Graco ti18496b, ti18526c, ti18524d User Manual

Instructions - Parts

3A2012J

FRP Proportioner

Low emission internal/external mix gel coat and chop proportioners. For use with resin and catalyst in hazardous and non-hazardous locations. For professional use only.

Important Safety Instructions

Read all warnings and instructions in this manual and all component manuals. Save all instructions.

See page 4 for model and agency approvals information. See page 83 for maximum working pressure and other specifications. For patent information, see www.graco.com/patents.

WARNING

FIRE AND EXPLOSION HAZARD

Oil left in the system at the factory can react with catalyst and create a fire or explosion.

• Flush before first use.

• Do not add catalyst to the catalyst reservoir until the system has been flushed.

ti18526c

ti18524d

Wall Mount SystemCart and Boom System

Cart System

ti18496b

II 2 Gc T5

Contents

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

Agency Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Important Methyl Ethyl Ketone Peroxide (MEKP)

Safety Information . . . . . . . . . . . . . . . . . . . . . . 8

Important Two-Component Material Information . 9

Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 9

Keep Resin and Catalyst Components Separate 9

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 9

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

Component Identification . . . . . . . . . . . . . . . . . . 11

Air Control Panel . . . . . . . . . . . . . . . . . . . . . . . . 12

Air Motor and Resin Displacement Pump . . . . . 13

Catalyst Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Solvent Flush Systems . . . . . . . . . . . . . . . . . . . 15

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Before Installation . . . . . . . . . . . . . . . . . . . . . . . 16

Location Requirements . . . . . . . . . . . . . . . . . . . 16

System Mounting (Wall Mount Systems Only) . 16

System Assembly . . . . . . . . . . . . . . . . . . . . . . . 18

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Connect Fluid and Air Lines . . . . . . . . . . . . . . . 21

Flush Before First Use . . . . . . . . . . . . . . . . . . . 23

Fill Supply Tanks . . . . . . . . . . . . . . . . . . . . . . . . 23

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Boom Operation . . . . . . . . . . . . . . . . . . . . . . . . 24

Pressure Relief Procedure and Shutdown . . . . 24

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Prime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

DataTrak Operation . . . . . . . . . . . . . . . . . . . . . 33

Replace DataTrak Battery or Fuse . . . . . . . . . . 38

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Catalyst Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Resin Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

General Information . . . . . . . . . . . . . . . . . . . . . . 42

Disconnect the Displacement Pump . . . . . . . . . 42

Reconnect the Displacement Pump . . . . . . . . . 43

Disconnect the Air Motor . . . . . . . . . . . . . . . . . . 44

Reconnect the Air Motor . . . . . . . . . . . . . . . . . . 44

Replace Pumpline . . . . . . . . . . . . . . . . . . . . . . . 46

Repair Catalyst Pump . . . . . . . . . . . . . . . . . . . . 47

System Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Carts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Wall or Pole Mount Kit, 16N918 . . . . . . . . . . . . 57

Boom, 16N761 . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Air Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Slave Pump Linkage, 16P125 . . . . . . . . . . . . . . 60

Resin Pumplines . . . . . . . . . . . . . . . . . . . . . . . . 61

Air Motor and Pump for

Resin Pumpline . . . . . . . . . . . . . . . . . . . . . . 62

Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Resin Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Resin Supply Hose . . . . . . . . . . . . . . . . . . . . . . 64

Catalyst Slave Pumps . . . . . . . . . . . . . . . . . . . 66

Catalyst Reservoir . . . . . . . . . . . . . . . . . . . . . . . 68

Hose Bundles . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Hose Bundles . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Accessory Parts . . . . . . . . . . . . . . . . . . . . . . . . . 72

Heater Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Solvent Pressure Pot Kits . . . . . . . . . . . . . . . . . 74

Solvent Diaphragm Pumps . . . . . . . . . . . . . . . . 76

DataTrak Upgrade Kit . . . . . . . . . . . . . . . . . . . . 77

Carts for 55 Gallon Barrel, 16M896 . . . . . . . . . 78

Roving Box Bracket . . . . . . . . . . . . . . . . . . . . . . 79

Extension Hoses . . . . . . . . . . . . . . . . . . . . . . . . 80

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Cart and Boom . . . . . . . . . . . . . . . . . . . . . . . . . 81

Cart Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Wall/Pole Mount . . . . . . . . . . . . . . . . . . . . . . . . 82

Pumpline Wall Mounting Bracket Dimensions . . 83

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

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

2 3A2012J

Related Manuals

Manuals are available at www.graco.com. Component manuals in English:

Manual Description

™

3A0232 RS 3A2313 U-Cup Displacement Pump

3A2315 NXT 332451 FRP Stainless Steel Fitting Kit 308981 Air Operated Diaphragm Pumps 309524 Viscon HP Heater Instructions

307363 Viscon

313541 DataTrak

308370 307273 Fluid Outlet Filter 407019 Chop Cart Legs Kit

Gun Instructions-Parts

Air Motor for FRP

Heater Instructions

™

Conversion Kit Instructions

ASME and CE-Approved Pressure Pot Instructions (Solvent Flush Pressure Pot)

Agency Approvals

Manual Description

407020 55 Gallon Drum Kit 407021 Roving Box Bracket Kit 407022 Deluxe Inlet Seat Removal Tool 407023 5 Gallon Catalyst Reservoir Kit 407024 Boom Kit

407025 DataTrak 407026 Wall or Pole Mount Kit 407027 Linkage Replacement Kit 407028 Resin Pump Connecting Kit 407031 Diaphragm Pump Solvent Flush Kit

Non-CE Approved Solvent Pressure Pot

407032

407033 407042 Heater Kits

Kits ASME and CE-Approved Pressure Pot

Kits

™

Upgrade Kit

FRP proportioner systems are approved for use in hazardous locations when the base model, all accessories, and all kits meet all wiring meet local, state, and national codes.

Base FRP System with no accessories*

Accessories

* Solvent pots do not affect Atex rating.

II 2 Gc T5

See accessory manuals listed in Related Manuals section for approvals.

3A2012J 3

Models

Internal or

Ratio

Internal Mix

13:1

Internal Mix

17:1

External

Mix

External

Mix

External

Mix

Gel or

Chop

Gel

Chop

Gel

Chop

Gel

No Cart Cart Cart, Mast, and Boom

Hose

Length

Part No.

16R065 25 (7.6) 16R002 25 (7.6) 16R053 25 (7.6)

16R068 35 (10.7) 16R044 35 (10.7) 16R056 35 (10.7)

16R071 50 (15.2) 16R047 50 (15.2) 16R059 50 (15.2)

16R074 --- 16R050 --- 16R062 ---

16R135 25 (7.6) 16R123 25 (7.6) 16R004 25 (7.6)

16R138 35 (10.7) 16R114 35 (10.7) 16R126 35 (10.7)

16R141 50 (15.2) 16R117 50 (15.2) 16R129 50 (15.2)

16R144 --- 16R120 --- 16R132 ---

16R030 25 (7.6) 16R001 25 (7.6) 16R018 25 (7.6)

16R033 35 (10.7) 16R009 35 (10.7) 16R021 35 (10.7)

16R036 50 (15.2) 16R012 50 (15.2) 16R024 50 (15.2)

16R039 --- 16R015 --- 16R027 ---

16R100 25 (7.6) 16R088 25 (7.6) 16R003 25 (7.6)

16R103 35 (10.7) 16R079 35 (10.7) 16R091 35 (10.7)

16R106 50 (15.2) 16R082 50 (15.2) 16R094 50 (15.2)

16R109 --- 16R085 --- 16R097 ---

16R205 25 (7.6) 16R006 25 (7.6) 16R193 25 (7.6)

16R208 35 (10.7) 16R184 35 (10.7) 16R196 35 (10.7)

16R211 50 (15.2) 16R187 50 (15.2) 16R199 50 (15.2)

16R214 --- 16R190 --- 16R202 ---

16R170 25 (7.6) 16R005 25 (7.6) 16R158 25 (7.6)

16R173 35 (10.7) 16R149 35 (10.7) 16R161 35 (10.7)

16R176 50 (15.2) 16R152 50 (15.2) 16R164 50 (15.2)

16R179 --- 16R155 --- 16R167 ---

ft (m) Part No.

Hose

Length

ft (m) Part No.

Hose

Length

ft (m)

4 3A2012J

Accessories

To avoid fire and explosion and electric shock, FRP proportioners are not approved for use in hazardous locations unless all accessories, all kits, and all wiring meet local, state, and national codes. See Agency Approvals on page 3.

Accessories

The following items can be purchased separately from the system to gain additional functions. Many of the items require user installation; refer to the System Assembly section beginning on page 18 for the required procedures.

Solvent Flush Diaphragm Pumps

Part Description

16M560 2 Gallon Solvent Flush Diaphragm Pump

16M561 5 Gallon Solvent Flush Diaphragm Pump

Solvent Flush Pressure Pots

Part Description

16M874

16M875

16M893 2 Gallon, ASME Solvent Flush Pressure Pot

16M894 5 Gallon, ASME Solvent Flush Pressure Pot

Heaters

Part Description

16N014★

16N015★

16N016

16N017

16N018

16N019

★

2 Gallon, ASME and CE-approved, Solvent Flush Pressure Pot

5 Gallon, ASME and CE-approved, Solvent Flush Pressure Pot

120V Viscon Heater, for hazardous locations

240V Viscon Heater, for hazardous locations

120V Viscon Heater, for hazardous locations and explosive atmospheres

240V Viscon Heater, for hazardous locations and explosive atmospheres

120V Viscon Heater, for non-hazardous locations

240V Viscon Heater, for non-hazardous locations

Heaters can be disassembled to remove cured material.

Extension Hoses

Part Description

16M712

16M718

16M719

55 Gallon Barrel Carts

Part Description

16M896 55 Gallon Barrel Cart

Roving Box Bracket

Part Description

16M961 Roving Box Bracket Kit

DataTrak Upgrade

Part Description

16M881 DataTrak Upgrade Kit

5 Gallon Catalyst Reservoir

Part Description

24M501 5 Gallon Catalyst Reservoir Kit

Wall Mounting

Part Description

16N918 FRP Pole or Wall Mount Kit

Pump Connecting Kits

Part Description

16N242 17:1 Pump Connecting Kit

16N243 13:1 Pump Connecting Kit

25 ft Extension Hose Bundle for Chop Systems

25 ft Extension Hose Bundle for Internal Gel Systems

25 ft Extension Hose Bundle for External Gel Systems

3A2012J 5

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

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.

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, 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.

• Engage trigger lock when not dispensing.

• Do not point dispensing device at anyone or at any part of the body.

• Do not put your hand over the fluid outlet.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop dispensing 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.

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.

6 3A2012J

Warnings

WARNING

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.

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.

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.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system

component. See Technical 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. Alterations or modifications may void agency approvals and create safety hazards.

• 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.

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.

3A2012J 7

Important Methyl Ethyl Ketone Peroxide (MEKP) Safety Information

MEKP is among the more hazardous materials found in commercial channels. Proper handling of the “unstable (reactive)” chemicals presents a serious challenge to the plastics industry. The highly reactive property which makes MEKP valuable to the plastics industry in producing the curing reaction of polyester resins and gel-coats also produces the hazards which require great care and caution in its storage, transportation, handling, processing and disposal.

Workers must be thoroughly informed of the hazards that may result from improper handling of MEKP, especially in regard to contamination and heat. They must be thoroughly instructed regarding the proper storage, use and disposal of MEKP and other hazardous materials used in the laminating operation.

MEKP is flammable and potentially explosive, as well as potentially damaging to the eyes and skin.

Read material manufacturer’s warnings and material MSDS to know specific hazards and precautions related to MEKP.

Contaminated MEKP can become explosive. Prevent contamination of MEKP with other materials, including but not limited to polyester overspray, polymerization accelerators and promoters, and non-stainless metals. Even small amounts of contaminates can make MEKP explosive. This reaction may start slowly, and gradually build-up heat, which can accelerate until fire or an explosion result. This process can take from seconds to days.

Heat applied to MEKP, or heat build-up from contamination reactions can cause it to reach what is called its Self-Accelerating Decomposition Temperature (SADT), which can cause fire or explosion. Spills should be promptly removed, so no residues remain. Spillage can heat up to the point of self-ignition. Dispose in accordance with manufacture’s recommendation.

Store MEKP in a cool, dry and well-ventilated area in the original containers away from direct sunlight and away from other chemicals. It is strongly recommended that the storage temperature remain below 86° F (30° C). Heat will increase the potential for explosive decomposition. Refer to NFPA 432. Keep MEKP away from heat, sparks and open flames.

Current catalysts are premixed and do not require any diluents. Graco strongly recommends that diluents not be used. Diluents add to the possibility of contaminates entering the catalyst system. Never dilute MEKP with acetone or any solvent since this can produce an extremely shock-sensitive compound which can explode.

Use only original equipment or equivalent parts from Graco in the catalyst system (i.e.: hoses, fittings, etc.) because a hazardous chemical reaction may result between substituted parts and MEKP.

To prevent contact with MEKP, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons and goggles are required for everyone in the work area.

8 3A2012J

Important Two-Component Material Information

Polyester Resins and Gel-Coats Spraying and Lamination Operations

Spraying materials containing polyester resin and gel-coats creates potentially harmful mist, vapors and atomized particulates. Prevent inhalation by providing sufficient ventilation and the use of respirators in the work area.

Read the material manufacturer’s warnings and material MSDSs to know specific hazards and precautions related to polyester resins and gel-coats.

To prevent contact with polyester resins and gel-coats, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons and goggles are required for everyone in the work area.

Remove all accumulations of overspray, FRP sandings, etc. from the building as they occur. If this waste is allowed to build up, spillage of catalyst is more likely to start a fire.

If cleaning solvents are required, read material manufacture’s warnings and material MSDS to know specific hazards and precautions. (Graco recommends that clean-up solvents be nonflammable.)

Graco recommends that you consult OSHA Sections

1910.94, 1910.106, 1910.107 and NFPA No. 33, and NFPA No. 91 for further guidance.

Important Two-Component Material Information

Material Self-ignition

Changing Materials

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

Some materials may become self-igniting if applied too thickly. Read material manufacturer’s warnings and material MSDS.

Keep Resin and Catalyst Components 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 catalyst (usually MEKP) and resin (usually polyester resin or gel-coat) parts.

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical compatibility.

3A2012J 9

Overview

The FRP proportioner dispenses pigmented, tooling, low-VOC, and specialty gel coats, as well as polyester resin and vinyl ester chemicals. The FRP proportioner supplies the individual catalyst and resin materials, and fiberglass roving to the gun. On internal mix systems, it also supplies solvent to the gun for clearing mixed material from the gun.

Typical Applications

• Marine and watercraft

• Pool and spa

•Bath ware

• Transportation

• Corrosion prevention

• Cultured marble

FRP proportioner systems are approved for use in hazardous locations when the base model, all accessories, and all kits meet all wiring meet local, state, and national codes.

10 3A2012J

Component Identification

Cart system shown with solvent flush diaphragm pump and external mix gel gun

WLF

Key:

ACart BAir Motor C Resin Displacement Pump DCatalyst Pump E Solvent Flush (Diaphragm Pump Option Shown,

Pressure Pot Options also available)* F Catalyst Reservoir G Boom (not shown)

* Internal mix systems only.

3A2012J 11

H Air Control Panel J Heater (not shown) K Grounding Wire (not shown) L Hook support for resin hose coil

(25 ft and 35 ft hose bundles only) M Spray gun N Air/Water Separator (customer supplied)

Component Identification

Air Control Panel

Air inlet (AA): from air line.

Air regulator 1 (AB): controls air to resin pump.

Air outlet 1 (AC): air line to resin pump.

Air pressure gauge 1 (AD): indicates air pressure to

resin pump.

Air regulator 2 (AE): for external mix guns only: con- trols catalyst atomization air. For internal mix guns only: controls solvent flush pressure.

Air outlet 2 (AF): for external mix guns only: catalyst air line to spray gun. For internal mix guns only: to solvent pump.

FRONT REAR

Air pressure gauge 2 (AG): indicates regulator 2 air pressure.

Air regulator 3 (AH): controls Air Assist Containment

™

(AAC

) air to spray gun.

™

Air pressure gauge 3 (AK): indicates AAC air pressure.

Air outlet 3 (AM): AAC air line to spray gun.

Air outlet 4 (AN): Chop air supply to spray gun. This

outlet is plugged at the factory. Plug must be removed to install chop air.

Air Shutoff valve (AP): shuts off air to entire system.

ti21338a ti21339a

ABAG

. 1: Air Control Panel Components

Air Outlet Fitting

Details

Air Outlet 2 (AF) 3/8 tube 1/4 tube 3/8 tube 1/4 tube

Air Outlet 3 (AM) 1/4 tube 1/8 npt 3/8 tube 1/8 npt

Air Outlet 4 (AN)★ 1/2 tube 1/2 tube Plugged Plugged

Internal Chop External Chop Internal Gel External Gel

★ Includes a 1/2 to 3/8 reducer to adapt to older chop hose bundles

12 3A2012J

Air Motor and Resin Displacement Pump

The air motor powers the resin displacement pump which supplies resin to the spray gun.

Air inlet (M): connect air hose to the air inlet.

Fluid filter (N): removes particles from the fluid.

Pressure relief/recirculation valve (P): relieves pres-

sure in the hose and gun.

Pressure relief/recirculation fluid outlet (P1): place container below fluid outlet or connect fluid hose and route back to the resin container, or install container below the outlet

Pressurized fluid outlet on filter (R): connect fluid hose to the 1/4 npt(f) fluid outlet reducer fitting supplied with Graco hoses.

Component Identification

ti18499c

Fluid inlet (S): connect fluid suction hose to the 3/4 npt(m) fluid inlet.

DataTrak (T) (optional): electronic monitoring for material tracking, system diagnostics, and pump runaway control. The DataTrak is located on the air control panel. See the NXT Air Motor manual for details of the DataTrak controls and indicators.

FIG. 2

3A2012J 13

Component Identification

Catalyst Pump

The catalyst pump supplies catalyst to the spray gun.

Pump arm (U): controls catalyst flow.

Ratio adjustment knob (V1): use to lock/unlock pump

position and adjust the resin to catalyst ratio. It is easiest to adjust the ratio when the pump is at the bottom of the stroke.

Pivot point (V2): when pump is moved to adjust ratio, this point stays stationary.

High pressure relief valve (W): directs catalyst to gun or back to tank to relieve pressure. It also automatically relieves pressure if it exceeds normal working pressure.

Fluid pressure gauge (X): indicates catalyst fluid pressure.

Fluid inlet (Y): fluid inlet from the catalyst reservoir.

Fluid Inlet Ball Valve (Y2): controls flow of catalyst to

the catalyst pump.

Weep line (Z): In the event of a throat seal failure, the fluid will flow into the weep line and back to the catalyst reservoir.

Fluid outlet (Z1): fluid out to the gun.

Fluid recirculation/high pressure relief (Z2): fluid out-

let to the catalyst reservoir.

Low pressure relief valve (Z3): External mix systems only. Directs catalyst to gun or back to tank to relieve pressure.

ti21340a

ti21342a

. 3: Catalyst Pump Components

14 3A2012J

Solvent Flush Systems

Component Identification

Solvent Flush Diaphragm Pump

The solvent flush diaphragm pump provides solvent to the gun to clear out mixed fluid and prevent it from curing in the gun. See the diaphragm pump manual listed on page 3 for detailed component identification.

3/4 npt(f) Fluid

1/4 npt(f)

Outlet

Air Inlet

3/4 npt(f) Fluid Outlet

ti9078a1

. 4: Solvent Pump Components

Solvent Flush ASME Pressure Pot

Solvent Flush ASME and CE-Approved Pressure Pot

The pressure pot works by using the incoming air pressure to expel the solvent in the pot out of the fluid outlet. See the ASME and CE-approved Pressure Pot manual listed on page 3 for detailed component identification.

Air Inlet Fill Cap Fluid Outlet

ti18531a

The pressure pot works by using the incoming air pressure to expel the solvent in the pot out of the fluid outlet. Verify supply tube is installed on fluid outlet port.

Air Inlet Fill Cap Fluid Outlet

ti18530a

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Setup

FRP proportioners are not approved for use in hazardous locations unless all accessories, all kits, and all wiring meet local, state, and national codes. See Agency Approvals on page 3.

This section provides instructions for basic system setup of the FRP proportioner. See the separate component manuals for detailed information.

Before Installation

• Have all system and component documentation

available during installation.

• If using a cart and boom system, ensure there is enough space overhead and surrounding the proportioner for the boom and mast to fully extend.

• Place on a flat and level surface.

System Mounting (Wall Mount Systems Only)

To reduce the risk of skin injection injury, make sure the system is depressurized before mounting any pump assembly. See the Pressure Relief Procedure and Shutdown on page 24.

For ease of operation and service, make sure the pump air inlet, fluid inlet, and fluid outlet ports are easily accessible. Mount the catalyst reservoir above the catalyst pump to enable gravity feed. Be sure the bracket is level.

• See component manuals for specific data on compo-

nent requirements. Data presented here applies to the FRP assemblies only.

• Be sure all accessories are adequately sized and

pressure-rated to meet system requirements. Accessories are available from Graco.

Component identification illustrations are only a guide for selecting and installing system components and accessories. Contact your Graco distributor for assistance in designing a system to suit your particular needs.

Location Requirements

Refer to Dimensions, page 81, for mounting and clearance dimensions.

Cart Mount Systems

• Position the FRP proportioner so the air controls and catalyst ratio adjustment arm are easily accessible.

ti18527d

NOTICE

To prevent damage to the system caused by the system falling off the wall, be sure the wall can support the weight of the pump, bracket, hoses and accessories, and stress caused during pump operation.

1. For systems using pole mount:

a. Insert pole clamp bolts through catalyst reser-

voir mounting plate then each of the two upper pole clamps, then install and tighten nuts to secure mounting plate and clamps in place.

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NOTE: Catalyst reservoir outlet must be above the catalyst pump inlet fitting for true gravity feeding.

b. Insert pole clamp bolts through pumpline

mounting plate then each of the two lower pole clamps, then install and tighten nuts to secure mounting plate and clamps in place.

c. Use four bolts and washers to secure catalyst

reservoir to catalyst reservoir mounting plate.

d. Use four bolts and washers to secure pumpline

to pumpline mounting bracket.

2. For systems bolting directly to wall (not using a pole):

a. Use four bolts, washers, and nuts to install cata-

lyst reservoir mounting bracket to wall.

Setup

b. Use four bolts, washers, and nuts to install cata-

lyst reservoir onto the catalyst reservoir mounting bracket.

c. Use four bolts, washers, and nuts to secure

pumpline mounting bracket to wall.

d. Use four bolts, washers, and nuts to secure

pumpline to pumpline mounting bracket.

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Setup

System Assembly

When the system is shipped from the factory some items may be shipped loose. Perform the following instructions to properly install each of the component items.

1. For cart and boom systems only, install legs:

a. With the system still on the pallet, use the sup-

plied hardware to install the legs onto the base as shown below. The two longer legs should be installed on the air control panel side of the machine. The two non-locking casters should be installed on the two longer legs.

2. Connect heater (if ordered):

• Improperly installed or connected equipment may create a hazardous condition that can cause fire, explosion, or electric shock.

• Refer to heater manual listed on page 3 for detailed instructions and warnings.

• You must have a qualified electrician connect heater wiring. Ensure wiring and installation comply with local electrical codes for hazardous areas.

• Wiring, wiring connections, switches, and electrical distribution panel must all meet flame-proof (explosion-proof) requirements.

a. Use supplied hardware to install heater onto

pole as shown below. Position the heater to ease hose routing between pump and heater. See Heater Kits manual for bolt hole patterns.

ti18523c

b. Use a forklift to raise the system off of the pallet,

remove the pallet, then place item directly on the floor.

Viscon Heater Shown

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b. Connect heater electrical connections. See

heater manual listed on page 3 for detailed instructions.

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Setup

3. Install solvent flush diaphragm pump or pressure pot (if ordered).

a. Use the supplied hardware to install the dia-

phragm pump or pressure pot onto the base of the cart in the mounting holes provided.

6. Use the supplied hardware to install the roving box bracket onto the pole. Install the top pole clamp above the lower arm of the boom as shown below (if ordered). If there is a second roving box, use long hex screws as shown below to secure mounting plate of second roving box to the mounting plate of the first roving box.

ti18525b

Solvent Flush Diaphragm Pump shown

ti18455c

b. Use supplied hardware to install solvent supply

tank onto the base of the cart.

4. Install DataTrak Upgrade Kit (if ordered). Follow the detailed instructions in DataTrak manual listed on page 3.

5. Assemble the boom as shown below then slide the boom onto the system pole (if ordered).

Spring

Chain

Roving Guides

Deflector Plates

ti18532b

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Setup

Grounding

The equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode. Improper grounding can cause electric shock. Grounding provides an escape wire for the electric current

General Grounding Guidelines

Pump: use ground wire and clamp (supplied). Connect

ground clamp to a true earth ground.

Air and fluid hoses: use only electrically conductive hoses.

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

Fluid supply container: follow local code.

FRP Proportioner Grounding

NOTE: All proportioners come with one grounding

clamp to ground the proportioner to a true earth ground. All accessories for internal mix systems come with a second grounding clamp to ground the solvent flush system to the cart.

1. Verify that the ground screw is attached and tightened securely to the air motor. Connect the other end of the ground wire to a true earth ground.

Ground

screw

Grounding wire

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FIG. 5: Ground Wire

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.

2. For internal mix systems only, ground the solvent flush system.

a. For solvent flush diaphragm pumps only, con-

nect one end of the second grounding clamp to the solvent pump grounding strip. See the diaphragm pump manual listed on page 3 for grounding details.

b. Connect the other end of the grounding clamp

to the cart.

3. Use an ohmmeter to verify all components are grounded to the earth ground.

4. If wall power is used to power the heater, ground electrical connection according to local codes.

5. For cart proportioners: Connect the other end of the second supplied grounding clamp to the cart. For wall proportioners: Connect the other end of the second supplied grounding clamp to a true earth ground.

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Setup

Connect Fluid and Air Lines

Oil left in the system at the factory can react with catalyst and create a fire or explosion.

• Flush before first use.

• Do not add catalyst to the catalyst reservoir until the system has been flushed.

NOTE: When connecting gun hose bundle, the whip end connections in the bundle should be connected to the gun and the non-whip end connections should be connected to the proportioner. The whip end of the bundle is the end with more flexible lines. See gun manual for hose bundle connection details and individual hose identification.

Resin (Whip

Hose)

Air (Chop/

Internal Gel

AAC)

. 6: Hose End Diagram

Solvent/ AAC Air

Catalyst

External Atomizing/ Internal Chop AAC Air

Air Connections

1. Verify air line from air outlet 1 (AC) on air control panel is connected to air inlet (M) on air motor. See F

. 2 on page 13 and FIG. 7.

2. Connect AAC air line from gun hose bundle to air outlet 3 (AM) on air control panel. See gun manual for AAC air line identification.

3. External mix proportioners only: Connect the sup- plied air tubing attached to air outlet 2 (AF) to atomized air line on gun. Internal mix proportioners only: Connect the supplied air tubing attached to air outlet 2 (AF) to solvent pump air inlet. See F

. 4 on page 15.

4. Chop systems only: Remove plug then connect the chop air line (0.375 in. tube) in the gun hose bundle to the chop air fitting (AN) on the air control panel.

5. Verify air shutoff valve (AP) is closed (handle is vertical) then connect the air supply line to the air inlet (AA) on the air control panel.

FRONT REAR

ti21338a ti21339a

ABAG

FIG. 7: Air Control Panel Components

Air Outlet Fitting

Details

Air Outlet 2 (AF) 3/8 tube 1/4 tube 3/8 tube 1/4 tube

Air Outlet 3 (AM) 1/4 tube 1/8 npt 3/8 tube 1/8 npt

Air Outlet 4 (AN)

★

Internal Chop External Chop Internal Gel External Gel

1/2 tube 1/2 tube Plugged Plugged

★ Includes a 1/2 to 3/8 reducer to adapt to older chop hose bundles.

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Setup

Resin Pump and Optional Heater Connections

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Catalyst Pump Fluid Connections

NOTE: See F

. 3 on page 14.

11. Verify the pressure relief/recirculation valve (W) is set to pressure relief (knob is horizontal).

ti21343a

FIG. 9: Catalyst Pump Pressure Relief Valve

12. Connect the catalyst line from the gun hose bundle to the catalyst outlet (Z1).

. 8

6. Verify the pressure relief/recirculation valve (P) is set to pressure relief.

7. Place a waste container below the fluid outlet then remove the pump fluid inlet cap. Drain the test oil then discard.

8. Connect resin suction hose to the resin pump 3/4 nptm fluid inlet (S). Place other end of suction hose in resin container.

9. For non-heated systems only: Connect resin hose from the gun hose bundle to the resin pump 1/4 nptf fluid outlet (R). Reducer fitting comes with Graco hose bundle. For heated systems only: attach resin hose from the gun hose bundle to the heater outlet. Verify fluid hose connecting resin pump outlet to heater inlet is installed and secure.

10. Connect resin recirculation hose to the pressure relief/recirculation line (P1) and route to the resin container.

22 3A2012J

Solvent Flush Connections (if applicable)

NOTE: See Solvent Flush Systems component identi-

fication on page 15 for connection locations.

13. Connect solvent air line from air control panel to diaphragm pump or pressure pot air inlet.

14. Connect solvent suction tube from solvent supply tank to solvent pump fluid inlet.

15. Connect solvent line from gun hose bundle to solvent fluid outlet.

Gun Connections

16. For 25 ft and 35 ft hose bundles only: Place the coil of resin hose in the hose bundle on the hook support located on the pole. Secure with the supplied rubber straps. The hook support should be inserted through the center of the hose coil.

17. Secure all connections on the whip-end of the hose bundle to the gun. See the gun manual listed on page 3 for detailed instructions.

Setup

Flush Before First Use

Oil left in the system at the factory can react with catalyst and create a fire or explosion.

• Flush before first use.

• Do not add catalyst to the catalyst reservoir until the system has been flushed.

Flush the system before first use to prevent contaminating the resin or catalyst. See page 30.

Fill Supply Tanks

Add fluid to the solvent flush supply tank (if applicable), the catalyst supply reservoir, and the resin supply container.

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Operation

Trigger Lock

Always engage the trigger lock when you stop spraying to prevent the gun from being triggered accidentally by hand or if dropped or bumped.

Boom Operation

ti18532b

The height of the boom can be adjusted by adjusting which link in the chain is secured to the boom arm.

Pressure Relief Procedure and Shutdown

The equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking or servicing the equipment.

1. Close the main air supply ball valve.

NOTICE

Stop the pump at the bottom of its stroke to prevent fluid from drying on the exposed displacement rod and damaging the throat u-cup seals.

2. Turn the main air supply pressure regulator fully counter-clockwise.

. 10

3. Disengage the trigger lock on the gun. See F

4. With a grounded bucket below the gun, press the gun against the side of the bucket and pull the trigger to relieve pressure in the fluid lines.

. 11

24 3A2012J

. 11.

Operation

5. Engage trigger lock.

. 12

6. Turn catalyst pump pressure relief/recirculation valve to the pressure relief position.

8. After the pressure is fully relieved, turn the pressure relief/recirculation valve to dispense position.

FIG. 15

9. If you suspect the spray tip, hose, or filter is completely clogged or that pressure has not been fully relieved after following the previous steps, very slowly loosen the hose end coupling and relieve pressure gradually; then loosen completely.

. 13

7. Verify that the resin pressure relief/recirculation fluid line is routed to a grounded container, then turn the pressure relief/recirculation valve to the pressure relief position.

. 14

10. See the gun manual listed on page 3 for shutdown and maintenance procedures.

11. Perform the scheduled maintenance items listed on page 38.

3A2012J 25

Operation

Startup

NOTE: Do not exceed 20 psi (0.14 MPa, 1.4 bar) on the

material air pressure regulator until a steady material flow has been established.

To avoid overpressurization, before turning on the main air supply ensure all regulators are adjusted fully counter-clockwise so they are set to zero pressure.

1. Verify wetcup is filled with Graco Throat Seal

™

Liquid (TSL

2. Ensure main air line is connected to the air control panel air inlet (AA).

3. For internal mix proportioners only, check solvent line:

a. Verify gun is ready to begin operation. See gun

manual.

5. As desired, perform Prime, Flush, or Spray proce-

dures beginning on page 27. Make sure to flush the system before first use to flush out oil used to test the equipment at the factory.

b. Turn shutoff valve (AP) on the air control panel

to the open position.

c. Open the air valve on the solvent pump and

adjust the solvent pressure to 90 psi (0.63 MPa,

6.3 bar).

d. Open the ball valve on the solvent pump.

e. Open solvent knob on the gun to verify that sol-

vent will flow out of the front of the gun through

the dispense tip, then close the valve.

Oil left in the system at the factory can react with catalyst and create a fire or explosion.

• Flush before first use.

• Do not add catalyst to the catalyst reservoir until the system has been flushed.

4. If this is the first startup of the machine, perform the

Flush procedure on page 30.

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