Graco 3A0420T User Manual
Instructions-Parts
3A0420T
XP Proportioners
Mechanically linked fixed ratio plural-component system used for proportioning, mixing,
and spraying two component coatings. For professional use only.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
See page 11 for maximum working pressure and model
information.
XP70 system shown with hoppers and optional
solvent flush pump and heaters.
EN
r_571100_3A0420A_1a-2
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Important Two-Component Material Information . 7
Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 7
Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 7
Keep Components A and B Separate . . . . . . . . . 7
Moisture Sensitivity of Isocyanates . . . . . . . . . . . 7
Foam Resins with 245 fa Blowing Agents . . . . . . 7
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 8
A and B Component Designations . . . . . . . . . . . 8
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Over Pressure Protection . . . . . . . . . . . . . . . . . . 9
Initial System Setup . . . . . . . . . . . . . . . . . . . . . . . 10
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cart-Mounted Systems . . . . . . . . . . . . . . . . . . . 11
Bare Proportioning Pump Packages . . . . . . . . . 13
Component Identification . . . . . . . . . . . . . . . . . . . 14
Fluid Control Assembly . . . . . . . . . . . . . . . . . . . 15
Main Air Controls . . . . . . . . . . . . . . . . . . . . . . . 15
45:1 Solvent Flush Pump Kit 262393 (optional) 16
Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fluid Line Accessories . . . . . . . . . . . . . . . . . . . 17
Flush Before Using Equipment . . . . . . . . . . . . . 17
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Wire Systems with Explosion-Proof Heaters . . . 19
Motor Position . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Connect Air Supply . . . . . . . . . . . . . . . . . . . . . . 21
Connect Static Mixers, Gun, and Hoses . . . . . . 21
Connect Fluid Hose Bundles (Remote Mix Manifold
Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 22
Prime Empty System . . . . . . . . . . . . . . . . . . . . . . . 23
Prime A and B Fluids . . . . . . . . . . . . . . . . . . . . 23
Prime Solvent Flush Pump . . . . . . . . . . . . . . . . 24
Recirculate Prior to Spraying or Re-Prime After a
Pump Runs Dry . . . . . . . . . . . . . . . . . . . . . 25
Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
B Side Mix Manifold Restriction . . . . . . . . . . . . . . 27
Flush Mixed Material . . . . . . . . . . . . . . . . . . . . . . . 28
Flush Mix Manifold, Hose, and Spray Gun . . . . 28
Empty and Flush Entire System
(new system or end of job) . . . . . . . . . . . . . . 29
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Park . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
System Verification . . . . . . . . . . . . . . . . . . . . . . . . 31
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Hose Electrical Resistance . . . . . . . . . . . . . . . . 32
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . 32
Recommended Spare Parts . . . . . . . . . . . . . . . 32
Change the Mix Ratio . . . . . . . . . . . . . . . . . . . . 32
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Pump Troubleshooting . . . . . . . . . . . . . . . . . . . 34
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 35
Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Mix Manifold Assembly . . . . . . . . . . . . . . . . . . . 38
Fluid Circulation Manifold with Over Pressure Relief
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Hoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Optional Solvent Pump . . . . . . . . . . . . . . . . . . . 40
Optional Fluid Heaters . . . . . . . . . . . . . . . . . . . . 41
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Cart-Mounted System . . . . . . . . . . . . . . . . . . . . 42
Bare Proportioning Pump Package . . . . . . . . . . 50
Air Controls, 258983 . . . . . . . . . . . . . . . . . . . . . 52
Fluid Circulation Manifold with Over Pressure Relief
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Recommended Spare Parts . . . . . . . . . . . . . . . . . 54
Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . . 55
Acceptable For Use in Explosive Atmospheres . 55
Not Approved For Explosive Atmospheres . . . . 56
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Bare Proportioner Mounting Hole Dimensions . 60
Wall Mount Bracket 262812 Dimensions . . . . . . 61
Floor Stand 24M281 Dimensions . . . . . . . . . . . 62
Hydraulic Unit Dimensions . . . . . . . . . . . . . . . . 62
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 64
2 3A0420T
Related Manuals
Manuals are available at www.graco.com. Component
manuals in English:
Manual Description
™
XTR
312145
Pump Package Components
307158
311238
311762
312747
406860
309524
309525 Heated Hose Kit, Instructions-Parts
5 and XTR™ 7 Spray Guns
Instructions-Parts
Viscount
®
II Hydraulic Motor Instruc-
tions-Parts
®
NXT
Air Motor Instructions-Parts
Xtreme
®
Displacement Pumps
Instructions-Parts
Hopper Kits
20 Gallon Double Wall Hopper Kit
Instructions-Parts
7 Gallon Hopper Installation Kit Instructions-Parts
Heating
Viscon
®
HP Heater Instructions-Parts
Related Manuals
313259 Hopper or Hose Heat Circulation Kit
406861
Viscon HP Heater Adapter Kit, Instructions-Parts
Solvent Flush
310863 Feed and Solvent Flush Kits
312794
Merkur
Instructions-Parts
®
Pump Assembly
Accessories and Kits
309852
311486
312769
339361
Polyurethane Circulation and Return
Tube Kits, Instructions-Parts
™
DataTrak
Conversion Kit, Instruc-
tions-Parts
Feed Pump and Agitator Kits
Instructions-Parts
High Pressure Hose and Accessories
Brochure
3A0421 Ratio Check Kit, Instructions-Parts
3A0590
3A2573
Mix Manifold, Quickset Mix Manifold
Instructions-Parts
Gun Splitter Valve with Independent
Flush, Instructions-Parts
406739 Desiccant Kit Instructions-Parts
3A0420T 3
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, 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.
WARNING
WARNINGWARNINGWARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
SPECIAL CONDITIONS FOR SAFE USE
• To prevent the risk of electrostatic sparking, the equipment’s non-metallic parts must be cleaned with
only a damp cloth.
• Refer to the Viscon HP Heater manual for special conditions for safe use.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric
shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
4 3A0420T
Warnings
WARNING
WARNINGWARNINGWARNING
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just
a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system com-
ponent. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about
your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment
and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure and disconnect all power sources.
3A0420T 5
Warnings
WARNING
WARNINGWARNINGWARNING
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 MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating area
of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of
toxic fumes, and burns. This equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns:
• Do not touch hot fluid or equipment.
6 3A0420T
Important Two-Component Material Information
Important Two-Component Material Information
Isocyanate Conditions
Spraying or dispensing materials containing
isocyanates creates potentially harmful mists,
vapors, and atomized particulates.
Read material manufacturer’s warnings and material
MSDS to know specific hazards and precautions
related to isocyanates.
Prevent inhalation of isocyanate mists, vapors, and
atomized particulates by providing sufficient
ventilation in the work area. If sufficient ventilation is
not available, a supplied-air respirator is required for
everyone in the work area.
To prevent contact with isocyanates, appropriate
personal protective equipment, including chemically
impermeable gloves, boots, aprons, and goggles, is
also required for everyone in the work area.
Material Self-ignition
Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings and
material MSDS.
Keep Components A and B
Moisture Sensitivity of Isocyanates
Isocyanates (ISO) are catalysts used in two component
foam and polyurea coatings. ISO will react with moisture
(such as humidity) to form small, hard, abrasive crystals,
which become suspended in the fluid. Eventually a film
will form on the surface and the ISO will begin to gel,
increasing in viscosity. If used, this partially cured ISO
will reduce performance and the life of all wetted parts.
NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the
humidity, and the temperature.
To prevent exposing ISO to moisture:
• 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 wetcup or reservoir (if installed)
filled with Graco Throat Seal Liquid (TSL
206995. The lubricant creates a barrier between the
ISO and the atmosphere.
• Use moisture-proof hoses specifically designed for
ISO.
• Never use reclaimed solvents, which may contain
moisture. Always keep solvent containers closed
when not in use.
• Never use solvent on one side if it has been contaminated from the other side.
• Always lubricate threaded parts with TSL or grease
when reassembling.
™
), Part
Separate
Cross-contamination can result in cured material in
fluid lines which could cause serious injury or
damage equipment. To prevent cross-contamination
of the equipment’s wetted parts, never interchange
component A (isocyanate) and component B (resin)
parts.
3A0420T 7
Foam Resins with 245 fa Blowing Agents
Some foam blowing agents will froth at temperatures
above 90°F (33°C) when not under pressure, especially
if agitated. To reduce frothing, minimize preheating in a
circulation system.
Important Two-Component Material Information
Changing Materials
• Changing material types used in your system
requires special attention to avoid equipment damage and downtime.
• Always clean the fluid inlet strainers after flushing.
• When changing between epoxies and urethanes or
polyureas, disassemble and clean all fluid components and changes hose sets.
• Check with your material manufacturer for chemical
compatibility.
• Most materials use ISO on the A side, but some use
ISO on the B side.
• Epoxies often have amines on the B (hardener)
side. Polyureas often have amines on the B (resin)
side.
A and B Component Designations
Material suppliers and markets refer to plural component materials differently. The table below summarizes the different designations for the components used in various machines.
Market Equipment Designations
Foam and Polyurea, and
Urethane Pour
Epoxy and Urethane
Protective Coatings
Epoxy, Silicone, Ure-
thanes, and other mate-
rials
All Reactors, HFR
®
, Xtreme-
™
and PR
™
and VRM
Hydra-Cat
™
, XM™, and XP
Mix
PR70
Letter
Color
™
,
Component Names
Major or Minor Component
(when not 1:1 mix)
Letter
Color
Component Names
Major or Minor Component
(when not 1:1 mix)
Letter
Color
Component Names
Major or Minor Component
(when not 1:1 mix)
Machine Left
Side
AB
Red Blue
ISO, Hardener,
Catalyst
Low Volume
Side
AB
Blue Green
Resin, Base
High Volume
Side
AB
Red Blue
Polyol, Resin,
Base
High Volume
Side
Machine Right
Side
Polyol, Resin,
Base
High Volume
Side
Hardener, Cata-
lyst
Low Volume
Side
ISO, Hardener,
Catalyst
Low Volume
Side
8 3A0420T
Overview
Overview
Usage
The XP 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) a remote mix manifold must be used or materials must mix at the gun.
Quickset manifold 24M398 is recommended for
quick-setting material.
The two pumps are carbide seat severe duty positive
displacement pumps that displace fluid on both strokes.
The XP 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 Important Two-Component Material
Information, page 7, to determine the appropriate
location for your particular XP model.
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 pres-
sure 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 Circu-
lation Manifold with Over Pressure Relief
Valves on page 38.
• When using an XP 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.
• On models other than 1:1 mix ratio, a rupture disc
is provided on the small side fluid pump (pumps
72cc 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 39.
3A0420T 9
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. Install optional solvent flush pump kit 262393, if
ordered. See manual 310863 for instructions.
4. Mount and connect optional heaters, if ordered. See
the heater adapter kit manual 406861 for instructions and the heater manual 309524.
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. Install hopper or hose heat circulation kit 24M224, if
ordered. See 313259 for instructions.
NOTE: Supply return lines must be used.
8. Connect the feed pumps, fluid strainers, and air
hoses as necessary. If your system does not use
hoppers, then see manual 312769.
9. Connect the air supply line. See Connect Air Sup-
ply, page 21.
10. Connect the fluid hose assembly, including the
static mixers, whip hose and gun. See Pressure
Relief Procedure, page 22.
11. Flush test oil from system as needed. See Empty
and Flush Entire System (new system or end of
job), page 29.
10 3A0420T
Models
The XP systems are approved for use in hazardous
locations only if the base model, all accessories, all
kits, and all wiring meet local, state, and national
codes.
Cart-Mounted Systems
Models
NOTE: All cart-mounted systems listed are Ex rated:
II 2 G
c IIA T2
See Accessories and Kits on page 55 for a list of all optional accessories.
NOTE: The “Standard” mix manifold selection means the mix manifold is mounted on the cart and comes with mix-
ers, 25 ft of 3/8 in. mix hose, and 10 ft of 1/4 in. whip hose. The “Quickset” mix manifold selection means the manifold
has dual flush valves, is mounted on a remote carriage, and comes with mixers and 10 ft of 1/4 in. whip hose. When
ordering the Quickset configuration, A and B hoses from the sprayer to the mix manifold must be ordered separately.
Volume
Typ
eModel
281000 --- --281101
281102 ✔
281105
281106 ✔
281201
281202 ✔
281205
281206 ✔
262804
281252 ✔
281255
281256 ✔
281301
281302 ✔
281305
XP35 with NXT 3400 Air Motor
281306 ✔
281401
281402 ✔
281405
281406 ✔
Pump
Package
281100 1.0:1 3500 (24, 241) 95 (0.65, 6.5) 38:1
281200 2.0:1
262803 2.5:1
281300 3.0:1
281400 4.0:1
Ratio
Mix
7 Gallon
Hoppers
Mix
Manifold Hose Gun
Standard
--- --- ---
Standard
--- --- ---
Standard
--- --- ---
Standard
--- --- ---
Standard
--- --- ---
35 ft
(10.7 m)
35 ft
(10.7 m)
35 ft
(10.7 m)
35 ft
(10.7 m)
35 ft
(10.7 m)
XTR5
XTR5
XTR5
XTR5
XTR5
Max Fluid
Working Pressure
psi (MPa, bar)
--- --- ---
3500 (24, 241) 85 (0.59, 5.9) 40:1
3500 (24, 241) 90 (0.62, 6.2) 34:1
3500 (24, 241) 100 (0.7, 7) 36:1
3500 (24, 241) 95 (0.65, 6.5) 38:1
Max Air
Pressure
psi (MPa, bar)
Pressure
Ratio
3A0420T 11
Models
Volume
Typ
e Model
282000 --- --282101
282102 ✔
282105
282106 ✔
282151
282152 ✔
282155
282156 ✔
282201
282202 ✔
282205
282206 ✔
282251
282252 ✔
282255
282256 ✔
282301
282302 ✔
282305
282306 ✔
282331
XP50 with 6500 Air Motor
282332 ✔
282401
282402 ✔
282405
282406 ✔
283101
283102 ✔
283201
283202 ✔
283301
283302 ✔
283401
283402 ✔
571000 --- --571101
571102 ✔
571151
571152 ✔
571201
571202 ✔
571251
571252 ✔
571301
571302 ✔
571401
XP70 with NXT 6500 Air Motor
571402 ✔
Pump
Package
282100 1.0:1 4500 (31, 310) 100 (0.7, 7) 45:1
282150 1.5:1
282200 2.0:1
282250 2.5:1
282300 3.0:1
282330 3.3:1
282400 4.0:1 4800 (33, 331) 100 (0.7, 7) 48:1
282100 1.0:1
282200 2.0:1 4800 (33, 331) 100 (0.7, 7) 48:1
282300 3.0:1 4500 (31, 310) 100 (0.7, 7) 45:1
282400 4.0:1 4800 (33, 331) 100 (0.7, 7) 48:1
571100 1.0:1 7250 (50, 500) 95 (0.65, 6.5) 76:1
571150 1.5:1 7250 (50, 500) 80 (0.5, 5.5) 91:1
571200 2.0:1 7250 (50, 500) 95 (0.65, 6.5) 76:1
571250 2.5:1 6500 (45, 448) 100 (0.7, 7) 65:1
571300 3.0:1 6800 (47, 469) 100 (0.7, 7) 68:1
571400 4.0:1 7250 (50, 500) 100 (0.7, 7) 73:1
Ratio
Mix
7 Gallon
Hoppers
Mix
Manifold Hose Gun
Standard
--- --- ---
Standard
--- --- ---
Standard
--- --- ---
Standard
--- --- ---
Standard
--- --- ---
Standard
--- --- ---
Quickset
Standard
35 ft
(10.7 m)
35 ft
(10.7 m)
35 ft
(10.7 m)
35 ft
(10.7 m)
35 ft
(10.7 m)
35 ft
(10.7 m)
10 ft
(3.0 m)
35 ft
(10.7 m)
XTR5
XTR5
XTR5
XTR5
XTR5
XTR5
FlexPlus
XTR7
Max Fluid
Working Pressure
psi (MPa, bar)
--- --- ---
5000 (34, 344) 90 (0.62, 6.2) 55:1
4500 (31, 310) 100 (0.7, 7) 48:1
5000 (34, 344) 95 (0.65, 6.5) 52:1
4500 (31, 310) 100 (0.7, 7) 45:1
5000 (34, 344) 90 (0.62, 6.2) 56:1
4500 (31, 310) 100 (0.7, 7) 45:1
--- --- ---
Max Air
Pressure
psi (MPa, bar)
Pressure
Ratio
12 3A0420T
Bare Proportioning Pump Packages
Models
Packages include motor, pump lowers, and all connection hardware.
Building systems with bare proportioning pump
packages:
• Over Pressure Protection must be used, see
page 9. See chart on page 39 to identify the over
pressure relief valves to use with your system.
• All components must meet or exceed maximum
working pressures.
Combined
Fluid
Output
cc/cycle
435 1.75:1 4.6 (17.4) 3150 (22, 217) 1800 (12, 124) Purple
435 1.75:1 4.6 (17.4) 3150 (22, 217) 1800 (12, 124) Purple
407 1.88:1 4.3 (16.3) 3400 (23, 234) 1800 (12, 124) Purple
388 1.97:1 4.1 (15.5) 3500 (24, 241) 1800 (12, 124) Purple
360 2.10:1 3.8 (14.4) 3800 (26, 262) 1800 (12, 124) Purple
Pressure
Ratio
Type
XP35 with
XP50 with
XP70 with
XP-h with
Volume
Pump
Package
281100 L090C0 L090C0 1.0:1 180 38:1 1.9 (7.2) 3500 (24, 241) 95 (0.65, 6.5)
281200 L115C0 L058C0 2.0:1 173 40:1 1.8 (6.8) 3500 (24, 241) 85 (0.59, 5.9)
262803 L14AC0 L058C0 2.5:1 202 34:1 2.1 (7.9 3500 (24, 241) 100 (0.7, 7)
281300 L14AC0 L048C0 3.0:1 192 36:1 2.0 (7.6) 3400 (23, 234) 95 (0.65, 6.5)
Air Motor
NXT 3400
281400 L14AC0 L036C0 4.0:1 180 38:1 1.9 (7.2) 3500 (24, 241) 90 (0.62, 6.2)
282100 L14AC0 L14AC0 1.0:1 288 45:1 3.1 (11.7) 4500 (31, 310) 100 (0.7, 7)
282150 L14AC0 L097C0 1.5:1 240 55:1 2.6 (9.8) 5000 (34, 345) 90 (0.62, 6.2)
282200 L18AC0 L090C0 2.0:1 270 48:1 2.9 (11.0) 4800 (33, 331) 100 (0.7, 7)
282250 L18AC0 L072C0 2.5:1 252 52:1 2.7 (10.2) 5000 (34, 345) 95 (0.65, 6.5)
282300 L22AC0 L072C0 3.0:1 288 45:1 3.1 (11.7) 4500 (31, 310) 100 (0.7, 7)
Air Motor
NXT 6500
282330 L18AC0 L054C0 3.3:1 234 56:1 2.5 (9.5) 5000 (34, 345) 95 (0.65, 6.5)
282400 L22AC0 L054C0 4.0:1 270 48:1 2.9 (11.0) 4800 (33, 331) 100 (0.7, 7)
571100 L090C0 L090C0 1.0:1 180 72:1 1.9 (7.2) 7250 (50, 500) 100 (0.7, 7)
571150 L085C0 L058C0 1.5:1 144 91:1 1.5 (5.6) 7250 (50, 500) 80 (0.55, 5.5)
571200 L115C0 L058C0 2.0:1 174 76:1 1.8 (6.8) 7250 (50, 500) 95 (0.65, 6.5)
571250 L14AC0 L058C0 2.5:1 203 65:1 2.1 (7.9) 6500 (45, 448) 100 (0.7, 7)
Air Motor
NXT 6500
571300 L14AC0 L048C0 3.0:1 193 68:1 2.0 (7.5) 6500 (45, 448) 100 (0.7, 7)
571400 L14AC0 L036C0 4.0:1 181 73:1 1.9 (7.2) 7250 (50, 500) 100 (0.7, 7)
284101 L22AC0 L22AC0
284102 L14AC0 L14AC0 293 2.63:1 3.1 (11.7) 4700 (32, 324) 1800 (12, 124) Gold
284103 L090C0 L090C0 180 4.21:1 1.9 (7.2) 7150 (49, 493) 1700 (12, 117) Silver
284201 L29AC0 L14AC0
284202 L18AC0 L090C0 274 2.81:1 2.9 (11.0) 5050 (35, 348) 1800 (12, 124) Gold
284203 L115C0 L058C0 170 4.39:1 1.8 (6.8) 7200 (50, 496) 1650 (11, 114) Silver
284251 L29AC0 L115C0
284252 L18AC0 L072C0 255 3.02:1 2.7 (10.2) 5000 (34, 345) 1650 (11, 114) Gold
284253 L14AC0 L058C0 199 3.77:1 2.1 (7.9) 6800 (47, 469) 1800 (12, 124) Silver
Viscount II
284301 L29AC0 L097C0
Hydraulic Motor
284302 L22AC0 L072C0 293 2.63:1 3.1 (11.7) 4700 (32, 324) 1800 (12, 124) Gold
284303 L14AC0 L048C0 189 3.95:1 2.0 (7.6) 7100 (49, 490) 1800 (12, 124) Silver
284401 L29AC0 L072C0
284402 L22AC0 L054C0 274 2.80:1 2.9 (11.0) 5000 (34, 345) 1800 (12, 124) Gold
284403 L14AC0 L036C0 180 4.21:1 1.9 (7.2) 7150 (49, 493) 1700 (12, 117) Silver
A Side
Pump
B Side
Pump
Mix
Ratio
1.0:1
2.0:1
2.5:1
3.0:1
4.0:1
NOTE: All pump packages are Ex rated except for the
XP-h pump packages (284xxx):
II 2 G
c IIA T2
Hydraulically powered pump packages (XP-h) are not
available as complete systems. Refer to manual 307158
for hydraulic application information.
Pump sizes are marked on the pump cylinder; sizes are
nominal. See technical data in manual 311762 for actual
displacement.
Over
Fluid Flow
at 40 cpm
gpm (lpm)
Maximum Fluid
Working
Pressure
psi (MPa, bar)
Maximum Air/
Hydraulic Oil
Working Pressure
psi (MPa, bar)
Ex
Rated
✔
Pressure
Relief
Valve To
Use
Purple
Gold
Silver
3A0420T 13
Component Identification
Component Identification
E
X
M
B
G
A
R
Mounting Components for
Pump Package
H
U
N
F
P
V
A
B
T
S
C
J
D
D
D
W
FIG. 1: XP70 system with optional accessories
Key:
A Air Supply Hose for Motor
B Main Air Controls; see page 15
C Air Inlet - 3/4 npsm(f)
D High Pressure Fluid Pump
EMotor
F Fluid Heater (optional)
G Solvent Flush Pump (optional); see page 16
H Solvent Flush Pump Air Controls; see page 16
J 7 Gallon Hoppers (optional)
KCart
L Brake
M Handle (lift to release)
Y
K
L
r_571101_3a0420a_1a-2
N Fluid Control Assembly; see page 15
P Tie Rods
R Motor Adapter Plate
S Adjustable Packing Nuts with Wet Cups
T Yoke With Rod Bearings
U Recirculation Lines
V Yoke Position Nut
W Static Mixer Tubes with Replacement Plastic Elements
X Motor Position Indicator Lines; see Motor Position on
page 20
Y Over Pressure Rupture Disc;
only 38cc, 48cc, 54cc, 58cc, and 72cc pumps
14 3A0420T
Fluid Control Assembly
Standard Mix Manifold shown
AA
AH
AF
AE
AJ
AB
AL
AC
AM
Component Identification
Key:
AA Fluid Manifold
AB Mix Manifold
AC Circulation Handle
AD Solvent Flush Valve
AE Dual Shutoff Handle
AF Fluid Pressure Gauges
AG Fluid Supply Inlet (Behind Fluid Manifold)
AH Fluid Circulation Fittings
AJ B Component Adjustable Fluid Restrictor; see
page 27
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 39
AN A and B Combined Outlet; 3/8 npt(m)
AN
FIG. 2
Main Air Controls
CE
CC
ti19167a
CB
CD
AK
AD
CA
Key:
CA Main Motor Shutoff Valve (Relieving)
CB Main Motor Air Pressure Regulator
CC Air Filter with Auto Drain
CD Main Motor Air Pressure Gauge
CE Filtered Air Distribution Manifold
FIG. 3
3A0420T 15
Component Identification
45:1 Solvent Flush Pump Kit 262393 (optional)
Pump
Key:
BA Solvent flush pump (Merkur Pump)
BA
BD
BF
BE
BB Fluid Inlet
BD Muffler
BE Prime/Flush/Sample valve
BF Fluid Outlet Hose
BG Circulation hose
FIG. 4
Air Controls
DC
DE
DB
BG
BB (suction hose not shown)
r_571100_3a0420a_4a-2
Key:
DA Solvent Pump Air Shutoff Valve (Relieving)
DB Solvent Pump Air Pressure Regulator
DC Solvent Pump Air Pressure Gauge
DD Air Outlet
DE Air Inlet
DA
DD
r_571101_3a0420a_5a-2
FIG. 5
16 3A0420T
Component Identification
Air Line
• Bleed-type master air valve (CA): Required in
your system to relieve air trapped between it and
the air motor when the valve is closed. Be sure the
valve is easily accessible from the pump and
located downstream from the air regulator.
Trapped air can cause the pump to cycle unexpectedly, which could result in serious injury from splashing or moving parts.
• Pump air regulator (CB): Controls pump speed
and outlet pressure.
• Air line filter (C): 40 micron filter removes harmful
dirt and moisture from compressed air supply. Accumulated water is automatically drained from the filter.
Fluid Line Accessories
Optional Accessories
• Optional Fluid Heaters (N): Heats the resin and
hardener before mixing. Improves the chemical
reaction and lowers viscosity to improve the spray
pattern.
• Optional Solvent Flush Kit (G): Flushes the mix
manifold. Includes a solvent pump, mounting hardware, and solvent supply hose.
Flush Before Using Equipment
The equipment was tested with lightweight oil, which is
left in the fluid passages to protect parts. To avoid 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 29.
• Fluid Manifold (AA): Controls circulation and pump
priming.
• Mix Manifold (AB): Combines A and B fluid into
one fluid line.
• Circulation Handle (AC): Directs fluid flow for cir-
culation or mixing. Move to open position to relieve
fluid pressure, prime pumps, and circulate material
in hoppers. Move to closed position to spray mixed
material.
• Dual Shutoff Handle (AE): Controls A and B fluid
flow for mixing and dispensing. Close before flushing.
• Solvent Flush Valve (AD): Controls solvent flow to
the mix manifold, hose, and spray gun.
• Static mixer/gun hose kit: Thoroughly mixes the
two fluids and delivers the mixed fluid to the spray
gun. Includes static mixer and hoses to the spray
gun.
3A0420T 17
Setup
Setup
Location
The XP35, XP50, and XP70 systems are approved
for use in hazardous locations only if the base model,
all accessories, all kits, and all wiring meet local,
state, and national codes.
1. Locate the proportioner on a level surface.
2. Position the proportioner for convenient operator
access and maintenance, safe routing of air and
fluid lines, and easy connection of components and
accessories.
3. For permanent mounting, remove wheels and
mount the frame to the floor. See Dimensions,
page 58.
4. Ensure that the cart brake (L) is in the locked position.
Grounding
Pump: use ground wire and clamp (supplied). Loosen
grounding lug locknut (W) and washer (X). Insert ground
wire end (Y) into lug (Z) slot and tighten locknut
securely. Connect ground clamp to a true earth ground.
Y
W, X, Z
Solvent Pump: use ground wire and clamp (supplied
with solvent pump). Follow instructions in pump manual.
Air and fluid hoses: use only static dissipation type
hoses with a maximum of 500 ft (150 m) combined hose
length to ensure grounding continuity. Check electrical
resistance of hoses regularly. If total resistance to
ground exceeds 29 megohms, replace hose immediately.
Air compressor: follow manufacturer’s recommendations.
Spray gun: ground through connection to a properly
grounded fluid hose and pump.
Fluid supply container: follow local code.
The equipment must be grounded. Grounding
reduces the risk of static and electric shock by providing an escape wire for the electrical current due to
static build up.
18 3A0420T
Object being sprayed: follow local code.
Solvent pails used when flushing: follow local code.
Use only conductive metal pails, placed on a grounded
surface. Do not place the pail on a nonconductive surface, such as paper or cardboard, which interrupts
grounding continuity.
To maintain grounding continuity when flushing or
relieving pressure: hold metal part of the spray gun
firmly to the side of a grounded metal pail, then trigger
the gun.
Wire Systems with Explosion-Proof Heaters
(Hazardous location systems only)
If your system is rated for hazardous areas, and you
have explosion-proof heaters, you must have a qualified electrician connect heater wiring. Ensure wiring
and installation comply with local electrical codes for
hazardous areas.
Improperly installed or connected equipment will create
a hazardous condition and cause fire, explosion, or
electric shock. Follow local regulations.
When explosion-proof heaters are used, ensure the wiring, wiring connections, switches, and electrical distribution panel all meet flame-proof (explosion-proof)
requirements.
Setup
Refer to the Viscon HP heater manual for electrical connection instructions and guidelines in hazardous locations.
3A0420T 19
Setup
Motor Position
The motor position must be set for the volume mix ratio
of the system.
NOTE: Changing the motor position does not change
the mix ratio.
Check Motor Position
1. Verify that the correct pumps are mounted for your
mix ratio by volume. See chart in Bare Proportion-
ing Pump Packages on page 13.
indicator line
indicator line
Air Motor shown
FIG. 6: Ratio indicators
r_258914_3a0420a_10b
3. Place wrench on adapter rod (104) then use supplied tool to loosen the serrated yoke nut (V) above
the yoke (T).
104
Air Motor shown
V
T
r_571101_3a0420a_2a-2
4. Loosen the three nuts (P2) below the motor tie rods.
E
piston rod
V
P2
T
2. Verify that the motor position is adjusted correctly
for that mix ratio. See F
IG
. 6. If not, perform the fol-
lowing Change Motor Position procedure.
Change Motor Position
There are specific motor positions for each mix ratio setting. To adjust the position of the air motor:
1. Perform Check Motor Position procedure. If position is incorrect, continue to next step.
2. Loosen the eight fasteners and remove the two
pump guards.
Air Motor shown
fastener
pump guard
fastener
r_258914_3a0420a_5a
Air Motor shown
FIG. 7
5. Grab the piston rod and slide the position of the
motor (E) until the indicator lines are aligned with
your ratio. See F
IG
. 6 and FIG. 7.
NOTICE
Do not hit tie rods (P) with a steel hammer. Damage
to the air motor base may result.
6. Tighten the three nuts (P2) and yoke nut (V).
7. Use supplied tool to tighten the yoke nut.
8. Install the pump guards.
pump guard
r_258914_3a0420a_4a-1
20 3A0420T
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