Heavy duty electrical airless sprayer of plasters and paints (10 pages)
Summary of Contents for Graco XP-hf 572407
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Instructions ™ 3A4381M XP-hf Proportioner Mechanically linked fixed ratio plural-component system used for proportioning, mixing, and spraying two-component coatings. For professional use only. Not approved for use in explosive atmospheres or hazardous locations except where indicated in the Models section. See page 11 for models numbers, descriptions and agency approval designations.
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Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
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Warnings WARNING SKIN INJECTION HAZARD High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment. • Do not spray without tip guard and trigger guard installed.
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Warnings WARNING EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. • Do not operate the unit when fatigued or under the influence of drugs or alcohol. • Do not exceed the maximum working pressure or temperature rating of the lowest rated system component.
Important Isocyanate (ISO) Information Important Isocyanate (ISO) Information Isocyanates (ISO) are catalysts used in two component materials. Isocyanate Conditions Keep Components A and B Separate Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and Cross-contamination can result in cured material in atomized particulates.
Important Isocyanate (ISO) Information Foam Resins with 245 fa Changing Materials Blowing Agents NOTICE Some foam blowing agents will froth at temperatures Changing the material types used in your equipment above 90°F (33°C) when not under pressure, especially requires special attention to avoid equipment damage if agitated.
Overview Overview Usage Over Pressure Protection The XP-hf is a mechanically linked fixed ratio system that can mix and spray most two-component epoxy and urethane protective coatings. When using quick-setting material (less than 10 minute Mechanically linked pumps can create excessive fluid pot life), the Remote Manifold Heater Block Kit (24Z934) pressure if the full motor force is applied to only one of is recommended for use (see Models section starting...
Models Models OEM Packages Packages include XP-hf pump assembly and connection components. Using an XP-hf system, or components on the system, not approved for hazardous locations or explosive atmospheres may result in a fire or explosion hazard. The XP-hf systems are not approved for use in Building systems with OEM packages: hazardous locations unless the base model, all High-pressure fluid from gun, hose leaks, or ruptured...
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Series Change Models PART NUMBER CODE EXAMPLE: First Fourth and Three Digits Fifth Digits Last Digit System *Volume #Components Pressure Ratio Mix Ratio (see page 12) System Pressure Ratio (First Three Digits of Part Number) First Three Maximum Fluid Working Pressure System Ratio Digits psi (MPa, bar)
Component Identification Component Identification XP-hf Proportioners (Model 572407 shown) XP-hf Pump Assembly Key: XP-hf Motor Air Supply Adjustable Packing Nuts with Wet Cups Main Air Controls; see page 16 Yoke with Rod Bearings XP Fluid Pump Connecting Rod Nut Static Mixer Tubes with Replaceable Plastic Elements ™...
Component Identification Fluid Control Assembly This is required to add to OEM Packages to make a complete system. Standard Mix Manifold shown Key: AA Recirculation Manifold AB Mix Manifold AC Recirculation Handle (shown closed) AD Solvent Flush Valve AE Dual Shutoff Handle (shown closed) AF Fluid Pressure Gauges AH Recirculation Fittings AJ B Component Adjustable Fluid Restrictor;...
Component Identification Main Air Controls This is required to add to OEM Packages (part number ending in zero “0” to make a complete system). Key: CA Motor Shutoff Valve (Relieving) CB Motor Air Pressure Regulator CC Air Filter with Auto Drain CD Main Motor Air Pressure Gauge CE Filtered Air Distribution Manifold CF Main Inlet Air Shutoff Valve...
System Components System Components * Indicates a customer-supplied component required to add to OEM Packages (part numbers ending in zero “0”) to make a complete system. *XP-hf Motor Air Valve (CA) *Main Air Filter (CC) Removes harmful dirt from compressed air supply. A minimum 40 micron filter is used.
Setup Setup Location Initial System Setup 1. Check the shipment for accuracy. Ensure you have received everything you ordered. See Component Identification, page 13. Using an XP-hf system, or components on the system, 2. Check for loose fittings and fasteners. not approved for hazardous locations or explosive atmospheres may result in a fire or explosion hazard.
Setup Grounding Solvent pump: Connect ground wire (ZD) and clamp (supplied with solvent pump) to the ground stud (GS) on the solvent pump (BA). 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.
Setup Connect Power 6. Tighten the strain relief (SR). 7. Install supplied terminal jumpers in the positions shown in the image below for the power source used. NOTE: Terminal jumpers are located inside the electri- All electrical wiring must be done by a qualified cal enclosure door.
Setup Wire Systems with Change Motor Position Explosion-Proof Heaters There are specific motor positions for each mix ratio setting. To Adjust the position of the air motor: (Hazardous location systems only) 1. Perform the Check Motor Position procedure. If the position is incorrect, continue to the next step. 2.
Setup Connect Static Mixers/Gun/Hoses Connect Air Supply Connect the air supply hose to the 1 in. npsm(f) swivel NOTICE air inlet (CH). To prevent creating a flare on the mixer tube, do not Use a 1.0 in. (25.4 mm) ID minimum air hose. Air con- use a union swivel end on the mix tube inlet.
Setup Connect Fluid Hose Bundles 7. Connect the resin and hardener hoses to the mix manifold. (Remote Mix Manifold Only) 8. Connect the extension glycol tubing from the hose bundle to the heater block (HB). Cut the tubing NOTE: For all steps below refer to the illustration on the squarely behind only one of the u-fittings.
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Setup Connecting Hoses BLUE BLUE 3A4381M...
Pressure Relief Procedure Pressure Relief Procedure 7. Hold a metal part of the gun firmly to a grounded Follow the Pressure Relief Procedure whenever metal pail. Trigger the gun to relieve pressure. you see this symbol. This equipment stays pressurized until pressure is manually relieved.
Prime Empty System Prime Empty System Prime A and B Fluids 2. Fill the A and B hoppers with proper materials. Fill the A side (blue) with major volume of material; fill the B side (green) with minor volume of material (unless 1:1 mix ratio).
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Prime Empty System 5. Open the motor shutoff valve (CA). Then slowly 7. Decrease air pressure. Close the motor shutoff open the motor pressure regulator (CB). valve (CA). 8. Move the recirculation lines (U) back to the correct 6. Dispense fluid into the containers until clean fluid hopper (J).
Prime Empty System Prime Solvent Flush Pump 6. Ensure the trigger lock is engaged. Remove the spray tip. Follow instructions if the solvent flush pump is used. TI1949a 1. Connect a ground wire (not included) to a metal pail of solvent. 7.
Prime Empty System Recirculate Prior to Spraying or Re-Prime After a Pump Runs Dry NOTE: Agitate, recirculate, and heat the material only 5. Turn down the air pressure regulator (CB) and then as necessary to avoid mixing air into the fluid. open the motor air shutoff valve (CA).
Spray Spray 4. Adjust the motor air regulator (CB) to 30 psi (0.21 MPa, 2.1 bar) minimum. NOTE: After the first day of spraying, re-tighten all hose connection fittings and tighten the throat packing nuts on both pumps. 1. If heaters are used, turn them on. To adjust the heater temperature, refer to the Viscon HF or HP manual for instructions, and the Heat Fluid section, page 30.
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Spray 6. Engage the trigger lock. Install the tip on the gun. 8. Check and record gauge readings frequently during operation. A change in gauge readings indicates a 7. Adjust the main pump air regulator (CB) to the change in system performance. necessary spraying pressure and apply a coating to a test panel.
B Component Adjustable Fluid Restrictor B Component Adjustable Fluid Restrictor The B side restrictor (AJ) reduces momentary “lead/lag” If the mix manifold (AB) is mounted on the machine, you ratio imbalance of the A and B flow into the static mixer do not need to adjust the restrictor.
Flush Mixed Material Flush Mixed Material 4. Lift to close the dual shutoff handle (AE). To avoid fire and explosion, always ground equipment and waste container. To avoid static sparking and injury from splashing, always flush at the lowest possible pressure. Hot solvent may ignite. To avoid fire and explosion: •...
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Flush Mixed Material 6. Open the solvent flush valve (AD) 8. Close the solvent pump air valve (DA). 7. Disengage the trigger lock, hold the gun against a grounded metal pail, and trigger the gun into the pail. Use a pail lid with a hole to dispense through. Seal around the hole and gun with a rag to prevent splash back.
Empty and Flush Entire System (new system or end of job) Empty and Flush Entire System (new system or end of job) Guidelines Flush new systems if the coating materials will be contaminated by mineral oil. Follow the Flush System Procedure on page 38 to ensure mineral oil is removed.
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Empty and Flush Entire System (new system or end of job) 5. Turn the motor air pressure regulator (CB) fully 7. Lower to open the recirculation handle (AC) and counter-clockwise to shut off. increase the motor air pressure regulator (CB) pressure to 20 psi (138 kPa, 1.38 bar).
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Empty and Flush Entire System (new system or end of job) Flush System Procedure 7. Turn off the air motor. 8. Lift to close the dual shutoff handle (AE). 1. Close the motor air shutoff valve (CA). 2. Wipe the hoppers (J) clean, then add solvent to each.
Park Park Shutdown 1. Lower to open the recirculation handle (AC) and 1. Flush mix manifold, hoses, and gun. See Flush Mix adjust the motor air regulator (CB) so that the pump Manifold, Hose, and Spray Gun, page 34. runs slowly. 2.
System Verification System Verification Graco recommends running the following tests daily. Check curing at various time intervals, listed on the safety data sheet. For example, check for dry to touch by running your finger along the test pattern’s entire Check for Normal Operation length at the time listed on the data sheet.
Troubleshooting Troubleshooting Always follow the Pressure Relief Procedure on page 26 before servicing the system. Fluid ratio will be wrong. Purge all air from system before proportioning fluids. Problem Cause Solution System stops or will not start. Air pressure or volume too low. Increase air pressure;...
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Troubleshooting Problem Cause Solution Relief valve (AM) leaks back to Relief valve is dirty or damaged. Replace over pressure relief supply, opens too soon, or will not valve (302). close. No pressure on hardener side; Overpressure rupture disk blown. Determine cause of fluid leaking from hardener pump overpressurization and correct.
Troubleshooting Pump Troubleshooting This chart uses proportioning fluid gauges to determine pump malfunctions. Observe the gauge readings during the stroke direction indicated by the bold arrow, and immediately after closing the gun or mix manifold. Refer to other manuals to troubleshoot individual components. TROUBLE AREA: TROUBLE AREA: Resin Pump Leakage...
Repair Repair 3. If feed pumps are installed, close the inlet ball valve. Remove inlet union (61). 4. Remove the spring clamp (930) and coupling (919 or 920). Follow the Shutdown procedure on page 39, which includes pressure relief and flushing if service time may exceed pot life time before servicing fluid components and before transporting system to a service area.
Repair Remove Motor 8. Follow the steps in reverse order to reinstall the air motor. 1. Follow the Park procedure and Shutdown NOTE: Position air motor for correct mix ratio. See procedure on page 39. Motor Position on page 22 for instructions. Torque nuts 2.
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Repair Air Control Assembly . 2: Air Control Assembly 3A4381M...
Repair Mix Manifold Assembly 5. Remove the two screws (37) and fluid circulation manifold (35) from the cart (1). 1. Follow the Park procedure and Shutdown procedure on page 39. 2. Disconnect the fluid hose (25) and the flush hose from the mix manifold (36).
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Repair 6. Slide handle (311) onto valve stem and rotate 11. Install two screws (313) in handles (311). approximately 90° until you feel it fully lock against 12. Check operation of the handle and valves. the valve seat. Repeat for opposite side. 13.
Repair Hoppers 6. Lift the hopper off of the mounting bracket. 7. Repeat for second hopper. 1. If material is in the hopper, pump out the remaining material. Solvent Pump 2. If the pump has failed: a. Place a waste container beneath the plug on fit- ting (61).
Repair Fluid Heaters Replace 1. Follow steps 1 through 2 in the Fluid Heaters Service and Repair section. Service and Repair 2. Loosen the four mounting screws, lock washers, and plain washers on back of the heater. Slide the 1. Follow Pressure Relief Procedure, page 26. heater up and remove from the cart.
Parts Complete System (continued) Label No. 16F359 C Modifying this machine or adding La modificaci ó n de esta máquina o adici ó n de Modification de cette machine ou de lajout Non-approved accessories voids the accesorios no autorizados anula la zona daccessoires non approuv és par les vides de peligrosa de idoneidad.
Parts XP-hf Pump Assembly Model 572100 shown Torque together to 230-250 ft-lb (312-339 N•m). Torque to 50-60 ft-lb (68-81 N•m). Torque together to 95-105 ft-lb (129-142 N•m). Torque to 145-155 ft-lb (196-210 N•m). Apply medium strength (blue) threadlock to top thread only. Pins and lanyards must be positioned toward the outside of the pump as shown.
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Parts Parts Common to All Pump Packages Ref. Part Description Qty. Ref. Part Description Qty. 921b 17N312 PLATE, XP-hf, finger guard 273087 PLATE, XP-hf, motor 273092 PUMP, cover, ASM 273086 ROD, tie 922a 121803 SCREW, cap, button head, 273088 MOTOR, air #10-32 273085 ROD, connection, yoke, XP-hf 922b...
Parts Heated Hose Recirculation Pump 273093 Apply thread sealant to all non-swiveling pipe threads. Orient fittings approximately 15 degrees away from pump. Orient fittings as shown. Install ground wire between screw and washer. The nut is held in the slot of the pump. Install two loose plugs and muffler provided with pump in the ports indicated.
Parts Hose Heater (bracket mounted) 273094 (Hazardous Locations, 240V) 273095 (Non-Hazardous Locations, 240V) 273102 (Non-Hazardous Locations, 480V) Orient fittings as shown. Tighten cord grip .75 in. back from cord cover end. Orient the port facing down. BLACK BLACK GREEN WHITE BLACK 3A4381M...
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Parts Mounted Heated Hose Parts List Ref. Part Description Qty. (273094) Qty. (273095) Qty. (273102) 245869 HEATER, paint, non-hazardous locations 245863 HEATER, paint, hazardous locations 245870 HEATER, paint, non-hazardous locations 24N445 BRACKET, heater, heated hose, paint 126898 FITTING, elbow, 1/2 tube x 1/2 NPTM 126896 FITTING, elbow, 1/2 tube x 1/2 NPTF 17P759...
Parts Heater Wiring Diagram Hose Heater Fluid Fluid Heater B Heater A Hopper Hopper Heater B Heater A Black Black Black White Green Green White White White White HOSE HEATER HOPPER HEATER A Black Black Black White Green Green Black Black White White...
Parts Air Controls 26C431 1. Apply anaerobic pipe sealant to all non-swiveling pipe threads. Mount with air flow arrows in the direction shown. Assemble with air flow arrows in the direction shown. Assemble plug supplied with air regulator (5). Ref. Part Description Qty.
Recommended Spare Parts Recommended Spare Parts 1/2 in. Mix Manifold Inlet Ball Valves Keep these spare parts on hand to reduce downtime. 24M601, Ball valve repair kit Pump Repair Kits 262740, Spare valve (no handle) 262739, Spare valve (single handle) See Models (page 10) to see what pumps are used on your system.
Accessories and Kits Accessories and Kits Acceptable For Use in 5:1 Feed Pump Kit, 256276 Explosive Atmospheres For supplying viscous materials from a drum to XP-hf system. See your feed pump and agitator kit manual for more information. ™ PressureTrak Kit, 25C452 Monitors pressures to provide ratio assurance on XP-hf 10:1 Drum Feed Kit, 256433...
Accessories and Kits Not Approved For Hazardous 2:1 Drum Feed Kit, 256232 Location/Explosive Atmospheres One T2 pump feed kit and one Twistork agitator kit for mixing and supplying viscous materials from a 55 gallon drum to XP-hf system. See your feed pump and agitator These kits do not carry the EX mark.
Dimensions Pump Dimensions Maximum Maximum Maximum Pump Package Part Width (A) Depth (B) Height (C) 572100, 572150, 572200, XP-hf with 572250, 572300, 572400, 18 in. 24 in. 48 in. XL 10000 Air Motor 573100, 573150, 573200, (46 cm) (61 cm) (122 cm) 573250, 573300, 573400 3A4381M...
Dimensions Floor Mounting Dimensions, Top View 32.0 in. (81.2 cm) 22.0 in. 16.9 in. (55.8 cm) (42.9 cm) 15.25 in. 6.75 in. (38.7 cm) (17.1 cm) 40.0 in. (101.6 cm) 3A4381M...
Dimensions Bare Proportioner Mounting Hole Dimensions The dimensions below is the minimum opening size for mounting a bare proportioner. 9.64 in. (24.4 cm) 3A4381M...
Technical Specifications Technical Specifications XP-hf Proportioners U.S. Metric Maximum Fluid Working Pressure See Models section beginning on page 10. Combined Fluid Output (cc/cycle) See Models section beginning on page 10. Pressure Ratio See Models section beginning on page 10. Fluid Flow at 20 cpm See Models section beginning on page 10.
Technical Specifications XP-hf Proportioners U.S. Metric Weight: XP-hf Pump Package (xxxxx0) 320 lb 145 kg Cart Unit (xxxxx1) 460 lb 209 kg Cart Unit with Hoppers (xxxxx2) 485 lb 220 kg Cart Unit with Solvent Pump, 640 lb 290 kg A/B Hazardous Location Heaters (xxxxx3) Cart Unit with Hoppers, Solvent Pump, 665 lb...
With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.