

Supply hose (not attached)

X

572000(#)

70:1 X

573000(#)

50:1 5000 (34, 344) X

# These pump packages without pump lowers are not operational and are not CE rated or Ex marked.

X

Approvals

II 2 G c ll A T3

All systems CE marked except where noted.

 All systems with a part number ending in 0, 1, 2, 3, 4, and 6 are Ex rated for use in explosive atmospheres except where noted.

3A4381G 13

Component Identification

Component Identification

XP-hf Proportioners (Model 572407 shown)

=3

( $

&$

Mounting Components for

Pump Package

0

=$

=%

8

$$

+

5

&%

9

1

/

:

$,

=/

;

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-

.

&)

&&

Key:

A Air Supply Hose for Motor

D Fluid Pump

E Xtreme XL Air Motor

H

Solvent Flush Pump Air Controls; see page 18

J 7 Gallon Hoppers (blue A-side shown)

K Cart

L Brake

M Handle (lift to release)

N

Mix Manifold; see page 16

P Pump Tie Rods

R Motor Adapter Plate

S Adjustable Packing Nuts with Wet Cups

T Yoke with Rod Bearings

U Recirculation Lines

V Connecting Rod Nut

14

W Static Mixer Tubes with Replaceable Plastic Elements

X Motor Position Indicator Bracket;

see Motor Position, page 23

Y Over Pressure Rupture Disc; only 145cc pumps or smaller

AA Fluid Manifold

AI Air Inlet 1 in. npsm(f)

CA Motor Air Shut Off Valve (Relieving)

CB Motor Air Pressure Regulator

CC Air Filter with Auto Drain

CF Main Inlet Air Shut Off Valve; see page 17

ZA Solvent Pump Ground Wire

ZB Air Motor Ground Wire

ZL Gun and Hose

ZP Power Disconnect

7

6

3

<

3A4381G

XP-hf Proportioners (continued)

Model 572407 Shown

=%

-

/

=/

Key:

F Viscon HF Fluid Heater

J 7 Gallon Hoppers (green B-side shown)

K Cart

L Brake

M Handle (lift to release)

ZB Pressure Trak

ZC Junction Box

ZD Pump

ZF Circulation Pump Reservoir

ZG Circulation Pump

ZH Viscon HP Hose Water Heater

ZK Solvent Prime/Flush Valve

ZL Heater ON/OFF Switches

.

=* =)

3A4381G


='

=+

0

=&

)

=.

WLE

15


Fluid Control Assembly

This is required to add to Bare Pump Packages to make a complete system.

Standard Mix Manifold shown

AA

AH

AF

AE

AJ

AB

AL

AC

AM

Key:

AA Fluid Manifold

AB Mix Manifold

AC Circulation Handle (shown closed)

AD Solvent Flush Valve

AE Dual Shutoff Handle (shown closed)

AF Fluid Pressure Gauges

AG Fluid Supply Inlet (Behind Fluid Manifold)

AH Fluid Circulation Fittings

AJ B Component Adjustable Fluid Restrictor;

see page 34

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; see page 49

AN A and B Combined Outlet; 3/8 npt(m)

AK

AN

AD ti19167a

16 3A4381G


Main Air Controls

This is required to add to Bare Pump Packages (part number ending in zero “0” to make a complete system).

&$

&'

&)

&*

&%

&(

&&

Key:

AI Main Air Inlet

CA Motor Shutoff Valve (Relieving)

CB Motor Air Pressure Regulator

CC Air Filter with Auto Drain

CD Main Motor Air Pressure Gauge

CE Filtered Air Distribution Manifold

CF Main Inlet Air Shutoff Valve

CG Pressure Relief Valve

$,

WLD

3A4381G 17


45:1 Solvent Flush Pump

Pump

BA

BD

Key:

BA Solvent flush pump (Merkur Pump)

BB Fluid Inlet

BD Muffler

BE Prime/Flush/Sample valve

BF Fluid Outlet Hose

BG Circulation hose

BE

BF

BG

BB (suction hose not shown) r_571100_3a0420a_4a-2

Air Controls

DC

Key:

DA Solvent Pump Air Shutoff Valve (Relieving)

DB Solvent Pump Air Pressure Regulator

DC Solvent Pump Air Pressure Gauge

DD Air Outlet

DE Air Inlet

DE

DB

DD

DA r_571101_3a0420a_5a-2

18 3A4381G

System Components

System Components

* Indicates a customer-supplied component required to add to Bare Pump Packages (part numbers ending in zero

“0”) to make a complete system.

*Bleed Type Motor Air Valve (CA) *Air Regulator Adjustment (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.

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

Valve to relieve trapped air.

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

The two steps below are required in your system 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.

Fluid Line Components

• *Fluid Manifold (AA): Controls circulation and pump priming.

• *Mix Manifold (AB): Combines A and B fluid into one fluid line.

• *Circulation Handle (AC): Directs fluid flow for circulation 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.

*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:

• *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.

Ratio

1:1

1.5:1

2:1

2.5:1

3:1

4:1

XP70-hf

Valve Part

113498

16M190

114055

103347

113498

114055

Ratio

1:1

1.5:1

2:1

2.5:1

3:1

4:1

XP50-hf

Valve Part

113498

103347

113498

113498

114055

16M190

• *Static mixer/gun hose kit: Thoroughly mixes the two fluids and delivers the mixed fluid to the spray gun. Includes static mixer and hoses to the spray gun.

• Fluid Heaters (F): Heats the resin and hardener before mixing. Improves the chemical reaction and lowers viscosity to improve the spray pattern.

• Solvent Flush Pump (ZD): Flushes the mix manifold. Includes a solvent pump, mounting hardware, and solvent supply hose.

*Air Filter (CC)

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

3A4381G 19

Initial System Setup

Initial System Setup

1. Check the shipment for accuracy. Ensure you have

received everything you ordered. See Component

Identification , page 14.

2. Check for loose fittings and fasteners.

3. Systems supplied as complete are already connected for fluid, air and electrical hookups.

4. If any accessories are added to a non-complete sys-

tem refer to the individual manual listed on page 3.

5. Install desiccant kits if using polyurethane isocyanates in hoppers. See manual 406739 for instructions.

6. Install circulation and return tube kits if you are feeding material from drums or remote hoppers. See manual 309852 if you are feeding urethane material.

7. Connect the feed pumps, fluid strainers, and air hoses as necessary. For systems without hoppers, see manual 312769.

8. Connect the fluid hose assembly, including the static mixers, whip hose and gun. See Connect

Static Mixers, Gun, and Hoses

, page 24.

9. Connect the battery in the PressureTrak module.

10. Connect the air supply hose. See Connect Air Supply

, page 24.

Flush test oil from system as needed. See Connect the resin and hardener hoses to the resin and hardener inlets on the mix manifold.

, page 25.

See Empty and Flush Entire System (new system or end of job) , page 37.

Flush Before Using Equipment

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

Empty and Flush Entire System (new system or end of job) , page 37.

20 3A4381G

Setup

Setup

Location

1. Connect the ground wire (244524) (ZB) to the ground stud on the air motor.




page 23.

1. Locate the proportioner on a level surface.

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

3. For permanent mounting, remove wheels and mount the frame to the floor. See Dimensions ,

page 75.

4. Make sure cart brake (L) is in the locked position.

Grounding

=%

WLD

*6

2. Connect the other end of the ground wire to a true earth ground for systems without heaters, otherwise connect to HF heater clamp bar.

3. Ground the object being sprayed, fluid supply container, and all other equipment in the work area. Follow your local code. Use only electrically conductive air and fluid hoses.

4. Ground all solvent pails. 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.

Solvent Pump: use ground wire and clamp (supplied with solvent pump).

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.

Tools Required:

• Grounding wires and clamps for pails

• Two 5 gallon (19 liter) metal pails

=%

*6

Air and fluid hoses: use only static dissipation type 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.

Air compressor: follow manufacturer’s recommendations.

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

3A4381G 21

Setup

Connect Power

4. Route the power cable through the strain relief in the electrical enclosure.

5. Connect incoming power wires as shown in the

Power Disconnect diagram below. Gently pull on all connections to verify that they are properly secured. All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

NOTE: This wiring method converts three input power types to 200-240 VAC, 1 Phase output power to all heaters.

NOTE: Terminal jumpers are located inside the electrical enclosure door.

6. Install supplied terminal jumpers in the positions shown in the Terminal Block diagram below for the power source used.

1. Turn main power disconnect switch (ZP) OFF.

2. Open the electrical enclosure door.

3. See the Power Cord Requirements table to select proper input power cord.

7. Verify that all items are connected properly as shown below, then close the electrical enclosure door.

Power Disconnect

Terminal Block

ti31899a ti31900a

Power Cord Requirements

Model

57xxx5

(two fluid heaters with two optional hopper heaters)

57xxx5

(two fluid heaters, one hose heater with two optional hopper heaters)

Input Power

200-240 VAC, 1 Phase

200-240 VAC, 3 Phase, DELTA

350-415 VAC, 3 Phase, WYE

200-240 VAC, 1 Phase

200-240 VAC, 3 Phase, DELTA

350-415 VAC, 3 Phase, WYE

Cord Specifications AWG

(mm^2) + Ground / PE

6 (13.3), 2 wire

8 (8.4), 3 wire

10 (5.3), 4 wire

6 (13.3), 2 wire

6 (13.3), 2 wire

10 (5.3), 4 wire

Full Load Peak

Current (Amps)

58

51

40

75

65

40

22 3A4381G

Setup

Wire Systems with

Explosion-Proof Heaters

(Hazardous location systems only)

Change Motor Position

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

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

2. Loosen the eight fasteners and remove the two pump guards.

Improperly installed or connected equipment will create a hazardous condition and cause fire, explosion, or electric shock. Follow local regulations.

If your system is rated for hazardous areas, and you have explosion-proof heaters, you must have a qualified electrician connect the heater wiring. Make sure the wiring and installation comply with local electrical codes for hazardous areas.

When explosion-proof heaters are used, ensure the wiring, wiring connections, switches, and electrical distribution panel all meet flame-proof (explosion-proof) requirements.

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

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 chart in Models

on page 11.

Volume mix ratio indicator lines

IDVWHQHU

SXPSJXDUG

IDVWHQHU

SXPSJXDUG

WLD

3. Loosen the three nuts (107) below the motor tie rods.

(

WLF

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

Air Motor shown

WLF

4. Slide the tie rods (102) 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.

5. Tighten the three nuts (107).

6. Install the pump guards.

3A4381G 23

Setup

Connect Air Supply

Connect the air supply hose to the 1 in. npsm(f) swivel air inlet (AI).

Use a 1.0 in. (25.4 mm) ID minimum air hose. Air consumption is 75 cfm per gallon per minute (2,100 lpm per

4 lpm) spraying. Do not use pin fitting type quick disconnects.

2. Add mixed material hose as necessary between the mix hose (25) and cleanup mixer (27, 28).

AB

$,

AN

W

WLD

Connect Static Mixers/Gun/Hoses

NOTICE

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

1. Connect the outlet of the two primary static mixer tubes with mixer elements (W) to the fluid mix hose (25), cleanup mixer (27, 28), whip hose (30), and spray gun (31).

25

Standard Mix Manifold shown

27, 28

30

31

24 3A4381G

Setup

Connect Fluid Hose Bundles

(Remote Mix Manifold Only)

NOTE: For all steps below refer to the illustration on the next page.

Refer to the mix manifold manual 3A0590 for details when the mix manifold (AB) is remotely mounted.

1. Connect additional resin and hardener fluid hose sections to the proportioner fluid manifold (AA) outlet. Hoses must be properly sized and balanced for your mix ratio.

2. Connect the resin and hardener hoses to the resin and hardener inlets on the mix manifold.

3. Connect the female quick-disconnect “Y” fitting assembly (FQ) to the blue tubing quick-disconnect from below the overflow bottles.

4. Connect the male quick-disconnect “Y” fitting assembly (MQ) to the red tubing quick-disconnect from the heater outlet.

5. Connect the glycol circulation tubing to the “Y” fitting assemblies. Cut the red and blue tubing squarely behind the hose union fittings. Connect to the “Y” fitting assembly.

NOTE: The tubes and fittings are color coded. Make sure all colors match when connecting the fittings.

6. Connect the mix manifold (MM) to the remote manifold carriage (MC) heater block (HB) and bracket using two screws (9).

7. Connect the resin and hardener hoses to the mix manifold.

8. Connect the extension glycol tubing from the hose bundle to the heater block (HB). Cut the tubing squarely behind only one of the u-fittings. Connect the two union fittings (10) to the hose tubing (one red, one blue). Cut the red tubing (11) piece and blue tubing (12) piece to length to fit between the hose bundle and heater block, then tighten the fittings.

Connecting Additional Hose

Lengths

NOTE: For all steps below refer to the illustration on the next page.

Up to six 50 ft (15.2 m) sections of heated hose can be attached for a maximum total length of 300 ft (91.4 m).

1. Remove the plastic u-turn fittings at the end of the heated hose assembly.

2. Connect the next length of hose, using union fittings supplied with the hose.

NOTE: The tubes and fittings are color coded. Make sure all colors match when connecting the fittings.

NOTICE

To prevent cross-contamination, ensure you connect the “A” side fluid hose to the “A” side fluid hose on the additional heated hose.

3A4381G 25

Setup

Connecting Hoses

26

WL[[[[D

A

)4

B

04

5('

B

A

%/8(

5('

%/8(

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3A4381G

Pressure Relief Procedure

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

8. Engage the gun trigger lock.

9. Close the dual shutoff handle (AE) and open the circulation handle (AC) to relieve A and B fluid pressure.

AC

(open)

AE

(closed)

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. Engage the gun trigger lock.

TI1949a

2. Close the motor air shutoff valve.

3. Shut off heaters, if used.

4. Shut off feed pumps, if used.

5. Remove the spray tip.

6. Disengage the trigger lock.

r_571101_3A0420A_9a-2

NOTE: Always flush the mix hose after relieving A and B fluid pressure through the mix manifold. Follow

Flush

Mixed Material , page 35 when you stop spraying or dis-

pensing; and before cleaning, checking, servicing, or transporting equipment.

NOTE: For longer valve life when using abrasive fluids, it is advisable to relieve high pressure out through the gun when possible.

• If you suspect the spray tip or hose is clogged or that pressure has not been fully relieved after following the steps above, very slowly loosen tip guard retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Clear hose or tip obstruction.

• If static mixer, whip hose, and gun cannot be flushed because of mixed and cured material, very slowly loosen static mixer tube from mix manifold outlet to relieve pressure gradually, then loosen completely. Replace or clean clogged components.

TI1950a

7. Hold a metal part of the gun firmly to a grounded metal pail. Trigger the gun to relieve pressure.

WLD

3A4381G 27

Prime Empty System

Prime Empty System

Prime A and B Fluids

2. Fill the A and B hoppers with proper materials. Fill the A side (blue) with major volume of material; fill the B side (green) with minor volume of material

(unless 1:1 mix ratio).

3. Move the recirculation lines (U) to empty containers.

To help prevent injury, wear gloves when using solvents and/or if the fluid temperature exceeds 110° F (48° C).

The equipment is tested with light weight oil at the factory. If necessary, flush out the oil with a compatible solvent before spraying. See

Empty and Flush Entire

System (new system or end of job) , page 37.

Do not install the gun spray tip yet. To avoid splashing, use the lowest pressure possible to prime.

1. Condition the materials prior to adding to the hoppers (J). Ensure that the resin materials are thoroughly mixed, homogeneous, and pour-able prior to adding to the hopper. Stir the hardeners back into suspension prior to adding material to hopper.

WLD

4. Close the dual shutoff handle (AE) and open the circulation handle (AC).

AC

(open)

J

WLD

AE

(closed)

28 3A4381G

Prime Empty System

5. Open the main air shutoff valve (CA). Then slowly open the air regulator (CB).

CA

7. Decrease air pressure. Close the main air shutoff valve (CA).

CA

A B

CB

WLD

6. Dispense fluid into the containers until clean fluid comes out of the A and B recirculation lines.

WLD

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

U

WLD

WLD J

9. If using heaters, heat fluid throughout system before spraying. See

Recirculate Prior to Spraying or

Re-Prime After a Pump Runs Dry , page 31.

3A4381G 29

Prime Empty System

Prime Solvent Flush Pump

Follow instructions if the solvent flush pump is used.

6. Ensure the trigger lock is engaged. Remove the spray tip.

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

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

BG

TI1949a

4)!

TI1948a

7. Disengage the trigger lock and trigger the gun into a grounded metal pail while holding against a 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.

BE r_571101_3A0420A_5b-2

3. Open the solvent prime valve (BE) on the solvent pump (BA) outlet.

4. Open the solvent pump air valve (DA). Slowly turn the solvent pump air regulator (DB) clockwise to prime the solvent pump and route solvent back to the pail. Close the solvent pump fluid valve (BE) and air valve (DA).

TI1950a

WLD

8. Open the solvent pump air valve (DA). Slowly turn the solvent pump air regulator (DB) clockwise to prime the solvent pump and push air out of the mix hose and gun. Trigger the gun until all air is purged.

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

Replace the spray tip.

DB

DA r_571101_3A0420A_5a-2

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

AE

(closed)

AB

AD

TI1949a

DA r_571101_3A0420A_12a-2

10. Close the solvent flush valve (AD).

NOTE: Solvent pump air and pressure may be left on while spraying.

NOTE: Never spray mixed material without the solvent pump and hose primed with solvent for proper flushing in time to clear the mixed material.

30 3A4381G

Prime Empty System

Recirculate Prior to Spraying or

Re-Prime After a Pump Runs Dry

NOTE: Agitate, recirculate, and heat the material only as necessary to avoid mixing air into the fluid.

Use the recirculation mode when heating the material is required. Note the temperature at the top of the heater

(outgoing or back to the hopper). When the thermometer reaches operating temperature, the material is ready to spray.

If using a system that does not require heat, recirculation is still required prior to spraying. Recirculation ensures that any settled fillers are mixed in, the pump lines are fully primed, and the pump check valves are operating smoothly.

Recirculation also allows you to re-prime one side that has run dry.

1. Follow

Prime Empty System , page 28.

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

AC

(open)

AE

(closed)

5. Turn down the air pressure regulator (CB) and then open the motor air shutoff valve (CA). Use the air pressure regulator to slowly increase the air pressure to the pumps to 15-30 psi (1-2 bar) until they start running slowly.

CA

A

B

CB

WLD

6. Run the pumps for a few minutes or until the material has reached the desired temperature. See

Heat

Fluid , page 31.

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

CA r_571101_3A0420A_9a-2

3. Ensure the recirculation hoses (U) are in the correct hoppers (J).

U

J

4. Lower to open the circulation valve handle (AC).

AC

WLD

Heat Fluid

To heat fluid evenly throughout the system:

1. Circulate the fluid at approximately 1/2 gpm

(10-20 cycles/min.) to raise the temperature of the hoppers to 80-90° F (27-32° C).

2. Decrease the circulation rate to approximately

0.25 gpm (5 cycles/min.) to increase the heater outlet temperature to match the spray temperature.

Circulating the fluid too quickly without decreasing the circulation rate will increase only the hopper temperature. Similarly, circulating fluid too slowly will increase only the heater outlet temperature.

WLD

3A4381G 31

Spray

Spray

4. Adjust the main air regulator (CB) to 30 psi

(0.21 MPa, 2.1 bar) minimum.

NOTE: After the first day of spraying, re-tighten all hose connection fittings and tighten the throat packing nuts on both pumps.

1. If heaters are used, turn them on. To adjust the heater temperature, refer to the Viscon HF or HP

manual for instructions, and the Heat Fluid section, page 31. Circulate as necessary.

2. Close the motor air pressure regulator (CB) and decrease to zero.

A B

CB

WLD

5. Remove tip. Disengage the trigger lock 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. Dispense out of the mix hose until a well mixed coating flows from the gun.

CB

WLD

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

AC

(closed)

TI1950a

AE

(open)

AD

WLD

32 3A4381G

Spray

6. Engage the trigger lock. Install the tip on the gun.

7. Adjust the main pump air regulator (CB) to the necessary spraying pressure and apply a coating to a test panel.

NOTE: Run System Verification tests everyday

(see page 41).

8. 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.

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

9. Follow Flush Mixed Material , page 35 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.

NOTE: Excess pressure increases overspray and pump wear.

3A4381G 33

B Component Adjustable Fluid Restrictor

B Component Adjustable Fluid Restrictor

The B side restrictor (AJ) reduces momentary “lead/lag” ratio imbalance of the A and B flow into the static mixer tubes 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.

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.

To Adjust the Restrictor:

Adjust the restrictor stem clockwise while spraying until you see a slight rise in the B side pressure gauge. The point where the pressure starts to rise is a good adjustment setting.

Unless you are dispensing directly out of the mix manifold and mixer, this is an approximate adjustment.

See the mix manifold manual 3A0590 for more information.

Restrictor

Stem

AJ

AB

34 3A4381G

Flush Mixed Material

Flush Mixed Material

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

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

• breaks in spraying

• overnight shutdown

• mixed material in system approaching end of potlife

Flush Mix Manifold, Hose, and

Spray Gun

If your system doesn’t include a solvent flush pump, see

Empty and Flush Entire System (new system or end of job) , page 37.

Turn off heaters. Allow heater and heated hoses to cool.

Follow the Pressure Relief Procedure

on page 27.

1. Close the motor air shutoff valve (CA) to turn off the pump air motor and reduce air pressure. Engage trigger lock. Remove the spray tip and soak in solvent.

CA

WLD


$(

3A4381G

3. Open the solvent pump air valve (DA). Slowly turn the solvent pump air regulator (DB) clockwise to increase air pressure.

WLD

DB

DA

AD

35

Flush Mixed Material

4. Open the solvent flush valve (AD)

5. Disengage the trigger lock, 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.

6. Close the solvent pump air valve (DA). Trigger the gun to relieve pressure. Close the solvent flush valve (AD) after relieving the pressure.

DA

AD

WLD

7. Follow Connect the resin and hardener hoses to the resin and hardener inlets on the mix manifold.

, page 25.

8. Engage the trigger lock. Disassemble and clean the spray tip with solvent by hand. Reinstall on the gun.

4)!

36 3A4381G

Empty and Flush Entire System (new system or end of job)

Empty and Flush Entire System

(new system or end of job)

• Anytime 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 flush solvent with light oil. Never leave the equipment empty of any fluid.

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

NOTE:

• If the system includes heaters and heated hose, turn them off and allow to cool before flushing. Do not turn on the heaters until the fluid lines are clear of solvent.

• Cover fluid containers and use the lowest possible pressure when flushing to avoid splashing.

• Before color change or shutdown for storage, circulate the solvent at a higher flow rate and for a longer time. Change the solvent when it gets dirty.

•

To only flush the fluid manifold, see Flush Mix Manifold, Hose, and Spray Gun , page 35.

• If the machine is inoperable, use drain plugs on the pump inlet fittings.

Guidelines

Flush new systems if the coating materials will be contaminated by mineral oil.

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

Empty System Procedure

1. Follow Prime Empty System

, page 28 and Flush

Mix Manifold, Hose, and Spray Gun , page 35, as

required.

2. Engage the trigger lock.

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

CB

TI1949a

WLD

3A4381G 37


4. Move the recirculation lines (U) to separate fluid containers to pump remaining fluid out of the system.

5. Lower to open the circulation handle (AC) and increase the motor air pressure regulator (CB) pressure to 20 psi (138 kPa, 1.38 bar).

&$

A

B

$&

U

WLD

&%

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

WLD

NOTE: If the system does not start with static pressure, increase the air pressure by 5 psi (35 kPa,

0.35 bar) increments. To avoid splashing, do not exceed 35 psi (241 kPa, 2.4 bar).

7. Run the pumps until the A and B hoppers (J) are empty. Salvage the material in separate, clean containers.

38 3A4381G

Flush System Procedure

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


6. Increase the motor air pressure regulator to dispense fresh solvent from the hoppers through the mix manifold valves and out the gun.

7. Turn off the air motor.


$(

WLD

CA

U

J

2. Wipe the hoppers (J) clean, then add solvent to each. Move the circulation lines (U) to waste containers and push out the dirty fluids.

3. Move the recirculation lines (U) back to the hoppers.

Continue recirculating until the system is thoroughly flushed.

4. Lift to close the circulation handle (AC) and lower to open the dual shutoff handle (AE).

AC

(closed)

AE

(open)

WLD

5. Open the motor air shutoff valve. Increase the air regulator pressure to 20 psi (1.9 bar).

9. Remove pump fluid filters, if installed, and soak in solvent. Clean and replace the filter cap. Always replace the filter o-rings. See Xtreme pump manual

311762.

10. Fill the A and B pump packing nuts with TSL. Also, always leave some type of fluid, such as solvent or oil, in the system to prevent scale build up. This build up can flake off later. Do not use water.

NOTE:

• If machine is set up with a remote mix manifold, the

A and B hose can be disconnected from the mix manifold, and secured back to each hopper for circulation of flush solvent.

• Change the flush solvent at least once until it circulates clean.

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

3A4381G 39

Park

Park

1. Lower to open the circulation handle (AC) and adjust the air regulator (CB) so that the pump runs slowly.

&$ A

B

Shutdown

1. Flush mix manifold, hoses, and gun. See Flush Mix

Manifold, Hose, and Spray Gun , page 35.

2. Close the main air shutoff valve (CA).

CA

$&

&%

WLD

2. Lift to close the circulation handle (AC) when the pump is at the bottom of the stroke.

WLD

3. Close solvent air valve and turn solvent air regulator fully counterclockwise. Trigger gun to relieve any residual pressure.

AC

0

STOP

WLD

3. Close the motor air valve (CA) and turn the air regulator (CB) counterclockwise. Lower to open the circulation handle (AC).

&$

WLD

4. Close solvent fluid valve and lower re-circulation handle (AC).

$&

$&

WLD

&%

WLD

40 3A4381G

System Verification

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. See

Pump Troubleshooting on page 44.

If one gauge drops, the others will rise.

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

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

Mix and Integration Tests

Use the following tests to check for proper mix and 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.

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.

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.

3A4381G 41

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 lower manual for instructions.

• Spray gun handle filter; see spray gun manual.

4. Flush mixed material. See

Flush Mixed Material

,

page 35.

5. Perform the Pressure Relief Procedure on page

27.

6. Perform Park and Shutdown

procedures, page 40.

Turn off all power.

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

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

Seals

Once a week, check and tighten throat seals on both pumps. See table for torque specifications. Be sure to follow the Pressure Relief Procedure

on page 27, 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 21.

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.

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 Varying Parts table on page 62 for the correct pump sizes.

2. Remove and replace pump. See Remove Displacement Pump page 45.

3. Adjust the position of the air motor. See Motor

Position

page 23.

4.

If changing from one type of XP-hf system to another (for example - changing from XP50-hf to

XP70-hf or from XP70-hf to XP50-hf): Remove the existing over pressure relief valves (302) and install the correct valves for the new system type. See

Replace Over Pressure Relief Valves on page 48.

5. Change the air pressure relief valve (CG) as required, depending on the ratio.

42 3A4381G

Troubleshooting

Troubleshooting

 Fluid ratio will be wrong.

 Purge all air from system before proportioning fluids.

System stops or will not start.

System speeds up or runs erratically.

upstroke.

Problem

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.

Pressure and flow surges on



Cause

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.

Resin output restriction.

Fluid supply low.



Fluid leak under packing nut

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

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

Loose packing nut or worn throat packings.

Packing cartridge o-ring.

Relief valve is dirty or damaged.

Overpressure rupture disk blown.

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.

Open.

Replace.

Air motor worn or damaged.

Displacement pump stuck.

Fluid containers are empty.



Air in fluid lines.



Repair air motor; see 311238.

Repair pump; see 311762.

Check often; keep filled.

Purge; check connections.

Repair pump; see 311762.

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.

Clean, repair pump; see 311762.


Fluid supply low.



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

Dirty, worn, or damaged hardener pump intake valve.

Clean, unplug hardener side. Open manifold restrictor.

Refill or change container.



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

Clean, unplug resin side.

Refill or change container.

Tighten; replace; see 311762.

Replace o-ring; see 311762

Replace over pressure relief valve (302)

Determine cause of overpressurization and correct. Replace rupture disk assembly 258962 (see page 62) and over pressure relief valve (302).

Reduce feed pressure. See Dimensions , page 75.

3A4381G 43

Troubleshooting

Problem

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

Cause Solution

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.

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

TROUBLE AREA:

Hardener Pump Leakage

1. Throat packing

2. Piston packing

3. Piston ball check

2. Piston packing

3. Piston ball check

Resin

Pump

Hardener

Pump

Resin

Pump

Hardener

Pump

TROUBLE AREA:

Resin Pump Leakage

1. Throat packing

2. Intake ball check

Falling Rising r_258914_3a0420a_11a

Rising

TROUBLE AREA:

Hardener Pump Leakage

1. Throat packing

2. Intake ball check

Falling r_258914_3a0420a_11a

Resin

Pump

Hardener

Pump

Resin

Pump

Hardener

Pump

Falling Rising r_258914_3a0420a_10a

Rising Falling r_258914_3a0420a_10a

44 3A4381G

Repair

Repair

Follow the Shutdown

procedure on page 40, which

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

3. If feed pumps are installed, close the inlet ball valve.

Remove inlet union (61).

4. Remove the spring clamp (130) and coupling (119 or 120).

Pump Assembly

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.

Remove Pump Assembly

1. Stop the pumps near the bottom of their stroke. Fol-

low the Park procedure and

Shutdown procedure

on page 40.

2. Disconnect all hoses from the pump assembly.

3. If hoppers are installed, disconnect the hopper fluid lines from the pump fluid inlet. See

Hoppers

, page

50.

NOTE: The hopper and hopper bracket do not need to be removed from the cart.

4. Remove screws (6) and washers (5) under the tie plate (101).

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

Remove Displacement Pump

1. Follow the

Park

procedure and Shutdown proce-

dure on page 40.

2. If hoppers are installed, remove the hopper and

hopper bracket from the cart. See Hoppers , page

50.

135

117

130

119

106

105

118

108

WLD

5. Use a wrench to hold the tie rod (105, 106) flats to keep the rods from turning. Unscrew the nuts (108) from the tie rods and carefully remove the displacement pump (117 or 118) and lower straps (135).

6. Refer to the Xtreme Displacement Pump manual to service or repair the displacement pump.

7. Follow the steps in reverse order to reinstall the displacement pump.

NOTE: Torque nuts (108) to 95-105 ft-lb (129-142 N•m).

3A4381G 45

Repair

Remove Motor

1. Follow the Park procedure and

Shutdown proce-

dure on page 40.

2. Disconnect the air line from the air motor.

3. Remove the air motor rod cover (121) and pump guards (122).

121

122

WLD

4. Use a wrench to hold the tie rod (102) flats to keep the rods from turning. Unscrew the nuts (108) from the tie rods.

WLD

102

MS

108

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

Loosen coupling nut (109).

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.

8. Follow the steps in reverse order to reinstall the air motor.

NOTE: Position air motor for correct mix ratio. See

Motor Position on page 23 for instructions. Torque nuts

(108) to 95-105 ft-lb (129-142 N•m). Torque the coupling nut (109) to 230-250 ft-lb (312-339 N•m).

Air Controls

See F IG . 1 on page 47.

Replace Air Filter Assembly

1. Close the main air shutoff valve on the air supply line and on the system. Depressurize the air line.

2. Loosen screws (715) and disconnect the air hose.

3. Remove the nuts (89) and screws (14). Remove the air filter assembly (96) from the cart. See F IG . 1 on page 47.

4. Follow the steps in reverse order to reinstall the new air control assembly.

Replace Air Filter Element

1. Close the main air shutoff valve on the air supply line and on the system. Depressurize the air line.

2. Unscrew the filter bowl (710).

3. Remove and replace the filter element (210a). See


, page 73.

Replace System Air Regulator Assembly

1. Close the main air shutoff valve on the air supply line and on the system.

2. Loosen the screws (715) and disconnect air hoses.

3. Remove the regulator assembly (95) and replace with new regulator. See F IG . 1 on page 47.

4. Follow the steps in reverse order to reassemble.

46 3A4381G

Repair

Air Control Assembly

95

96

87

14

97

86

715

F IG . 1: Air Control Assembly

89

3A4381G

WLD

47

Repair

Mix Manifold Assembly


Shutdown proce-

dure on page 40.

2. Disconnect the fluid hose (25) and the flush hose from the mix manifold (36).

3. Loosen the union fittings (306) that connect to the mix manifold adapter fittings.

4. Remove the mix manifold assembly (36).

5. See mix manifold manual for service and repair instructions.

5. Remove the two screws (37) and fluid circulation manifold (35) from the cart (1).

1

35

37

36

306 r_571101_3a0420a_38a

Fluid Circulation Manifold with

Over Pressure Relief Valves


Shutdown proce-

dure on page 40.

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

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

fluid circulation manifold. See Mix Manifold

Assembly for instructions.

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

(35) to the cart (1).

r_571101_3a0420a_39a

Replace Over Pressure Relief Valves

1. Follow the

Park

procedure and Shutdown proce-

dure on page 40.

2. Ensure handle (312) is in the down position.

Remove the screws (313), jam nut (304), handles

(311), handle rod (312), clips (318), and springs (320).

311

313

312

302

311

302

313

304

318

320

302

304

320

318 r_258988_3a0420a_2b

3. Unscrew both over pressure relief valves (302) from the manifold.

NOTE: The correct over pressure relief valve must be used on all systems. Choose the correct color coded valve from the chart on page 49.

4. Apply blue threadlock to new over pressure relief valves (302) and install in the manifold. Torque to

28-32 ft-lb (38-43 N•m).

5. Place a spring (320) over each valve stem. Place a clip (318) in each valve stem groove to retain the springs.

48 3A4381G

Repair

6. Slide handle (311) 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 (311) on valve stem (302) at the vertical, or near vertical, position.

8. Apply blue threadlock on the nut (304) threads and tighten the handle against the spring (320) and clip (318). Torque to 70-80 in-lb (7.9-9 N•m).

9. Place the rod (312) and the second handle (311) on second valve stem aligned with the opposite handle.

10. Repeat step 9.

Fluid Circulation Manifold Replacement Guide

11. Install two screws (313) in handles (311).

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.

Colored Valve Sleeve ti19169a ti19168a

Circulation

Manifold (35)

Part No.

262783

262806

Relief

Valve (302)

Part No.

262809

262520

Valve Sleeve

Color

Gold

Silver

Target Opening


7100 (49, 490)

9250 (64, 638)

Use with:

All XP50-hf models

All XP70-hf models

3A4381G 49

Repair

Hoppers

1. If material is in the hopper pump out the remaining material.

2. If the pump has failed: a. Place a waste container beneath the plug on fitting (61). Remove the plug.

b. Drain all material from hopper into the waste container.

c. Install plug after material is no longer draining from fitting (61).

6. Lift the hopper off of the mounting bracket.

7. Repeat for second hopper.

Solvent Pump

1. Follow the Pressure Relief Procedure

on page 27.

2. Disconnect the fluid line and air lines from the solvent pump.

3. Loosen the four screws that attach the solvent pump to the cart (1). Lift and pull pump from the slots.

1 plug 61

3. Follow the Pressure Relief Procedure

on page 27.

4. Loosen fitting (61) and disconnect hopper from pump.

5. Remove the recirculation line from the hopper and place in a waste container.

screw

4. Refer to the Merkur Pump Assembly manual to service or repair the solvent pump.

5. Follow the steps in reverse order to reinstall the solvent pump.

U r_571101_3a0420a_18a

50 3A4381G

Repair

Fluid Heaters

Service and Repair

1. Follow

Pressure Relief Procedure , page 27.

2. Disconnect the fluid lines and electrical wiring from the fluid heater (F).

3. Refer to the Viscon HF heater manual to service or repair.

4. Reconnect the fluid lines and electrical wiring.

Replace

1. Follow steps 1 through 2 in the Fluid Heaters Service and Repair section.

2. Loosen the four mounting screws, lock washers, and plain washers on back of the heater. Slide the heater up and remove from the cart.

3. Replace the heater. Follow the steps in reverse order to install a new heater.

F

3A4381G

WLD

51

Parts

Parts

Complete System (572107 shown)

TSL

52

A

B

A B

WLE

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

3A4381G

Complete System (continued)

Parts

3A4381G

WLE

53

Parts


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.

54

WLE

3A4381G


Parts

WLE

3A4381G 55

Parts


56

WLD

3A4381G

Parts

Parts Common to All Systems

10

Ref. Part Description

3

5

1

2

6

7

8

9

154628

113436

10 124410

11

258913 CART, weldment, painted

16E105 AXLE

111841

100133

100101

113362

WASHER, plain 5/8

WASHER, lock, 3/8

SCREW, cap, hex hd

(3/8-16 x 1 in. lg)

WHEEL, semi-pneumatic

124664

WASHER

RING, retaining

BEARING, sleeve, 1.00 x 1.25 x

1.5

WASHER

12 15A913 AXLE

13 191824 WASHER, space

14 113807

15 258982

WHEEL, flat free, urethane

HANDLE, cart, painted

16 101242

18 100131

RING, retaining, ext.

NUT, full hex

19 16F206 LABEL, XP70, handles

20 512519 MIXER, 1/2-12 element

21 111218

22 158491

CAP, tube, square

FITTING, nipple

23 15M987 FITTING, elbow, 60 deg

24 H75003 HOSE, cpld, 7250 psi, .50 ID, 3 ft

26 15B729 COUPLING

27 15E592 HOUSING, mixer

28 248927 KIT, mixer element, 25 pack

Qty.

1

1

2

6

4

2

2

2

1

1

3

2

2

1

4

4

1

3

2

2

2

1

2

1

4


29 150287 COUPLING, pipe, 1/4 x 3/8

32 162024 COUPLING

36 262807 MANIFOLD, mix, 1/2 valves

37 106212 SCREW, cap, hex hd

38 116139 GRIP, handle

41 158683 FITTING, elbow, 90 deg

43 16G819 TOOL, wrench, Xtreme, filter

47 206995 FLUID, TSL, 1 qt.

48 101566 NUT, lock

49 15U654 LABEL, identification, A/B

50 555357 SCREW, hh st 1/4 x .500 zn

51 16F536 LABEL, arrow

52 124293 BOLT, u-bolt, 3/8-16, 1.00 dia

53 124259 BRAKE, plunger clamp

54 124291 PIN, spring

55  16F359 LABEL, warning, fire/expl hazard

58 16F615 TOOL, wrench, Xtreme

71 15B772 HOSE, air, 18 in.

80 112395 SCREW, cap, flng hd

89 112958 NUT, hex, flanged

93 17N936 MONITOR, PressureTrak, XPhf

94 17N487 HOSE, coupled, 1 in. NPT

95 17N503 MODULE, air controls, regulator

96 17N504 MODULE, air controls, filter

98 126786 TOOL, restrictor

99 3A5076 DOCUMENT, guide, quick start

112 113974 SCREW, thrd forming (10-24)

1

2

2

2

1

1

2

1

1

1

1

1

1

1

4

2

2

1

1

1

Qty.

1

2

2

2

1

2

 Replacement Danger and Warning labels, tags, and cards are available at no cost.

3A4381G 57

Parts

Parts Varying by System Pressure Ratio (third digit) and Mix Ratio (fourth and fifth digit)

Quantity (By System)

70:1 50:1

No

Lowers

Ref.

Part Description

4 572100 PUMP, bf, 145/145, 1:1, XP

572150 PUMP, bf, 145/90, 1.5:1, XP

572200 PUMP, bf, 180/90, 2:1, XP

572250 PUMP, bf, 180/72, 2.5:1, XP

572300 PUMP, bf, 220/72, 3:1, XP

572400 PUMP, bf, 220/54, 4:1, XP

573100 PUMP, bf, 220/220, 1:1, XP

573150 PUMP, bf, 220/145, 5:1, XP

573200 PUMP, bf, 290/145, 2:1, XP

573250 PUMP, bf, 290/115, 2.5:1, XP

573300 PUMP, bf, 290/97, 3:1, XP

573400 PUMP, bf, 290/72, 4:1, XP

273097 PUMP, XP-hf, no lowers


H53825 HOSE, cpld, 5600 psi, .375 ID, 25 ft



31 XTR702 GUN, XTR7, ovl hnd, 4 fng, XHDRAC

XTR502 GUN, XTR5, ovl hnd, 4 fng, XHDRAC

35 262806 MANIFOLD, recirc, XP70

262783 MANIFOLD, recirc, XP50

56 113498 VALVE, safety, 110 psi

16M190 VALVE, safety, 95 psi

114055 VALVE, safety, 105 psi

103347 VALVE, safety, 100 psi

100 H52510 HOSE, cpld, 5600 psi, .25 ID x 10 ft

* See Parts Varying by Component (sixth digit)

on page 59.

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 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 1 1

1 1 1

1

1 1 1

1 1

* * * * * * * * * * * * 2

1

1

1

1

3

1

1

58 3A4381G

Parts

Parts Varying by Components (sixth digit)

Quantity (By System)

Ref.



61

64

79


59 262479 HOPPER, blue, packaged

60 262480 HOPPER, green, packaged

16D376 FITTING, swivel, 1-1/4, mod, with plug

62 24E872 BRACKET, hopper, painted

63 124450 CLAMP, spring, constant tension

15V421 TUBE, recirculation

65 116704 ADAPTER, 9/16 JIC x 1/4 npt

66



15T468 LABEL, warning

67 111192 SCREW, cap flange hd

68 24F126 MODULE, air controls, solvent

69 262392 PUMP, solvent, 6.0 in., 50 cc, std

70 061132 HOSE, nylon

72 16F537 HOSE, coupled, 6 ft, 1/4 npsm, 5/16

73 205447 COUPLING, hose


76 104984 FITTING, tee, pipe

77 156971 FITTING, nipple, short

78 214037 VALVE, ball

25C962 HEATER, hf, haz, tstat, XP

25C961 HEATER, XPhf, non-haz, tstat

81 273096 ENCLOSURE

82 17P846 BRACKET, painted, junction box

83 273093 PUMP, XPhf, htd-hose, re-circ

84 17P092 PLATE, XPhf, re-circ, painted

85 110755 WASHER, plain

86 100016 WASHER, lock

87 104429 SCREW, cap hex hd

88

273094 HEATER, hose, hazardous locations

273095 HEATER, hose, non-hazardous locations

93 17N936 MONITOR, PressureTrak, XPhf

100

101



H75003 HOSE, (lower to man/htr)

H75004 HOSE, (htr to manifold)

102 248208 HOSE, cpld, 4 ft.

103 17N598 HARNESS, SW3 to fluid A

104 17N599 HARNESS, SW4 to fluid B

105 113796 SCREW, flanged, hex hd

106 115942 NUT, hex, flange head

108 16E791 STRAINER, hopper, 7 gallon

109 17P594 FITTING, assy, hose coupler, split

110 17S051 FITTING, assy, hose nipple, split

111 24Z934 HEATER BLOCK, remote manifold

112 113974 SCREW, thrd forming (10-24)

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

1

1

1 1 1 1

1 1 1 1

1

3 1 3 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

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 1 1

2 6 2 6 6 6 6 2 6 2 6 6 6 6

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 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 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 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

1

1

1 1 1 1

1 1 1 1

2 2 2 2 2 6 6 2 2 2 2 2 6 6

1

1

2 2 2 2 2 6 6 2 2 2 2 2 6 6

2 2 2 2 2 6 6 2 2 2 2 2 6 6

1

1

1 1

1

1

1 1

2 2

2 2 2 2 2 2 2 2 2 2

2 2 2 2 2 2 2 2 2 2 2 2 2 2

2 2 2 2 2

1 1 1 1 1

1

1

1

1

2

1

2

1

2

1

1

1

2

1

2

1

1

1

8

2

8

2

2 2

1 1

1 1

1 1

1 1

8

2

2 2

1 1

1 1

1 1

1 1

8

2


3A4381G 59

Parts

Bare Proportioning Pump Package

Model 572100 shown

E

D

F

E

G

D

WLE

60

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 motor, then use to install cable.

12

13

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

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

3A4381G

Parts

Parts Common to All Pump Packages

107

108

109

110

111

112

113

116

Ref.

101

102

103

104

105

106


273087 PLATE, XP-HF, motor

273086 ROD, tie, 4.00 long, 1.00 dia

273088 MOTOR, air, 13 in., XP-HF

273085 ROD, connecting, yoke, XP-HF

262468 ROD, tie, 14.25 in. long, w/shoulder

262469 ROD, tie, 14.25 in. long, 1.25 dia

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

101712 NUT, lock

626264 NUT, coupling

17R501 BRACKET, ratio indicator

273090 YOKE, pump, assembly, HF

273091 ROD, adapter, Xtreme, HF

262472 SLEEVE, bearing

123976 RING, snap, external

121+ - - - - BRACKET, painted, finger guard

121a+ - - - - - PLATE, painted, finger guard

121b+ 16P338 SCREW, mach, serrated hex head

122# - - - - - COVER, XP-HF, pump

122a# 121803 SCREW, cap, button head

122b# 124172 WASHER, retaining, nylon, 10-32

122c# 124665 NUT, captive, 10-32

122d#  15T468 LABEL, warning

130 124078 CLAMP, spring, constant tension

131  15H108 LABEL, safety, warning, pinch

132

134

135

140

111192 SCREW, cap flange hd

184130 COLLAR, coupling

16E882 STRAP, lowers

244524 WIRE, ground assembly w/ clamp



Replacement Danger and Warning labels, tags, and cards are available at no cost.

+ Included in Motor Cover Kit 273089.

# Included in Pump Cover Kit 273092.

2

2

1

2

1

1

3

6

Qty.

1

3

4

2

1

1

4

2

8

8

2

2

2

1

1

1

2

2

2

1

3A4381G 61

Parts

Parts Varying by System by Pressure Ratio (third digit) and Mix Ratio (fourth and fifth digit)

70:1

Quantity (By Pump Package)

50:1

Ref.

Part

117

118

119

120

129

L14AC0

Description

PUMP, lower, 145 cc

L18AC0 PUMP, lower, 180 cc


L22XC0 PUMP, lower, 220 cc


L054C0 PUMP, lower, 54 cc







244819

247167

COUPLING, for 145-290 cc lower

COUPLING, for 54-115 cc lower

17N281 LABEL, branding, XP70-hf

17N282 LABEL, branding, XP50-hf

No

Lowers

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

1 1 1 1 1 1

1 1

1

2 1 1 1 1 1 2 2 2 1 1 1

1 1 1

1 1

1 1 1 1 1 1 1 1

62 3A4381G

Heated Hose Recirculation Pump

273093

Parts

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.

WLE

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.

Mounted Heated Hose Parts List


301 108126 FITTING, tee, street

302 126897 FITTING, elbow, 1/2 tube x 1/4

NPTM

303 126898 FITTING, elbow, 1/2 tube x 1/2

NPTM

304 126899 FITTING, 1/2 tube x 1/2 NPTM

305 16D939 FITTING, nipple, reducing

306 16R871 BOTTLE, overflow, 1/2 NPT

307 17P088 BRACKET, XP-HF, re-circ, painted

308 206264 VALVE, needle

Qty.

1

2

1

1

1

1

1

1


309 24P835 PUMP, acetal, w/pvdf check,

Husky

310 113161 SCREW, flange, hex hd

311 17N910 TUBE, 35 in. x .5 OD, nylon

312 17N911 TUBE, blue, .5 OD, nylon

(48 in. long)


315 17D307 FITTING, nipple, quick coupling

318 17N795 WIRE, ground

Qty.

1

1

1

1

2

2

1

3A4381G 63

Parts

Hose Heater (bracket mounted)

273095 (Non-Hazardous Locations)

273094 (Hazardous Locations)

F

E

D

5('

LQFP

WLF

3 Orient fittings as shown.

4 Tighten cord grip .75 in. back from cord cover end.

5 Orient the port facing down.

410

BLACK BLACK

GREEN

WHITE

410

BLACK

64

WLD

3A4381G

Mounted Heated Hose Parts List


401 245869 HEATER, paint, non-hazardous locations

245863 HEATER, paint, hazardous locations

402 24N445 BRACKET, heater, heated hose, paint

403 126898 FITTING, elbow, 1/2 tube x 1/2 NPTM

404 126896 FITTING, elbow, 1/2 tube x 1/2 NPTF

405 17P759 TUBE, 48 in. x .5 OD, nylon


407 17D306 FITTING, coupler, quick coupling

408 17N600 HARNESS, sw5 to hose heat

409 116171 BUSHING, strain relief

410 122032 NUT, wire

411 166590 FITTING, elbow, street

413 123443 SCREW, cap, flng hd

414 24N447 BRACKET, base, heated hose, painted

415 113981 NUT, lock, high tensile

416 185065 ADAPTER, cable

Qty. (273095) Qty. (273094)

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

4

1

4

1

4

1

4

1


Parts

3A4381G 65

Parts

Enclosure Junction Box

Kit 273096*

1 Torque to 20-23 in-lb (2.2-2.6 N•m).

2 Torque to 55-60 in-lb (6.2-6.8 N•m).

3 Torque to 13-15 in-lb (1.5-1.8 N•m).

4 Torque to 25-28 in-lb (2.8-3.2 N•m).

5 Torque to 18-20 in-lb (2.0-2.3 N•m).

6 Torque to 10-12 in-lb (1.1-1.3 N•m).

8 Assemble with washer under ground wire.


WLD

[

66

WLE

3A4381G

Enclosure Junction Box (continued)

Module 17N687

CB01 CB02 CB03 CB04 CB05 CB06

;I

;H

;J

WLD

D

Module 17N688

D F F E G

E

F

Parts

WLD

D

3A4381G 67

Parts

Enclosure Junction Box Parts List


82* 17P846 BRACKET, painted (not shown)

105* 113796 SCREW, 1/4-20 x .75 L

(not shown)

106* 115942 NUT, flg hd, 1/4-20 (not shown)

501 - - - - - ENCLOSURE, XP, electrical

502 123967 KNOB, operator disconnect

503 123968 SWITCH, disconnect, ph exp 100 amp

504 123969 SWITCH, disconnect, 100a (E-30)

505 15U423 SWITCH, 2P, 25A

506 17N687 MODULE, din rail assy, circuit brk

506a 17A311 CIRCUIT BREAKER, 2P, 10A,

UL489

506b 17N315 CIRCUIT BREAKER, 2P, 25A,

UL489

506c 17N316 CIRCUIT, BREAKER, 2P, 30A,

UL489

506d 17C190 CIRCUIT BREAKER, 2P, 1A,

UL489

506e 17N690 BAR, power bus, 2P, 6 pin

506f 17N691 CONNECTOR, terminal, buss bar

506g 120838 BLOCK, clamp ends

507 17N688 MODULE, din rail assy, term blks

507a 120570 MODULE, din rail assembly, terminal blocks

507b 120490 COVER, end

507c 126811 BLOCK, clamp ends

507d 120573 BRIDGE, plug in, jumper


509 120858 BUSHING, strain relief, M40 thread

Qty.

1

8

1

2

1

2

1

1

1

1

5

1

2

2

1

2

4

5

1

2

2

2

1

Ref. Part Description Qty.

510 120859 NUT, strain relief, M40 thread

511 15U544 PLUG, hole, 1 1/8 in.

512 117666 TERMINAL, ground


514 109466 NUT, lock, hex

515 112948 SCREW, mach

516 122313 BAR, ground, kit

517 113783 SCREW, machine, pn hd

518 113505 NUT, keps, hex hd

521  196548 LABEL, warning, shock

524 17N590 HARNESS, term block to circuit bkr

525 17N592 HARNESS, circuit brkr to sw1, sw2 1

526 17N593 HARNESS, circuit brkr sw3, sw4, sw5

1

527 17N720 HARNESS, disconnect to term block

528 17N595 WIRE, ground, door to enclosure

1

1

529 17N594 WIRE, ground, gnd1 to gnd2

530 17N601 HARNESS, circuit brkr-press montr

1

1


535 555629 WASHER, #10 lock external

536 558685 WASHER, 1/4 external tooth lock

537  15F674 LABEL, safety

1

1

1

2

1

1

1

3

1

3

1

1

1

1

4

* Kit includes these loose parts.


68 3A4381G

Parts

Heater Wiring Diagram

SW5

Hose

Heater

2

3

4

SW4

Fluid

Heater B

2

3

4

SW2

Hopper

Heater B

2

3

4

SW3

Fluid

3

Heater A

2 4

SW1

Hopper

3

Heater A

2 4

Black White

Green

White

HOPPER HEATER A

Black White

White

Green

White

HOPPER HEATER B

ACCESSORIES

White

3A4381G

Black Black

Green

White

HOSE HEATER

Black Black

White

Black Black

Green

White

FLUID HEATER A

White

Green

White

FLUID HEATER B

White

69

Parts

Heater Block Remote Manifold Kit

Kit 24Z934

[

WLD

[

[ [

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


601 24F834 CARRIAGE, weldment, remote manifold

602 16T294 PLATE, heater transfer, PFP 2k

603 110837 SCREW, flange, hex


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, .375 (9.5 mm) ID (1.5 ft)

612* 054961 TUBE, blue, nylon, .375 (9.5 mm) ID (1.5 ft)

* Supplied loose, not installed.


Qty.

1

2

2

2

2

2

1

1

2

1

1

2 Supplied loose, not installed.

70 3A4381G

Parts

Air Controls

1 p/n ###

WLE

Ref.

702

703

704

705

706

707

708

709

710

711

712

713

714

1


116648 FITTING, swivel, 1 in. m x f

17N485 FITTING, tee, 1 x1 x 1 NPT(F), cs, 2.2k

158555 FITTING, nipple, 1 x 3/4 NPT

15E145 MANIFOLD, air distribution

100505 BUSHING, pipe

157350 ADAPTER

115781 CAP PLUG

17N486 FITTING, elbow, 1 in. NPT

17N462 FILTER, air, 1 in. NPT

113163 VALVE, ball, vented

127784 COUPLING, universal, 1 in. NPTM

127785 COUPLING, universal, 1 in. NPTF

16W586 CABLE, lanyard, whip check

Qty.

2

1

1

1

4

2

1

4

1

1

1

1

1

803

804

805

806

807

808

809

810

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

2 Mount with air flow arrows in the direction shown.

3 Assemble with air flow arrows in the direction shown.

4 Assemble plug supplied with air regulator (5).

Ref.

715

716

717

718

802


113161 SCREW, flange, hex hd

16P338 SCREW, mach, serrated hex head

17N988 BRACKET, XP-HF, filter, mount

17N987 BRACKET, XP-HF, filter

127945 FITTING, swivel, 45 deg, 1 NPT x 1

NPSM

113163 VALVE, ball, vented

17S719 FITTING, nipple, 3.0 in.

17N463 REGULATOR, air, 1 in. NPT

108638 FITTING, pipe, tee

100960 GAUGE, press air

116648 FITTING, swivel, 1 in. m x f

16P338 SCREW, mach, serrated hex head

17N985 BRACKET, XP-HF, reg

Qty.

1

1

2

4

1

4

1

1

1

1

1

1

1

3A4381G 71

Recommended Spare Parts

Recommended Spare Parts

Keep these spare parts on hand to reduce downtime.

Pump Repair Kits

See Models

(page 11) 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

Recirculation/Overpressure Valve

(see page 49)

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.

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)

XHDxxx, Spray Tips

See spray gun manual for tips.

72 3A4381G

Accessories and Kits


Acceptable For Use in

Explosive Atmospheres

PressureTrak

™

Kit, 17N936

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

Blue 7 Gallon Hopper Kit, 24F376

Green 7 Gallon Hopper Kit, 24F377

Mount to the sides of the XP-hf system. See manual

406860 for more information.

Solvent Pump Kit, 262393

For supplying solvent to the mix manifold. See manual

310863 for more information.

Desiccant Dryer Kit, 262454

For use with polyurethane isocyanates in 7 gallon hoppers. See manual 406739 for more information.

Desiccant Dryer Filter 2 Pack, 24K984

Heater Adapter Kit

Hose and fittings for connecting Viscon HP heaters to

XP-hf system.

See manual 406861 for parts. Purchase heaters separately, see heater manual for part numbers.

Twistork

®

Agitator Kit, 256274

For mixing viscous materials held within a 55 gallon drum. See manual 312769 for more information.

5:1 Feed Pump Kit, 256276

For supplying viscous materials from a drum to XP-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.

20 Gallon Hopper Kit, 255963

Floor Stand for 20 Gal. Hopper, 262824

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

XP Wall Mount Bracket, 262812

Works with air 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.

3A4381G 73

Accessories and Kits

Not Approved For

Explosive Atmospheres

These kits do not carry the EX mark.

2:1 Feed Pump Kit, 256275

For supplying viscous materials from a drum to XP-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, 25C008

Air Turbine Powered Pressure Monitor Kit, 25C009

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

74 3A4381G

Dimensions

Top View

LQ

PP

Side View

LQ

PP

LQ

PP

LQ

PP

Dimensions

WLD

3A4381G 75

Dimensions

Floor Mounting Dimensions, Top View

32 in.

(812.8 mm)

22 in.

(558.8 mm)

6.75 in.

(171.45 mm)

15.25 in.

(387.35 mm)

40 in.

(1016 mm)

16.90 in.

(429.26 mm)

76 3A4381G

Dimensions

Bare Proportioner Mounting Hole Dimensions

The dimensions below is the minimum opening size for mounting a bare proportioner.

LQ

PP

LQ

PP

LQ

PP

[

PP

LQ

PP LQ

PP

LQ

PP

LQ

PP

LQ

PP

LQ

PP

LQ

PP

LQ

PP LQ

PP LQ

PP

LQ

PP

LQ

PP

LQ

PP

9.64 in

(244.86 mm)

LQ

PP

WLD

3A4381G 77

Dimensions

Wall Mount Bracket 262812 Dimensions

LQ

PP

LQ

PP ti19046c

LQ

PP

78 3A4381G

Floor Stand 24M281 Dimensions

21.2 in.

(538 mm)

17.8 in.

(451 mm)

Dimensions

30.3 in.

(770 mm)

32.7 in.

(829 mm) ti19047a

3A4381G 79

Technical Data

Technical Data

XP-hf Proportioners

Maximum Fluid Working Pressure

Combined Fluid Output (cc/cycle)

Pressure Ratio

Fluid Flow at 20 cpm

Fluid pump inlets without hoppers

Fluid gauge manifold outlets

Fluid mix manifold inlets

Mix manifold material outlet

Air Inlet Size

Sound Data

Maximum feed pressure from remote source

Maximum Storage Time

Air consumption per 1 gallon (3.78 l) of flow

XP70

XP50

Air supply pressure range

Electrical Specifications:

Configurable Voltage / Phase / Hz

Full Load Amps

Filtration:

Air inlet filtration

XP pump outlets

XTR Spray Gun

Fluid Viscosity Range:

Gravity feed with 7 gallon (26 liter) hoppers

Pressure feed

Ambient Temperature Range:

Operating

Storage

Maximum Fluid Temperature

Wetted materials:

Housings and manifolds

Miscellaneous parts

Pump packings

Flush pump suction tube

Hoses

U.S.

Metric

See Models section beginning on page 11.




1-1/4 in. npsm(m)

1/2 in. npt(f)

1/2 in. npt(f) ball valves

1/2 in. npt(f)

1 in. npsm(m)

See XL 10,000 Air Motor manual for sound data

250 psi 1.7 MPa, 17 bar

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

75 scfm at 100 psi/gpm

60 scfm at 100 psi/gpm

30-100 psi

2.12 m

1.7 m

3 /min at 7 bar, 0.7 MPa

3

/min at 7 bar, 0.7 MPa

0.2-0.27 MPA, 2.0-6.7 bar

See Connect Power

on page 21

See Power Cord Requirements

on page 22

40-micron filter/separator included

30 mesh

60 mesh

200 to 20,000 cps (pourable)

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

40-130° F

30-160° F

160° F

4-54° C

-1-71° C

71° C

Carbon steel with electroless nickel plating

Plated carbon steel, stainless steels, carbide, acetal,

UHMWPE, nylon, PTFE solvent resistant plastics

Carbon filled PTFE, proprietary UHMWPE

Aluminum

Nylon core

80 3A4381G

Weight:

Bare XP-hf Pump Package only (xxxxx0)

Cart Unit (xxxxx1)

Cart Unit with Hoppers (xxxxx2)

Cart Unit with Solvent Pump,

A/B Hazardous Location Heaters (xxxxx3)

Cart Unit with Hoppers, Solvent Pump,

A/B Hazardous Location Heaters (xxxxx4)

Cart Unit with Hoppers, Solvent Pump,

A/B Non-Hazardous Location Heaters, Junction Box

(xxxxx5)

Complete Unit with A/B/Hose Hazardous Location

Heaters,

Hose Circulation Pump, Pressure-Trak (xxxxx6)

Complete Unit with A/B/Hose Non-Hazardous Location Heaters,

Junction Box, Hose Circulation Pump, Pressure-Trak (xxxxx7)

320 lb

460 lb

485 lb

640 lb

665 lb

715 lb

735 lb

775 lb

145 kg

209 kg

220 kg

290 kg

302 kg

324 kg

333 kg

352 kg

Technical Data

3A4381G 81

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 3A4381

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

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

Copyright 2016, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revision G, November 2017

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