Graco XP-hf 572407 User manual

Instructions
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.
Important Safety Instructions
Read all warnings and instructions in this
manual before using the equipment. Save
these instructions.
WLE
3A4381M
EN

2 3A4381M
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Important Isocyanate (ISO) 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 . . . . . . . . . . . 8
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Over Pressure Protection . . . . . . . . . . . . . . . . . . . . . . . 9
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Series Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . 13
XP-hf Proportioners (Model 572407 shown) . . . . . . . . 13
XP-hf Proportioners (continued) . . . . . . . . . . . . . . . . . 14
Fluid Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . 15
Main Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
45:1 Solvent Flush Pump . . . . . . . . . . . . . . . . . . . . . . 17
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
*XP-hf Motor Air Valve (CA) . . . . . . . . . . . . . . . . . . . . 18
*XP-hf Motor Air Pressure Relief Valve (CG) . . . . . . . 18
*Main Air Filter (CC) . . . . . . . . . . . . . . . . . . . . . . . . . . 18
*XP-hf Motor Air Regulator (CB) . . . . . . . . . . . . . . . . . 18
Fluid Line Components . . . . . . . . . . . . . . . . . . . . . . . . 18
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Initial System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Flush Before Using Equipment . . . . . . . . . . . . . . . . . . 20
Connect Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Wire Systems with Explosion-Proof Heaters . . . . . . . 22
Motor Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Connect Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Connect Static Mixers/Gun/Hoses . . . . . . . . . . . . . . . 23
Connect Fluid Hose Bundles (Remote Mix Manifold Only)
24
Connecting Additional Hose Lengths . . . . . . . . . . . . . 24
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . . . 26
Prime Empty System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Prime A and B Fluids . . . . . . . . . . . . . . . . . . . . . . . . . 27
Prime Solvent Flush Pump . . . . . . . . . . . . . . . . . . . . . 29
Recirculate Prior to Spraying or
Re-Prime After a Pump Runs Dry . . . . . . . . . . . . 30
Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
B Component Adjustable Fluid Restrictor . . . . . . . . . . . 33
Flush Mixed Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Flush Mix Manifold, Hose, and Spray Gun . . . . . . . . . 34
Empty and Flush Entire System
(new system or end of job) . . . . . . . . . . . . . . . . . . . 36
Park . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
System Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Hose Electrical Resistance . . . . . . . . . . . . . . . . . . . . . 41
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Change the Mix Ratio . . . . . . . . . . . . . . . . . . . . . . . . . 41
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Pump Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 44
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Mix Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . 48
Fluid Circulation Manifold with Over Pressure Relief
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Hoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Solvent Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Fluid Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Complete System (572107 shown) . . . . . . . . . . . . . . . 52
Complete System (continued) . . . . . . . . . . . . . . . . . . 53
Complete System (continued) . . . . . . . . . . . . . . . . . . 54
Complete System (continued) . . . . . . . . . . . . . . . . . . 55
XP-hf Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . 61
Heated Hose Recirculation Pump . . . . . . . . . . . . . . . . 63
Hose Heater (bracket mounted) . . . . . . . . . . . . . . . . . 64
Heater Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . 66
Heater Block Remote Manifold Kit . . . . . . . . . . . . . . . 67
Air Controls 26C431 . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . 69
Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Acceptable For Use in
Explosive Atmospheres . . . . . . . . . . . . . . . . . . . . 70
Not Approved For Hazardous Location/Explosive
Atmospheres . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
System Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Pump Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Floor Mounting Dimensions, Top View . . . . . . . . . . . . 74
Bare Proportioner Mounting Hole Dimensions . . . . . . 75
Wall Mount Bracket 262812 Dimensions . . . . . . . . . . 76
Floor Stand 24M281 Dimensions . . . . . . . . . . . . . . . . 77
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 78
California Proposition 65 . . . . . . . . . . . . . . . . . . . . . . . . 79
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . 80

Related Manuals
3A4381M 3
Related Manuals
Manuals are available at www.graco.com.
Component manuals in English:
Manual in
English Description
312145 XTR 5™and XTR 7™Spray Guns, Instructions - Parts
Pump Package Components
334644 Xtreme®XL Air Motor, Instructions - Parts
311762 Xtreme Displacement Pumps, Instructions - Parts
Hopper Kits
312747 20 Gallon Double Wall Hopper Kit, Instructions - Parts
406860 7 Gallon Hopper Installation Kit, Instructions - Parts
Heating
3A2954 Viscon®HF Heater, Instructions - Parts
309524 Viscon HP Heater, Instructions - Parts
406861 Viscon HP Heater Adapter Kit, Instructions - Parts
3A5313 Xtreme-Wrap Water Heated Hose, Instructions - Parts
3A5314 Hose Heat Circulation XP and XP-hf Kit, Instructions - Parts
Solvent Flush
310863 Feed and Solvent Flush Kits, Instructions Parts
312794 Merkur®Pump Assembly, Instructions - Parts
Accessories and Kits
3A3320 XP and XP-hf PressureTrak Kit, Instruction - Parts
3A1331 XP Pressure Monitor Kit, Instructions - Parts
312769 Feed Pump and Agitator Kits, Instructions - Parts
339361 High Pressure Hose and Accessories Brochure
3A0421 Ratio Check Kit, Instructions - Parts
3A0590 Mix Manifold, Quickset Mix Manifold, Instructions - Parts
3A2573 Gun Splitter Valve, Instructions - Parts
406739 Desiccant Kit, Instructions - Parts
3A5312 Junction Box XP, Instructions - Parts

Warnings
4 3A4381M
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.
SEVERE ELECTRIC SHOCK HAZARD
This equipment can be powered by more than 240V. Contact with this voltage will cause death or
serious injury.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
• This equipment must be grounded. Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or
solvent flowing through the equipment can cause static sparking. To help prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic
drop cloths (potential static sparking).
• Ground all equipment in the work area. See Grounding instructions.
• Never spray or flush solvent at high pressure.
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are anti-static or conductive.
•Stop operation immediately if static sparking occurs or you feel a shock.Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
Static charge may build up on plastic parts during cleaning and could discharge and ignite flammable
vapors. To help prevent fire and explosion:
• Clean plastic parts only in well ventilated area.
• Do not clean with a dry cloth.
• Do not operate electrostatic guns in equipment work area.
SPECIAL CONDITIONS FOR SAFE USE
• If using the Viscon HP and HF Heaters see manuals for special conditions for safe use.
• If using the PressureTrak, see the manual for special conditions for safe use.

Warnings
3A4381M 5
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like
just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Equipment can start without warning. Before checking, moving, or servicing equipment, follow the
Pressure Relief Procedure and disconnect all power sources.
WARNING

Warnings
6 3A4381M
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 Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical
Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For
complete information about your material, request Safety Data Sheet (SDS) from distributor or
retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and
create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
PERSONAL PROTECTIVE EQUIPMENT
Always wear appropriate personal protective equipment and cover all skin when spraying, servicing
equipment, or when in the work area. Protective equipment helps prevent serious injury, including
long-term exposure; inhalation of toxic fumes, mists or vapors; allergic reaction; burns; eye injury
and hearing loss. This protective equipment includes but is not limited to:
• A properly fitting respirator, which may include a supplied-air respirator, chemically impermeable
gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and
local regulatory authority.
• Protective eyewear and hearing protection.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled or
swallowed.
• Read Safety Data Sheets (SDSs) for handling instructions and to know the specific hazards of the
fluids you are using, including the effects of long-term exposure.
• When spraying, servicing equipment, or when in the work area, always keep work area
well-ventilated and always wear appropriate personal protective equipment. See Personal
Protective Equipment warnings in this manual.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
WARNING

Important Isocyanate (ISO) Information
3A4381M 7
Important Isocyanate (ISO) Information
Isocyanates (ISO) are catalysts used in two component materials.
Isocyanate Conditions
Material Self-Ignition
Keep Components A and B
Separate
Moisture Sensitivity of
Isocyanates
Exposure to moisture (such as humidity) will cause ISO
to partially cure, forming small, hard, abrasive crystal
that become suspended in the fluid. Eventually a film will
form on the surface and the ISO will begin to gel,
increasing in viscosity.
NOTE: The amount of film formation and rate of
crystallization varies depending on the blend of ISO, the
humidity, and the temperature.
Spraying or dispensing fluids that contain isocyanates
creates potentially harmful mists, vapors, and
atomized particulates.
• Read and understand the fluid manufacturer’s
warnings and Safety Data Sheets (SDSs) to know
specific hazards and precautions related to
isocyanates.
• Use of isocyanates involves potentially hazardous
procedures. Do not spray with this equipment
unless you are trained, qualified, and have read
and understood the information in this manual and
in the fluid manufacturer’s application instructions
and SDSs.
• Use of incorrectly maintained or mis-adjusted
equipment may result in improperly cured
material. Equipment must be carefully maintained
and adjusted according to instructions in the
manual.
• To prevent inhalation of isocyanate mists, vapors,
and atomized particulates, everyone in the work
area must wear appropriate respiratory protection.
Always wear a properly fitting respirator, which
may include a supplied-air respirator. Ventilate the
work area according to instructions in the fluid
manufacturer’s SDSs.
• Avoid all skin contact with isocyanates. Everyone
in the work area must wear chemically
impermeable gloves, protective clothing and foot
coverings as recommended by the fluid
manufacturer and local regulatory authority.
Follow all fluid manufacturer recommendations,
including those regarding handling of
contaminated clothing. After spraying, wash
hands and face before eating or drinking.
Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings and
Safety Data Sheets (SDSs).
Cross-contamination can result in cured material in
fluid lines which could cause serious injury or damage
equipment. To prevent cross-contamination:
•Never interchange component A and component
B wetted parts.
• Never use solvent on one side if it has been
contaminated from the other side.
NOTICE
Partially cured ISO will reduce performance and the life
of all wetted parts.
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere. Never
store ISO in an open container.
• Keep the ISO pump wet cup or reservoir (if
installed) filled with appropriate lubricant. The
lubricant creates a barrier between the ISO and the
atmosphere.
• Use only moisture-proof hoses compatible with
ISO.
• Never use reclaimed solvents, which may contain
moisture. Always keep solvent containers closed
when not in use.
• Always lubricate threaded parts with an appropriate
lubricant when reassembling.

Important Isocyanate (ISO) Information
8 3A4381M
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.
Changing Materials
NOTICE
Changing the material types used in your equipment
requires special attention to avoid equipment damage
and downtime.
• When changing materials, flush the equipment
multiple times to ensure it is thoroughly clean.
• Always clean the fluid inlet strainers after flushing.
• Check with your material manufacturer for
chemical compatibility.
• When changing between epoxies and urethanes or
polyureas, disassemble and clean all fluid
components and change hoses. Epoxies often
have amines on the B (hardener) side. Polyureas
often have amines on the B (resin) side.

Overview
3A4381M 9
Overview
Usage
The XP-hf is a mechanically linked fixed ratio system
that can mix and spray most two-component epoxy and
urethane protective coatings.
When using quick-setting material (less than 10 minute
pot life), the Remote Manifold Heater Block Kit (24Z934)
is recommended for use (see Models section starting
on page 10).
Over Pressure Protection
Using an XP-hf system, or components on the system,
not approved for hazardous locations or explosive
atmospheres may result in a fire or explosion hazard.
The XP-hf systems are not approved for use in
hazardous locations unless the base model, all
accessories, all kits, and all wiring meet local, state,
and national codes.
See Wire Systems with Explosion-Proof Heaters on
page 22.
Mechanically linked pumps can create excessive fluid
pressure if the full motor force is applied to only one of
the fluid pumps.
•Cart-Mounted Systems Only: Maximum air
pressure set point blow off valves are provided to
limit maximum fluid pressure. Do not remove these
valves.
• Color coded automatic over pressure relief valves
are used on cart-mounted systems to dump excess
fluid pressure back to the supply. Never plug these
return hoses. See Fluid Circulation Manifold with
Over Pressure Relief Valves on page 48.
• When using an XP-hf pump assembly to build a
system, use the over pressure relief valves
referenced above.
• Never install individual shut off valves on the “A” and
“B” lines. On cart-mounted systems, common
handles link the fluid control valves.
• A rupture disc is provided on the small side fluid
pump (pumps 145 cc and smaller) as a back-up to
the over pressure relief valve. If the rupture disc ever
opens, do not operate the machine until the over
pressure valve and the rupture disc have been
replaced.
• If changing pump lowers or motor on your system,
use the correct over pressure relief valves from the
chart on page 49.

Models
10 3A4381M
Models
NOTE: See special conditions for safe use in your
Viscon HF Heater manual and your Viscon HP Heater
manual.
OEM Packages
Packages include XP-hf pump assembly and
connection components.
Pump sizes are marked on the pump cylinder; sizes are
nominal. See the technical specifications in your pump
lower manual for actual displacement.
OEM packages require additional components to make
a complete system. See Fluid Control Assembly, page
15; Main Air Controls, page 16; and System
Components, page 18.
Series Change
The XP cart frame was upgraded to allow better access
to the pump lowers.
Benefits of the new frame include:
• Ease of use
• Ease of service and greater access to lowers
Using an XP-hf system, or components on the system,
not approved for hazardous locations or explosive
atmospheres may result in a fire or explosion hazard.
The XP-hf systems are not approved for use in
hazardous locations unless the base model, all
accessories, all kits, and all wiring meet local, state,
and national codes.
See Wire Systems with Explosion-Proof Heaters on
page 22.
Building systems with OEM packages:
High-pressure fluid from gun, hose leaks, or ruptured
components may result in pierced skin.
•Over Pressure Protection must be used, see
page 9. See chart on page 18 to identify the over
pressure relief valves to use with your system.
• All components must meet or exceed maximum
working pressures.
WLD
WLE
Series A and B Series C
Series Change Description
C Upgraded XP frame

Series Change
3A4381M 11
Models
PART NUMBER CODE EXAMPLE:
System Pressure Ratio (First Three Digits of Part Number)
*Volume Mix Ratios - 70:1 (Fourth and Fifth Digits of Part Number)
*Volume Mix Ratios - 50:1 (Fourth and Fifth Digits of Part Number)
System
Pressure Ratio
*Volume
Mix Ratio
#Components
(see page 12)
57 x x x x
First
Three Digits
Fourth and
Fifth Digits Last Digit
First Three
Digits System Ratio Maximum Fluid Working Pressure psi (MPa, bar)
572xxx 70 : 1 7250 (50, 500)
573xxx 50 : 1 5000 (34, 344)
Fourth
and
Fifth
Digits
Pump
Ratio
(A/B)
A Side
Pump
B Side
Pump
Combined
Fluid
Output
(cc/cycle)
Fluid Flow
at 40 cpm
gpm (lpm)
Over
Pressure
Relief Valve
Maximum Air
Working
Pressure
psi (MPa, bar)
Fluid to Air
Pressure
Ratio
Maximum Fluid
Working
Pressure
psi (MPa, bar)
xxx10x 1 : 1 L14AC0 L14AC0 290 3.0 (11.3) Silver 100 (0.7, 7) 71 : 1 7100 (49, 490)
xxx15x 1.5 : 1 L14AC0 L097C0 242 2.6 (9.8) Silver 85 (0.59, 5.9) 86 : 1 7250 (50, 500)
xxx20x 2 : 1 L18AC0 L090C0 270 2.8 (10.6) Silver 95 (0.65, 6.5) 76 : 1 7250 (50, 500)
xxx25x 2.5 : 1 L18AC0 L072C0 252 2.6 (9.8) Silver 90 (0.62, 6.2) 81 : 1 7250 (50, 500)
xxx30x 3 : 1 L22XC0 L072C0 292 3.0 (11.3) Silver 100 (0.7, 7) 71 : 1 7100 (49, 490)
xxx40x 4 : 1 L22XC0 L054C0 274 2.8 (10.6) Silver 95 (0.65, 6.5) 76 : 1 7250 (50, 500)
Fourth
and
Fifth
Digits
Pump
Ratio
(A/B)
A Side
Pump
B Side
Pump
Combined
Fluid
Output
(cc/cycle)
Fluid Flow
at 40 cpm
gpm (lpm)
Over
Pressure
Relief Valve
Maximum Air
Working Pressure
psi (MPa, bar)
Fluid to Air
Pressure
Ratio
Maximum Fluid
Working Pressure
psi (MPa, bar)
xxx10x 1 : 1 L22AC0 L22AC0 440 4.6 (17.4) Gold 100 (0.7, 7) 48 : 1 4750 (33, 330)
xxx15x 1.5 : 1 L22AC0 L14AC0 365 3.8 (14.4) Gold 90 (0.62, 6.2) 56 : 1 5000 (35, 345)
xxx20x 2 : 1 L29AC0 L14AC0 435 4.6 (17.4) Gold 100 (0.7, 7) 48 : 1 4750 (33, 330)
xxx25x 2.5 : 1 L29AC0 L115C0 405 4.2 (15.9) Gold 100 (0.7, 7) 50 : 1 5000 (35, 345)
xxx30x 3 : 1 L29AC0 L097C0 387 4.0 (15.1) Gold 95 (0.65, 6.5) 53 : 1 5000 (35, 345)
xxx40x 4 : 1 L29AC0 L072C0 362 3.8 (14.4) Gold 85 (0.59, 5.9) 59 : 1 5000 (35, 345)

Approvals
12 3A4381M
#Components (Sixth Digit of Part Number)
† OEM packages require additional components to make a complete system, see page 61.
HAZ Hazardous Location - Class 1 Division 1
EX Rated for use in explosive atmospheres
ORD Not for use in explosive atmospheres or hazardous locations
Approvals
Sixth Digit XP-hf Pump
Assembly Cart
Hose
and XTR
Gun
7 Gallon
Hoppers
Viscon HF
Heaters
(Primary
A&B)
Solvent
Pump
Junction
Box
Water Hose
Heater with
Circulation Pump
Location
Approval
xxxxx0 (†)x(†)
xxxxx1 xxx HAZ, EX
xxxxx2 xxxx HAZ, EX
xxxxx3 xxx 240 V x HAZ, EX
xxxxx4 x x x x 240 V x HAZ, EX
xxxxx5 x x x x 240 V x x ORD
xxxxx6 x x x x 240 V x 240 V HAZ, EX
xxxxx7 x x x x 240 V x x 240 V ORD
xxxxx8 x x x x 480 V x x ORD
xxxxx9 x x x x 480 V x x 480 V ORD
Pump Packages
without Pump Lowers Includes:
Part System Ratio Maximum Fluid Working
Pressure psi (MPa, bar) Cart XTRxxx Spray Gun and 35 ft (10.7 m) Supply hose (not attached)
572000(#) 70:1 7250 (50, 500) X X
573000(#) 50:1 5000 (34, 344) X X
# These pump packages without pump lowers are not operational and are not CE or Ex marked.
All systems CE marked except where noted.
All systems with a part number ending in 0, 1, 2, 3, 4, and 6 are
Ex rated for use in explosive atmospheres except where noted.
II 2 G Ex h IIA T3 Gb

Component Identification
3A4381M 13
Component Identification
XP-hf Proportioners (Model 572407 shown)
Key:
A XP-hf Motor Air Supply
C Main Air Controls; see page 16
D XP Fluid Pump
EXL
™10000 Air Motor
H Solvent Flush Pump Air Controls; see page 17
K Cart
L Brake
N Fluid Control Assembly; see page 15
P Pump Tie Rods
R Motor Adapter Plate
S Adjustable Packing Nuts with Wet Cups
T Yoke with Rod Bearings
V Connecting Rod Nut
W Static Mixer Tubes with Replaceable Plastic Elements
X Motor Position Indicator Bracket;
see Motor Position, page 22
Y Over Pressure Rupture Disc; only 145cc pumps or smaller
ZB Air Motor Ground Wire
ZD Solvent Pump Ground Wire
ZL Gun and Hose
ZP Main Power Disconnect
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Component Identification
14 3A4381M
XP-hf Proportioners (continued)
Key:
F Viscon HF Fluid Heater (A and B material)
J 7 Gallon Hoppers (green B-side shown)
M Handle (lift to release)
U Recirculation Lines
BA Solvent Flush Pump
ZA Pressure Trak
ZC Junction Box
ZF Circulation Pump Reservoir
ZG Circulation Pump
ZH Viscon HP Hose Water Heater
ZK Solvent Prime/Flush Valve
ZM Heater ON/OFF Switches
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Component Identification
3A4381M 15
Fluid Control Assembly
This is required to add to OEM Packages to make a complete system.
AC
AA
AF
AE
AD
AB
AM
AL
AK
AJ
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; see page 33
AK A and B Mix Manifold Check Valves
AL Solvent Inlet Check Valve
AM Automatic, Spring Loaded, Color-Coded Over Pressure
Relief Valves; with grease fittings; see page 49
AH
ti19167a
Standard Mix Manifold shown

Component Identification
16 3A4381M
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
CG Motor Air Pressure Relief Valve
CH Main Air Inlet
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Component Identification
3A4381M 17
45:1 Solvent Flush Pump
Pump
Air Controls
Key:
BA Solvent flush pump (Merkur Pump)
BB Siphon Tube
BD Muffler
BE Solvent Prime Valve
BF Solvent Outlet Hose
BG Solvent Circulation Hose
BH Solvent Pump Wet Cup
BA
BB
BD
BG
BF
BE
(suction hose not shown)
BH
Key:
DA Solvent Pump Air Shutoff Valve (Relieving)
DB Solvent Pump Air Pressure Regulator
DC Solvent Pump Air Pressure Gauge
DD Solvent Pump Air Outlet
DE Solvent Pump Air Inlet
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System Components
18 3A4381M
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)
Be sure the valve is easily accessible from the pump
and located downstream from the air regulator (CB).
The two steps below are required in your system to
relieve air trapped between the air motor when the valve
is closed:
1. Open the valve to supply air to the motor.
2. Close the valve to shut off air to the motor, and
bleed any trapped air from the motor.
*XP-hf Motor Air Pressure Relief
Valve (CG)
Automatically opens to relieve air pressure if supplied
pressure exceeds preset limit. Use the correct air
pressure relief valve for the system ratio:
*Main Air Filter (CC)
Removes harmful dirt from compressed air supply. A
minimum 40 micron filter is used.
*XP-hf Motor Air Regulator (CB)
Adjusts air pressure to the motor and fluid outlet
pressure of pump. Locate the air regulator close to the
pump. Read air pressure on the gauge.
Fluid Line Components
•*Recirculation Manifold (AA): Controls circulation
and pump priming.
•*Mix Manifold (AB): Combines A and B fluid into
one fluid line.
•*Recirculation Handle (AC): Directs fluid flow for
circulation or mixing. Move to open position to
relieve fluid pressure, prime pumps, and circulate
material in hoppers. Move to closed position to
spray mixed material.
•*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 (W): Thoroughly mixes
the two fluids and delivers the mixed fluid to the
spray gun. Includes static mixer and hoses to the
spray gun.
•Viscon HF Fluid Heaters (F): Heats the resin and
hardener before mixing. Improves the chemical
reaction and lowers viscosity to improve the spray
pattern.
•Solvent Flush Pump (BA): Flushes the mix
manifold. Includes a solvent pump, mounting
hardware, and solvent supply hose.
Trapped air can cause the pump to cycle
unexpectedly, which could result in serious injury from
splashing or moving parts. Use the Bleed Type
Master Air Valve to relieve trapped air.
XP70-hf XP50-hf
Ratio Valve Part Ratio Valve Part
1:1 113498 1:1 113498
1.5:1 16M190 1.5:1 103347
2:1 114055 2:1 113498
2.5:1 103347 2.5:1 113498
3:1 113498 3:1 114055
4:1 114055 4:1 16M190

Setup
3A4381M 19
Setup
Location
1. Locate the proportioner on a level surface.
2. Position the proportioner for convenient operator
access and maintenance, proper routing of air and
fluid lines, and easy connection of components and
accessories.
3. For permanent mounting, remove wheels and
mount the frame to the floor. See Dimensions,
page 72.
4. Make sure cart brake (L) is in the locked position.
Initial System Setup
1. Check the shipment for accuracy. Ensure you have
received everything you ordered. See Component
Identification, page 13.
2. Check for loose fittings and fasteners.
3. Systems supplied as complete are already
connected for fluid, air and electrical hookups.
4. If any accessories are added to a non-complete
system refer to the individual manual listed on page
3.
5. Install desiccant kits if using polyurethane
isocyanates in hoppers. See desiccant dryer kit
manual for instructions.
6. Install circulation and return tube kits if you are
feeding material from drums or remote hoppers.
See your circulation and return tubes kit manual if
you are feeding urethane material.
7. Connect the feed pumps, fluid strainers, and air
hoses as necessary. For systems without hoppers,
see your feed pump and agitator kit manual.
8. Connect the fluid hose assembly, including the
static mixers, whip hose and gun. See Connect
Static Mixers, Gun, and Hoses, page 23.
9. Connect the battery in the PressureTrak module.
10. Connect the air supply hose. See Connect Air
Supply, page 23.
Flush test oil from system as needed. See Connect the
resin and hardener hoses to the resin and hardener
inlets on the mix manifold., page 24. See Empty and
Flush Entire System (new system or end of job),
page 36.
Using an XP-hf system, or components on the system,
not approved for hazardous locations or explosive
atmospheres may result in a fire or explosion hazard.
The XP-hf systems are not approved for use in
hazardous locations unless the base model, all
accessories, all kits, and all wiring meet local, state,
and national codes.
See Wire Systems with Explosion-Proof Heaters on
page 22.

Setup
20 3A4381M
Grounding
Junction Box: Connect the power cable ground wire to
the ground terminal (GT). Follow Connect Power on
page 21.
Pump: Connect ground wire 244524 (ZB) to the ground
stud (GS) on the air motor (E).
Connect the other end of the ground wire to a true earth
ground for systems without heaters, otherwise connect
to HF heater clamp bar.
Object being sprayed: Ground the object being
sprayed, fluid supply container, and all other equipment
in the work area. Follow your local code. Use only
electrically conductive air and fluid hoses.
Solvent pail: Ground all solvent pails. Use only metal
pails, which are conductive, placed on a grounded
surface. Do not place pail on a non-conductive surface,
such as paper or cardboard, which interrupts grounding
continuity.
Solvent pump: Connect ground wire (ZD) and clamp
(supplied with solvent pump) to the ground stud (GS) on
the solvent pump (BA).
Air and fluid hoses: use only static dissipation type
hoses with a maximum of 300 ft (91 m) combined hose
length to ensure grounding continuity. Check electrical
resistance of hoses regularly. If total resistance to
ground exceeds 29 megohms, replace hose
immediately.
Air compressor: follow manufacturer’s
recommendations.
Spray gun: ground through connection to a properly
grounded fluid hose and pump.
Flush Before Using Equipment
The system 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 36.
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.
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