XP Plural Component Spray System Brochure

XP Plural Component Spray System Brochure
Turn-key Plural Component
Spray Solutions
Custom Packages to Spray High Solids, Quick-Setting Protective Coatings
Designed to Perform. Built to Last.
Engineered Customized Packages for the Latest Coating Technologies
Purchase pre-engineered packages from CJ Spray
and take the guess work out of configuring your
own solution.
Turn-key Solutions
CJ Spray has designed equipment packages to spray
hundreds of different coatings, including some of the most difficult to spray coatings in the world.
Work out of the box
Pre-assembled packages come configured with electrical
wiring and air/fluid plumbing already installed.
Reduce material and solvent waste
Properly configured equipment allows you to mix closer to
the tip, reducing mixed material and solvent waste.
Simplified operation and training
Centralized control panels with well-labeled knobs and
switches simplifies operation.
Minimize human error
Easier operation means less mistakes. Optional warnings
and alarms will shut down the machine if problems occur.
Applications
Infrastructure
• Water towers
• Wastewater facilities
Oil and Gas
• Tank storage facilities
• Pipelines
• Fireproofing
• Off-shore
• Gas processing and LNG
• Secondary Containment
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Transportation
• Railcar
• Shipping
• Marine
Building and
Construction
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Roof Coatings
Structural Steel
Rust Proofing
Floor Coatings
Waterproofing
Air Vapor Barrier
Roadways
• Bridges
• Highways
• Manhole and Sewer
Production and
Manufacturing
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Heavy Equipment
Steel Structure
Walkway and Mezzanine
Tank/Container
Pipe
Utilities and Power
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Electrical Utilities
Nuclear
Wind
Coal
Mining
• Extraction
• Processing
• Infrastructure
Features and Benefits of Graco XP Proportioning Technology
Engineered Specifically for Two-component Coatings
High-pressure to handle highviscosity coatings
•
Rated up to 7250 psi (500 bar, 50
MPa) to handle viscous materials
and long hose lengths
NXT Air Motor
•
Standard anti-icing feature means
production won’t stop due to motor icing
•
Modular design for easier maintenance
•
Rugged body armor won’t rust or dent
Compact cart-mounted
•
Designed for easy
handling by one person
•
Can be floor mounted
after removing wheels
•
Easy mounting of optional
flush pump and heaters
Outlet manifold and valves
•
Fluid pressure gauges to
monitor pump output
•
Provides automatic
overpressure relief
•
•
Material Hoppers
•
Includes circulation back
to the supply for pump
priming, purging, or
relieving outlet pressure
Side-mounted 7-gal
(26 liter) hoppers hold
A and B components
until it’s time to spray
•
Allows fluid warm-up
circulation when optional
heaters are used
Made of rugged
polyethylene —
unaffected by harsh
solvents
•
Optimized for direct
pump feed
Xtreme Pump lowers
•
Standard Severe Duty® coating
on rods and cylinder maximizes
wear life
•
Quick knockdown design and
throat seal cartridges provide
fast and easy maintenance
•
Multiple sizes available to
provide various fixed mix ratios
•
Easily change one or both
lowers to get desired mix ratio
Mix Manifold
•
Provides simple fluid control for mixing or flushing
•
Accurately dispenses A and B fluids to the static mix tube
•
Handles high-solids coatings with large ports and low pressure drop
•
Choose to use mix manifold remote to reduce solvent and material waste
Questions? Need advice? Call CJ Spray toll-free today! 1-888-CJSPRAY (1-888-257-7729)
2
Features and Benefits of CJ Spray XP Systems
Engineered Specifically for Two-component Coatings
Master Electrical Control Panel
•
All electrical components come
pre assembled and wired to best
practice industry standards
•
Panel is well labeled with
illuminated switches for easy
operation and training
•
Optional digital controls for set-it
and forget-it temperature control
Air Control Panel
•
All pneumatic components come pre assembled and plumbed
•
Panel comes well labeled with regulator and gage for each
component simplifying operation and training
Auto Fill Panel
•
Automatically fill heated
hoppers from larger bulk
containers
•
Allows for continuous
spraying by adding
material in small volumes
(reducing temperature
drop of product in hopper)
Solvent Flush Pump
•
Integrated flush pump quickly flushes mixed material from mix
manifold through integrated hose and spray gun
•
Integrated air regulator and gauge allows operator to easily
increase fluid pressure up to 4,500 psi to flush the thickest
protective coatings
•
3
Optional Solvent Flush Pump Auxiliary Air Tank provides
dedicated air source to flush in the event air source is disrupted
Inlet Y-Strainer
•
Filters incoming material reducing downtime
Material Supply Systems
Heated and Unheated 25 and 35 gallon Hoppers
•
Pressure feed material to the proportioner inlet to avoid risk of
cavitation causing an off-ratio condition
•
Large volume hoppers with optional heaters to
precondition material
•
Packages for hoppers, 5-gallon pails, 55-gallon drums and bulk tanks
•
•
Agitators, elevators, heat, auto-fill, meters, and level sensors are
options to improve efficiencies
Durable carbon steel design. Powder coated blue
(A component) and green (B component) for easy
identification
•
Immersion heaters available in standard or
explosion proof design
•
Easily mounts to Graco XP cart or CJ Spray
custom frames
Auto Fill Sensors
•
Low, Full and Over Fill Level
Sensors on hoppers works in
tandem with the Auto Fill panel
to automatically keep the hoppers
filled from a bulk supply container
(i.e.., 55 gallon drum or other bulk
container)
•
As material is dispensed out
of hoppers the Auto Fill kit
automatically turns on feed supply
pumps. It adds approximately 35%
of tank volume per fill. This dosing
amount prevents the remaining
pre-conditioned material from
being overly cooled causing
potential issues with mil coverage
•
Over Fill Level Sensor signals
operator at panel in event Full
Level Sensor fails — preventing
overfilling
Power Unit
•
Electric Hydraulic (shown) —
available in single or three
phase to power Graco XP-h
•Pneumatic — Graco’s reliable NXT
air motor design standard on XP
CJ Spray Frames
Single Air Inlet and Electrical Connection
•
Quick and easy setup with single air and
electrical connection
•
Heavy-duty powder coated frames allow easy access to key
components for maintenance and repair
•
Optional wheel kit available (not shown)
•
Forklift pockets accessible from all four sides with D-Ring lift hooks
4
XP Pneumatic-driven Proportioners
Mix Ratio Max Fluid
by Volume Pressure
(psi)
Flow Rate
at 40cpm
(gpm)
XP70*
1:1
7250
1.91
1.5:1
7250
1.52
2:1
7250
1.84
2.5:1
6500
2.14
3:1
6800
2.04
4:1
7250
1.91
1:1
4500
3.06
1.5:1
5500
2.55
2:1
4800
2.87
2.5:1
5200
2.68
3:1
4500
3.06
4:1
4500
2.87
1:1
3800
1.91
2:1
4000
1.84
2.5:1
3400
2.14
3:1
3600
2.04
4:1
3800
1.91
XP50*
XP35*
*Other mix ratios available
Benefits of Pneumatic-Driven XP Proportioner:
•
Utilize your own air source to power the proportioner (80 140 scfm depending on options)
•
Lower initial cost than Hydraulic system
•
Easy operation and minimal maintenance
Three Models to Choose From:
5
•
XP70 — Extreme pressure (up to 7,250 psi) to handle high
viscosity epoxy coatings up to 100% solids content
•
XP50 — Same equipment as XP70 but with larger
volume displacement pumps. Ideal for high volume
applications when extreme pressure is not required
•
XP35 — Uses smaller NXT 3400 air motor which is
optimal for lower viscosity coatings. Lower 3,500 psi
pressure rating is ideal for mix-at-gun applications.
XP-h Hydraulic-Driven Proportioner
Mix Ratio Max Fluid
by Volume Pressure
(psi)
Flow Rate
at 40cpm
(gpm)
XP-h 70*
1:1
7250
1.9
2:1
7250
1.8
2.5:1
6786
2.1
3:1
7100
2
4:1
7250
1.9
1:1
4700
3.1
2:1
5050
2.9
2.5:1
5430
2.7
3:1
4700
3.1
4:1
5000
2.9
1:1
3150
4.6
2:1
3150
4.6
2.5:1
3384
4.3
3:1
3500
4.1
4:1
3800
3.8
XP-h 50*
XP-h 35*
*Other mix ratios available
Benefits of Hydraulic-Driven XP Proportioner:
•
Ideal for turn-key mobile systems or in-plant when
compressed air system is adequate, or for improved
energy efficiency
•
Lower operating cost than Pneumatic system. Hydraulic
system is more energy efficient than Pneumatic
•
Mobile systems
•
Easy operation and minimal maintenance
•
Like XP: Three pressure ranges to choose from
Power Unit Options:
•
Electric — Available in 240 V or 480 V. Single or three phase
•
Gasoline — Air or liquid cooled
•
Diesel — Liquid cooled
•
PTO Takeoff — From vehicle or generator engine
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Material Feed Supply
Plastic 7 gallon non-heated hoppers
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Manually filled from pails
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Made of polyethylene and unaffected by harsh solvents
•
Color coded
Metal heated hoppers
•
For temperature conditioning of high viscosity materials
•
25 gallon and 35 gallon double-walled fluid hoppers
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Comes standard with agitator
•
Set up for gravity or accommodates supply pump (2:1, 5:1, 10:1)
•
Three heat options:
- Immersion heater with thermostat (non-hazardous)
- Explosion proof immersion heater with thermostat (hazardous)
- Viscon in line heaters
•
Porting to accommodate circulation from heated hose and/or proportioner
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Manually filled from pails or bulk container using pump
•
Automatically filled from bulk supply with optional Auto-Fill kit
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Can be mounted to Graco’s standard XP cart or CJ’s custom skid and cart
Auto Fill System
•
Automatically fill heated hoppers from larger supply container (55 gallon or tank)
•
Fills hoppers more often in smaller dosing amounts preventing delays during
application while waiting for material to come up to temperature
•
Overflow sensor provides extra layer of protection against overfill if main fill
sensor fails. Indicator light alerts applicator of failure
•
Manual Fill Override easily allows applicator to top off hoppers at end of day
55 gallon drum supply
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Can configure for open and tight head drums
•
Supply pumps include 1:1, 2:1, 5:1 and 10:1 options
•Agitators
- Bung mount Twistork (screw) or expandable blade
- Back-geared paddle agitators for higher viscosity materials
•
Drum heaters
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Elevators for open head drum applications
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Drum return tubes for circulation kits with optional desiccant dryer cartridges
Bulk tank supply
•
Dimple-jacketed stainless steel heated tanks (hot glycol flows through dimple-jacket)
•
Polyurethane bulk tanks
•
Pressure tanks in various sizes
Questions? Need advice? Call CJ Spray toll-free today! 1-888-CJSPRAY (1-888-257-7729)
7
Primary Heaters
Condition the A/B material providing a consistent spray pattern and consistent mil coverage control
In remote mixing applications, independent heaters and temperature controls help balance the fluid back
pressures at the mix manifold to assure mix ratio accuracy
Reduce the component viscosities allowing the mixed materials to be applied using lower fluid pressures
Graco Viscon® HP
•
Models available for hazardous and non-hazardous locations
•
7250 psi maximum fluid working pressure
•
2300 watt models available in 120VAC, single phase
•
4000 watt models available in 200, 240, 380 and 480VAC, single phase
•
Set-it-and-forget-it temperature controls available with “Advanced” control panel
Graco Viscon® HF
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Supports high production flow rates — 7250 psi maximum fluid working pressure
•
Models available for non-hazardous locations
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5400 watt thermostat controlled or externally controlled RTD feedback model available
•
Cleanable heater core design
•
Set-it-and-forget-it temperature controls available with “Advanced” control panel
Remote Mix Manifold and Static Mixers
Reduce material waste and solvent costs by locating the mix manifold close to the spray gun. This minimizes the
amount of mixed coating and solvent required to flush. Also, required for coatings with short pot lives. Manifold
meters A/B material into downstream static mixers that thoroughly blend the two mixed materials for spraying
Optional Carriage
•
Standard single-flush mix manifold is mounted on sprayer and can be
removed and remote mounted using an optional carriage
Quick-Set Manifold
•
Quick-set mix manifold includes independent A/B solvent flush ports (dualflush), carriage, gauges and static mixers
www.cjspray.com
8
Heated and Unheated Hose
Maintains primary heater set-point temperature.
Graco Water (glycol)-jacketed Heated Hose
•
Uses Graco Husky diaphragm pump and Viscon heater to circulate glycol to heat hose
•
Faster temperature rise than electrical heated
•
More uniform heat over length of hose without “hot-spots” for more consistent
spray pattern and mil coverage (pressure ranges up to 7250 psi)
•
Approved for hazardous environments
Graco Low-Voltage Heated Hose
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Graco Low-Voltage Heated Hose (pressure ranges up to 5000 psi)
•
Not approved for hazardous environments
•
Uniform and even heated material, however “hot-spots” arise when hose overlap occurs
•
Large transformer controller required to convert high voltage to low voltage
WIWA High-Voltage Heated Hose
•
Pressure ranges up to 8100 psi
•
Approved for hazardous environments
•
Digital controller available for hazardous and non-hazardous environments
•
Uniform and even heated material, however “hot-spots” arise when hose
overlap occurs
Unheated Hose
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•
Pressure ranges up to 7250 psi
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Custom and pre-configured sizes and lengths
•
Insulation and scuff jacket available to help better maintain fluid temperatures
Spray Guns
Graco XTR 5 (5,000 psi) and XTR 7 (7,250 psi)
•
Two and four-finger trigger options
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Insulated and non-insulated handles
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Built-in hose swivel
•
Change tip sizes in seconds without removing the tip guard housing
Binks Airless 75 (shown) and 75 Direct Connect (7,500psi)
•
Airless 75 equipped with large fluid tube inlet
•
Airless 75 Direct-Connect utilizes spray hose connecting to gun inlet
•
Both models ideal for high solids and filled materials due to low inlet restriction
•
Heated material does not pass through handle for operator comfort
•
Change tip sizes in seconds without removing the tip guard housing
Graco XHF Spray Gun (7,250 psi)
•
High-flow, high pressure gun
•
Easily handles high-viscosity coatings, fiber filled materials and epoxy
intumescent materials
•
Reduced clogging means more uptime
Binks Airless 43P (3,500 psi)
•
Two-component mechanically operated spray gun
•
Solvent purge
•
Equal and off-ratio mix ratio available
Graco Probler P2 (3,500 psi)
•
Two component air-operated spray gun
•
Air purge
•
Equal and off-ratio mix available
Graco Fusion MP and AP (3,500 psi)
MP
•
Two component air-operated spray gun
•
Mechanical Purge MP / Air Purge AP
•
Equal and off-ratio mix available
AP
Other manual and automatic spray gun models available. Optional accessories are also available including tips, extensions, swivels, RAC
tips and pole guns.
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Optional Equipment
Graco Pressure Monitor
•
Monitors A/B spray pressure and shuts down sprayer if conditions occur such
as running out of material, pump cavitation, packing failures, leaks in valves
and fittings or plugged filters
•
Provides better overall productivity — projects are done on time!
•
Reduced labor and rework costs — confidence in end results and quality
Graco Merkur 45:1 Solvent Flush Pump
•
Higher output pressure allows spraying out of mixed material reducing waste
•
Easily mounts on slotted holes of Graco XP cart
Data Track
•
Material usage
•
Runaway protection
•
Pump Diagnostics
Stroke Counter
•
Totalizer and resetable job counter
•
Inexpensive proximity sensor design
•
No moving parts
•
Does not come into contact with fluid
Graco Gun Splitter
•
Allows two spray guns with XP proportioner systems improving production
•
Can independently clean and flush one gun while the other remains in use
•
Optional mixed material through port for third gun
CJ Spray Custom Frame Assembles
11
•
Provided completely assembled and ready for use (optional wheel kit available)
•
Rugged, durable frame construction
•
Panel controls centrally located for ease of use
•
Equipment accessible for easy service and repair
•
Single electrical and pneumatic connection
Integrated Controls
Electrical Enclosure
Graco electric heaters come without electrical wiring leaving it up to the end user to safely wire an electrical control
enclosure and associated wiring. CJ Spray’s optional electrical enclosures come pre configured using industry best practices
for safety and equipment protection. Available in 240 or 480 Volt power source.
CJ Spray electrical enclosure features:
•
All electrical equipment comes pre-wired to control panel reducing setup time and cost
•
Clearly labeled controls and illuminated switches simplify operation
•
Each electrical component is safely protected by a dedicated circuit breaker
•
Main on/off disconnect for incoming power to enclosure
•
Emergency Stop (e-stop) shuts down all pumps and electrical components
Basic Electrical Enclosure (not for explosive atmospheres):
Clearly labeled controls simplifies employee training and reduces operator error. Package
comes completely wired and ready to accept a single incoming power source. Power cord
and plug styles are available upon request. Packages include NEMA 4 enclosure with main
on/off power disconnect, individual on/off illuminated switches per heater, circuit breakers,
and vapor-tight connections.
The basic electrical configuration provides best practice electrical design and the on/
off electrical function for the heaters only. The temperature setting is controlled at the
thermostat knob on each individual heater.
•
Primary heater
•
Heated hose (electrically heated or Graco water (glycol)-jacketed heated hose
•
Heated Hoppers
Advanced Electrical Configuration (not for explosive atmospheres) —
“Set-It and Forget-It Controls”:
This package makes “dumb” Graco heaters “smart” by providing controls to monitor
and maintain a fluid temperature set-point.
Digital controllers work with:
•
Graco Viscon family of primary heaters
•
Graco water (glycol)-jacketed heated hose — monitors product temperature
and controls glycol temperature to maintain product temperature set-point.
•
WIWA electric heated hose
•
Immersion heaters used on heated hoppers
Explosion-proof control panel (for use in explosive atmospheres):
Same functionality as basic electrical enclosure package but configured with a Class 1,
Division 2 electrical control box for hazardous duty environments. Use in combination with
hazardous duty Viscon heaters and hazardous duty immersion tank heaters.
Questions? Need advice? Call CJ Spray toll-free today! 1-888-CJSPRAY (1-888-257-7729)
12
Pneumatic Controls
Air Control Panel
Simplify operation and setup using CJ Spray’s pre configured pneumatic control panel.
CJ Spray pneumatic control panel features:
•
All pneumatic equipment comes pre-plumbed to control panel providing single air inlet
attachment for the system
•
Clearly labeled regulators and gauges all in one place simplifies operation
•
Single 3/4” vented inlet air valve quickly shuts off all pneumatic equipment in case of emergency
(not used with e-stop configured electrical control panel)
Independently control:
•
Each feed pump
•
Hose heat pump (water-(glycol) jacketed hose only)
•
Solvent flush pump
•
Agitator on/off valve (tamper-proof regulator and needle valve used to control agitators)
Auxiliary Solvent Flush Pump Air Tank
Dedicated air source to solvent flush pump allowing applicator to flush integrated hose
even if air source is interrupted.
XM Plural Component Sprayer
For more info check out the
XM Sprayer Brochure
Variable Ratio Control with the Push of a Button
Be more flexible with your coatings by investing in a system that can quickly and
accurately change ratios from 1:1 to 10:1. Go to www.cjspray.com/graco-xm for more
information and configure your own XM.
13
Premium Mobile Spray Rigs
The Lineup
16 ft Bumper-Pull Trailer
20 ft Bumper-Pull Trailer
28 ft Gooseneck Trailer
Custom Box Truck
Turn-key Trailer and Truck Installations
CJ Mobile Rigs are designed specifically for the protective coatings market. We understand
what it takes to make a successful, portable spray system. Our rigs are completely turnkey with the spray system, generator, air compressor, air drying equipment, fresh air supply,
heaters, air conditioners and circulation systems. Go to www.cjspray.com/mobile-foam-spray-rig
for more information.
For more info check out the
Mobile Spray Rig Brochure
Standard Features
Fully Insulated
Heated Hose Wrap
Work Bench and Cabinet
Generator/Air Compressor
CJ Spray Mobile Rigs are
fully insulated with sprayed
polyurethane foam for the
best insulation while adding
structural strength to the trailer.
Holds up to 410 ft. of hose.
Designed with no sharp edges to
tear or fray protective scuff jacket.
Includes mounting bracket for
heated hose circulation manifold.
Galvanized steel work
bench with vise, grinder and
overhead white aluminum
locking cabinets.
All rigs come with generators
and air compressors from
leading manufacturers and
are approved installations
backed by warranty.
Fit and Finish
Trailer Specs
Barrel Braces
Separated Utility Room
Interior lined with white
laminated plywood. White
aluminum trim in corners
keeps the fluid and air hoses
concealed for professional look.
Manufactured by United
Trailers w/ 7.5’ interior height,
double I-beam construction w/
support studs on 16” centers.
Backed with a 5-year warranty.
Engineered to hold two
or three sets of material
securely for a mobile
application.
Generator is installed in
separate utility compartment,
sealed from the spray/work
space — reducing noise and
exposure to emissions.
14
CJ Spray
6270 Claude Way E.
Saint Paul, MN 55076
2845 W. Service Road
Eagan, MN 55121
Toll-free 1-888-CJSPRAY (1-888-257-7729)
[email protected]
www.cjspray.com
About CJ Spray, Inc.
CJ Spray was formally a spray equipment manufacturer which was purchased by Graco Inc. in 1993. In 1995, CJ Spray
was started as a distributor/wholesaler of equipment to spray, meter, mix and dispense liquids servicing consumer,
contractor and industrial markets. By teaming with material supplier, CJ Spray has developed turn-key spray
packages for some of the most difficult to handle coatings in the world. For more information on CJ Spray equipment
solutions, visit us at www.cjspray.com.
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