SPI LPG Synergy Series User manual

SPECIALTY-PRODUCTS.COM
LPG
SYNERGY SERIES
™
LOW PRESSURE,
PLURAL COMPONENT
PROPORTIONER
Designed
for Spraying or Pouring
Polyurethane Foam
& Polyurea Coatings,
from the SPI SYNERGY
Family of Products
LPG VIDEO
MANUAL
PROUDLY
made in the USA

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LPG™INTRODUCTION
VIDEO
TABLE OF CONTENTS
MANUAL CONVENTIONS 4
TYPICAL EQUIPMENT INSTALLATION 9
COMPONENT IDENTIFICATION 10
INITIAL SET-UP 18
DAILY START-UP 28
SPRAY 30
DAILY SHUT DOWN 31
PRESSURE RELIEF PROCEDURE 32
FLUSH PROCEDURE 33
PROPORTIONING PUMP REPLACEMENT 34
PARTS MANUAL 36
TROUBLESHOOT 42
110 VOLT WIRING DIAGRAM 43
HITACHI AC DRIVE 100v/0.75kW 44
DIMENSIONS 45
TECHNICAL DATA 46
LPG™ PUMP OUTPUT CHART 47
LIMITED LIFETIME WARRANTY 48

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WARNING
CAUTION
NOTE
ISOCYANATE HAZARD
A caution alerts you to possible equipment damage or destruction,
if you do not follow instructions.
Read SPI’s warnings and material MSDS to know the specific hazards
of isocyanates. Use equipment in a well-ventilated area. Wear respirator,
gloves, and protective clothing when using isocyanates.
A note indicates additional helpful information.
A warning alerts you to possible serious or fatal injury if you do not
follow instructions.
Symbols, such as respiratory hazard ( ), alert you to a specific
hazard and direct you to read the indicated hazard warnings on page
4 and 5.
MANUAL CONVENTIONS
MANUAL CONVENTIONS
& SAFETY VIDEO

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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.
SEEK IMMEDIATE SURGICAL TREATMENT:
»DO NOT point the gun at anyone or at any part of the body.
»DO NOT put your hand or fingers over the gun fluid nozzle.
»DO NOT stop or deflect leaks with your hand, body, glove, or rag.
»DO NOT “blow back” fluid; this is not an air spray system.
»Follow Daily Shut Down Procedure chapter, when you stop spraying and before cleaning,
checking, or servicing equipment.
»Use lowest possible pressure when flushing, priming, or troubleshooting.
»Close gun manual valves when not spraying.
»Tighten all fluid connections before operating the equipment.
»Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
High pressure hose cannot be re-coupled; replace the entire hose.
FIRE, EXPLOSION & ELECTRIC SHOCK HAZARD
Solvent and fumes in work area can ignite or explode. High voltage components can
cause electric shock. To help prevent fire, explosion, and electric shock:
»Shut o main power switch and wait 5 minutes before opening LPG™top cabinet door.
»All electrical wiring must be done by trained and qualified personnel and comply with
all local codes.
»Use equipment only in well ventilated area.
»Eliminate all ignition sources, such as pilot lights, cigarettes and plastic drop cloths
(potential static arc).
»DO NOT plug or unplug power cords or turn lights on or o when flammable fumes
are present.
»Keep the work area free of debris, including solvents, rags and gasoline.
»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.
»To avoid chemical reaction and explosion, DO NOT use trichloroethane, methylene
chloride, other halogenated hydrocarbon solvents or fluids containing such
solvents in pressurized aluminium equipment.
»Always use provided GFCI 20AMP Circuit Breaker for LPG™ Hose Heat power
cord connection.
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WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause serious injury or death.
• For professional use only.
• Use equipment only for its intended purpose. Call SPI technical support (1-800-627-0773)
for information.
• Read manuals, warnings, tags, and labels before operating equipment.
Follow instructions.
• Check equipment daily. Repair or replace worn or damaged parts immediately.
• DO NOT alter or modify equipment. Use only SPI parts and accessories.
• DO NOT exceed the maximum working pressure or temperature rating of the lowest
rated system component. See Technical Data chapter.
• Use fluids and solvents that are compatible with equipment wetted parts.
See Technical Data in all equipment manuals.
• Route hoses and cables away from trac areas, sharp edges, moving parts
and hot surfaces.
• DO NOT use hoses to pull equipment.
• Comply with all applicable safety regulations.
BURN HAZARD
This equipment can be used with heated fluid, which can cause equipment surfaces to
become very hot. To avoid severe burns:
• DO NOT touch hot fluid or equipment.
• Allow equipment to cool completely before touching it.
• Always wear gloves if fluid temperature exceeds 110°F (43°C).
PERSONAL PROTECTIVE EQUIPMENT
You must wear proper protective equipment when operating, servicing, or when in the
operating area of the equipment to help protect you from serious injury, including eye
injury and inhalation of toxic fumes. This equipment includes but is not limited to:
• Protective eye wear.
• Gloves, clothing and respirator as recommended by the MSDS.
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 Material Safety Data Sheet (MSDS) 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.
MANUAL CONVENTIONS

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OPERATOR NOTES
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TYPICAL EQUIPMENT INSTALLATION
EQUIPMENT
LOCK N LOAD™Gun A
25’ or 50’ Heated Spray Hose B
LPG™Proportioner C
LPG™Transfer Assembly with Riser Tube D
and Strainer
Synergy Series Product Drums E
C
D
E
B
A
100 TO 110 GALLON DRUM SET30 GALLON DRUM SET10 GALLON DRUM SET
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COMPONENT IDENTIFICATION
LPG™
Operating Control Panel A
(See page 10)
Acomponent Over-Pressure B
Safety Switch
Acomponent Pressure Gauge C
Acomponent Hose Fluid D
Pressure Fitting
Acomponent Proportioning Pump E
1 HP AC Motor F
Low Pressure Air Compressor G
(Not Shown)
Bcomponent Over-Pressure H
Safety Switch
Bcomponent Pressure Gauge I
Desiccant Air Dryer J
Bcomponent Hose Fluid K
Pressure Fitting
Bcomponent Proportioning Pump L
A
HB
I
K
L
C
D
E
F
J

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A & B PRESSURE GAUGE
The LPG™incorporates two pressure gauges to indicate the
dynamic back pressure of each component while the machine
is running. The amount of back pressure at dierent motor
speed settings will vary based on; length of spray hose,
temperature/viscosity of the fluid product, and/or type of
static-mixer.
The pressure gauges can also be used to identify the cause of
a motor controller fault code. See Troubleshooting chapter of
this manual.
Unlike high-pressure, plural component spray equipment,
the LPG™does not build and maintain a static pressure; its
unique on-demand delivery system will only generate flow,
at the spray gun, with user input.
A & B OVER PRESSURE SAFETY SWITCH
In addition to a visual indication of the pressure of either
component, via the pressure gauges, the LPG™also incorporates
an electrical overpressure safety circuit to monitor for unsafe
conditions. This safety circuit consists of two normally closed
pressure switches monitored by the motor controller. In the
event either component exceeds 1000 psi, the motor controller
will stop the motor and display the fault code EF-2 on the Gun
Flow Control display.
LOW PRESSURE AIR COMPRESSOR
The Low Pressure Air Compressor supplies 5-7 psi of dry air to
the A and B component containers. Pressure to the containers
is regulated by the material supply pressure switch.
MATERIAL SUPPLY AIR DRYER
Do to the moisture sensitivity of the A component air to the A
component container is directed through the Air Dryer. The Air
Dryer contains silica crystal to absorb moisture from the air. The
color of serviceable silica crystal is deep blue. As the crystal
absorbs moisture the crystal will change to pink. The silica crystal
may be regenerated up to three times in an electric oven using
the following method:
Remove the 2” threaded plug, and foam filter from the end
of the dryer.
Empty crystals on to a cooking sheet and distribute evenly.
Bake in an electric oven at 250° for up to 8 hours until crystal have
returned to a deep blue color.
Re-fill tube and reinstall filter and 2”threaded plug.
If browning occurs, the silica must be replaced.

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OPERATING CONTROL PANEL
Gun Flow Control Display A
Motor Stop IControl Reset B
Main Power Switch C
Pump Pre-Heater Switch D
Front Panel Indication Lights E
Output Meter F
AC
B
D
E
F
COMPONENT IDENTIFICATION

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GUN FLOW CONTROL DISPLAY
Displays the current flow setting of the Motor Controller.
Also displays any error code identified in the
Troubleshooting chapter of this manual.
FRONT PANEL INDICATION LIGHTS
SYSTEM PRESSURIZED:
The green light indicates that the material supply system is
pressurized, and the on-board supply air compressor is o.
COMPRESSOR ON:
The yellow light indicates that the on-board supply air
compressor is running and building pressure in the material
supply system/material containers.
HEATER ON:
The yellow light indicates that the Pump Pre-Heater is on
and will apply heat to the pump-line. It will cycle on and o
to maintain a pre-set temperature.
MOTOR STOP ICONTROL RESET
The Motor Stop/Control Reset button functions as a
alternate method to discontinue flow to the spray gun.
It also functions as a control system reset in the event that
there has been a error code. The reset function will only
reset the controller once the fault has been cleared.
OUTPUT METER
Counts plural component product output, in tenths of gallons,
processed through the machine. It is powered by an internal,
replaceable battery, which has an average life of seven years.
Pressing the button in the lower right corner will zero the
Output Meter. The numerical quantity displayed is total material
output (example: 1 gallon displayed = 0.5 gal of A component
+ 0.5 gal B component).
MAIN POWER SWITCH
Controls the application of 115 Volt AC power to the LPG™.
Once actuated, the on-board motor controller will turn on,
the on-board air compressor will begin to pressurize the
material supply system, and power will be supplied to the
Pump Pre-Heater Switch.
The Main Power Switch also serves as over current safety switch.
It will trip if an unsafe condition exists.
PUMP PRE-HEATER SWITCH
This switch will activate the 80 watt pump pre-heater
located on the B component proportioning pump. Once
actuated, the heater will begin to apply heat and will
automatically cycle to maintain 130 degrees Fahrenheit.
The pump pre-heater is intended to pre-heat motor gear box in
colder climates to reduce initial system load. It is not intended to
heat the B component product during processing.
The Main Power Switch must be engaged to supply power to
the Pump Pre-Heater. The Pump Pre-Heater Switch also acts as
an over current protection device and will disengage if an unsafe
condition exists.

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A
D
B C E GF H IK
J
LOCK N LOAD™GUN
Static Mixer Safety Shroud A
Mixer Retainer Latch ILock B
Mixer Retainer C
Gun Dispensing Trigger D
Fluid Block E
Nucleating Air Line Fitting F
Manual Valve Grease Zerk G
Fluid Manual Shut-o Valve H
Nucleating Air Flow Control Valve I
Flow Control Dial J
Control Cable K
COMPONENT IDENTIFICATION

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MIXER RETAINER LATCH ILOCK
The LOCK N LOAD™mixer retainer latch provides an ecient
means to quickly remove and replace the static mixer. The
latch is adjustable to provide the optimum seal between the
static mixer and fluid block.
FLUID MANUAL SHUT-OFF VALVE
The fluid manual shut-o valves isolate the A and B
component product from the heated hose assembly and
gun block. They provide a means to safe the gun while not
actively spraying.
NUCLEATING AIR FLOW CONTROL VALVE IFLOW
CONTROL DIAL
Spray pattern control is accomplished by making adjustments
to both the Nucleating Air Flow Control Valve and the Flow
Control Dial. A spray pattern can be fine-tuned by making
minor adjustments to both, and visually monitoring the
spray pattern.
Flow Control Dial can be set and locked to a desired control
speed. Using a 5/16 wrench to tighten down the lock nut on
the control speed shaft.

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8
5
6 4
3
9
10
1
11
2
7
13
12
14
18
ITEM NO. PART NUMBER DESCRIPTION
DESCRIPTION
QTY.
1 L-202002 Gun handle with trigger assembly, ow control, and mount bolt 1
2
L-202001 LOCK N LOAD™ Gun Block Assembly 1
3
L-202004 Manual Valve - A 1
4
L-202005 Manual Valve - B 1
5
L-202006 25 psi Check Valve, Kit (Replace in pairs) 2
6
R-200021 Push to Connect Air Fitting 1
7
R-100035 Safety Shroud Thumb Screw 1
8
L-202007 LOCK N LOAD™ lever latch replacement, Kit 1
9
P-100548 B Component Swivel Fitting 1
10
P-100549 A Component Swivel Fitting 1
11
See Table 2 Side Cleanout Plug
Side Cleanout Plug (NPT)
2
12
L-202009
R-200019B001 - B099
Side Cleanout Plug (BSPP)
R-200051B100 - Above
12 in Safety Shroud 1
13
L-202010 7 in Safety Shroud 1
14
L-202003 Air Nucleation Flow Control Assembly 1
15
P-100291-(12/100)* 12" Round Static Mixer (Available in 12 and 100 packs) SERIAL
NUMBER
PART
NUMBER
1
16
P-100320-(12/100)* 7" Round Static Mixer (Available in 12 and 100 packs) 1
17
P-100299-(12/100)* 9" Square Static Mixer (Available in 12 and 100 packs) 1
18
L-202008 33" Air Nucleating Replacement Set (Package of 12 lines) 1
9” SQUARE
JOINT FILL & POUR POLYUREA
COMPONENT IDENTIFICATION
8
5
6 4
3
9
10
1
11
2
7
13
12
14
18
ITEM NO. PART NUMBER DESCRIPTION
DESCRIPTION
QTY.
1 L-202002 Gun handle with trigger assembly, ow control, and mount bolt 1
2
L-202001 LOCK N LOAD™ Gun Block Assembly 1
3
L-202004 Manual Valve - A 1
4
L-202005 Manual Valve - B 1
5
L-202006 25 psi Check Valve, Kit (Replace in pairs) 2
6
R-200021 Push to Connect Air Fitting 1
7
R-100035 Safety Shroud Thumb Screw 1
8
L-202007 LOCK N LOAD™ lever latch replacement, Kit 1
9
P-100548 B Component Swivel Fitting 1
10
P-100549 A Component Swivel Fitting 1
11
See Table 2 Side Cleanout Plug
Side Cleanout Plug (NPT)
2
12
L-202009
R-200019B001 - B099
Side Cleanout Plug (BSPP)
R-200051B100 - Above
12 in Safety Shroud 1
13
L-202010 7 in Safety Shroud 1
14
L-202003 Air Nucleation Flow Control Assembly 1
15
P-100291-(12/100)* 12" Round Static Mixer (Available in 12 and 100 packs) SERIAL
NUMBER
PART
NUMBER
1
16
P-100320-(12/100)* 7" Round Static Mixer (Available in 12 and 100 packs) 1
17
P-100299-(12/100)* 9" Square Static Mixer (Available in 12 and 100 packs) 1
18
L-202008 33" Air Nucleating Replacement Set (Package of 12 lines) 1
8
5
6 4
3
9
10
1
11
2
7
13
12
14
18
ITEM NO. PART NUMBER DESCRIPTION
DESCRIPTION
QTY.
1 L-202002 Gun handle with trigger assembly, ow control, and mount bolt 1
2
L-202001 LOCK N LOAD™ Gun Block Assembly 1
3
L-202004 Manual Valve - A 1
4
L-202005 Manual Valve - B 1
5
L-202006 25 psi Check Valve, Kit (Replace in pairs) 2
6
R-200021 Push to Connect Air Fitting 1
7
R-100035 Safety Shroud Thumb Screw 1
8
L-202007 LOCK N LOAD™ lever latch replacement, Kit 1
9
P-100548 B Component Swivel Fitting 1
10
P-100549 A Component Swivel Fitting 1
11
See Table 2 Side Cleanout Plug
Side Cleanout Plug (NPT)
2
12
L-202009
R-200019B001 - B099
Side Cleanout Plug (BSPP)
R-200051B100 - Above
12 in Safety Shroud 1
13
L-202010 7 in Safety Shroud 1
14
L-202003 Air Nucleation Flow Control Assembly 1
15
P-100291-(12/100)* 12" Round Static Mixer (Available in 12 and 100 packs) SERIAL
NUMBER
PART
NUMBER
1
16
P-100320-(12/100)* 7" Round Static Mixer (Available in 12 and 100 packs) 1
17
P-100299-(12/100)* 9" Square Static Mixer (Available in 12 and 100 packs) 1
18
L-202008 33" Air Nucleating Replacement Set (Package of 12 lines) 1
STATIC MIXERS
12” ROUND
SPRAY & POUR POLYUREA
7” ROUND
SPRAY & POUR FOAM

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LPG™ SYNERGY SERIES R06262018
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2.1.
INITIAL SET-UP
1. LOCATE LPG™
1.1. Position LPG™on a level surface.
1.2. DO NOT expose LPG™to moisture.
2. CONNECT COMPONENT TRANSFER HOSES
2.1. Apply teflon tape to threads identified in illustration.
2.2. Connect the Acomponent transfer hose to the
Acomponent proportioning pump inlet fitting.
2.3. Connect the Acomponent airline to the outlet
of the air dryer.
2.3.
Heat material supply containers to the required
temperatures in accordance with the material drum
labels and technical data prior to beginning initial
set-up. The time required to reach the material
optimum application temperature will vary based on,
ambient conditions, starting temperature volume
of material in the containers, and the method used
to heat the material containers.
Placement of the Aand Bcomponent supply
containers must not cause any sharp bends or
excessive pressure on the component transfer
hose assembly. The component transfer hose
must be as straight as possible with a slight
downward angle toward the LPG™inlets.
INITIAL SET-UP
VIDEO

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2.5.
2.6.
2.5. Locate the appropriate material supply riser tube and
insert into the Aside insert assembly. Install the supply
riser tube that is the correct length depending on which
LPG™container you will be using. (5, 15 & 55 gal)
2.6. Insert the quick disconnect receiver/riser tube
assembly into the material container.
2.4. Locate the Aside fluid container near the LPG™to
install the Aside transfer assembly.
Apply the supplied Super Lube [or equivalent]
to the visible seals and threads of all Aside
components.
Use Blue Drum wrench provided in SPI LPG™tool kit
to hand tighten only.

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2.8. Thread the Aside combo coupler into the Aside
insert [aligning keys with key ways] until the connector
is hand tight.
Over tightening the transfer quick disconnect can
cause an air leak which will not allow the transfer
supply system to properly pressurize as designed.
2.8.
2.7. Remove Aside insert storage plug.
2.7.
The bottom of each LPG™fluid strainer/air trap must
be positioned at a minimum of 4 inches above the
top of the LPG™proportioning pump inlet.
4” MIN
INITIAL SET-UP