Graco 313289s User Manual

Repair-Parts

XM Plural-Component

313289S

Sprayers

For spraying two-component epoxy and urethane protective coatings in hazardous and non-hazardous locations. For professional use only.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

See pages 7 and 8 for model information and agency approvals. See page 85 for maximum working pressure.

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Contents

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

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Isocyanate Hazard . . . . . . . . . . . . . . . . . . . . . . . 9

Material Self-Ignition . . . . . . . . . . . . . . . . . . . . . . 9

Moisture Sensitivity of Isocyanates . . . . . . . . . . . 9

Components A and B . . . . . . . . . . . . . . . . . . . . 10

Changing Materials . . . . . . . . . . . . . . . . . . . . . . 10

Before Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Proper Lifting of Sprayer . . . . . . . . . . . . . . . . . . 11

Pressure Relief Procedure . . . . . . . . . . . . . . . . 12

Flush Before Using Equipment . . . . . . . . . . . . . 13

Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Flush Mixed Material . . . . . . . . . . . . . . . . . . . . . 14

Empty and Flush Entire System (new sprayer or end

of job) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Shutdown Entire System . . . . . . . . . . . . . . . . . . . 18

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . 18

XM Setup and Troubleshooting Guide . . . . . . . . 19

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

View Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Diagnose Alarms . . . . . . . . . . . . . . . . . . . . . . . . 23

Clear Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Replace Air Filter Element . . . . . . . . . . . . . . . . 31

User Interface/Control Box . . . . . . . . . . . . . . . . 32

Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Fluid Control Assembly . . . . . . . . . . . . . . . . . . . 42

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . 44

Solvent Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Fluid Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . 47

Simplified Electrical Schematic, XM Sprayer with

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Detailed Electrical Schematic, XM Sprayer with

Alternator (page 1) . . . . . . . . . . . . . . . . . . . 49

Simplified Electrical Schematic, XM Sprayer with

Wall Power . . . . . . . . . . . . . . . . . . . . . . . . . 51

Detailed Electrical Schematic, XM Sprayer with Wall

Power (page 1) . . . . . . . . . . . . . . . . . . . . . . 53

Junction Box Wiring Schematics . . . . . . . . . . . . . 55

Fluid Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Hopper Heaters . . . . . . . . . . . . . . . . . . . . . . . . . 56

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Control Box (255771) Parts . . . . . . . . . . . . . . . . 70

Junction Box (256540) Parts . . . . . . . . . . . . . . . 75

Fluid Control Assembly Parts . . . . . . . . . . . . . . 76

Air Inlet Manifold (255762) Parts . . . . . . . . . . . . 77

Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . . 80

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

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

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 86

2 313289S

Related Manuals

Manuals are available at www.graco.com.

Component Manuals in U.S. English:

Manual Description

312359

313292

311762

311238

312747

309524

312145

312769

312794

406699

406739 Desiccant Kit Instructions-Parts

XM Plural-Component Sprayers Operation

XM Plural-Component OEM Sprayers Instructions-Parts

Xtreme Instructions-Parts

NXT Double Wall Hopper Kit

Instructions-Parts

Viscon

XTR Instructions-Parts

Feed Pump and Agitator Kits Instructions-Parts

Merkur Instructions-Parts

7-Gallon Hopper Installation Kit Instructions-Parts

Displacement Pumps

™

Air Motor Instructions-Parts

HP Heater Instructions-Parts

™

5 and XTR™ 7 Spray Guns

Pump Assembly

Related Manuals

406690 Caster Kit Instructions-Parts

406691 Hose Rack Kit Instructions-Parts

313258

313259

312770

312749

313293

313342

313343

Electric Heated Hose Power Supply Kit Instructions-Parts

Hopper or Hose Heat Circulation Kit Instructions-Parts

Lower Strainer and Valve Kit Instructions-Parts

XM Mix Manifold Kit Instructions-Parts

Alternator Conversion Kits Instructions-Parts

Dosing Valve Repair Kit Instructions-Parts

High Flow Severe Duty Shutoff Check Valve Repair Kit Instructions-Parts

313289S 3

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 symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.

WARNING

WARNINGWARNINGWARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

• Do not connect USB device in explosive atmospheres.

SPECIAL CONDITIONS FOR SAFE USE

• To prevent the risk of electrostatic sparking, the equipment’s non-metallic parts must be cleaned with only a damp cloth.

• Refer to the Viscon HP Heater manual for special conditions for safe use.

ELECTRIC SHOCK HAZARD

Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment.

• Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

4 313289S

Warnings

WARNING

INTRINSIC SAFETY

Intrinsically safe equipment that is installed improperly or connected to non-intrinsically safe equipment will create a hazardous condition and can cause fire, explosion, or electric shock. Follow local regulations and the following safety requirements.

• Only models with model number XM_D_ _ or XM_E_ _, and packaged models with part numbers ending in 00-13, 17-23, 27-29, 31, utilizing the air-driven alternator are approved for installation in a Hazardous (explosive atmosphere) Location - see Approvals:, page 8. Only the models stated above meet all local safety fire codes including NFPA 33, NEC 500 and 516, and OSHA 1910.107. To help prevent fire and explosion:

• Do not install equipment approved only for a non-hazardous location in a hazardous location.

See model ID label for intrinsic safety rating of your model.

• Do not substitute system components as this may impair intrinsic safety.

• Equipment that comes in contact with the intrinsically safe terminals must be rated for Intrinsic Safety. This includes DC voltage meters, ohmmeters, cables, and connections. Remove the unit from the hazardous area when troubleshooting.

• Do not connect, download, or remove USB device unless unit is removed from the hazardous (explosive atmosphere) location.

• If explosion-proof heaters are used, ensure wiring, wiring connections, switches, and electrical distribution panel all meet flame-proof (explosion-proof) requirements.

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 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.

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

•Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.

PRESSURIZED EQUIPMENT HAZARD

Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury.

•Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

MOVING PARTS HAZARD

Moving parts can pinch 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 in this manual. Disconnect power or air supply.

313289S 5

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. 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 forms from distributor or retailer.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

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 MSDS’s to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

• Always wear impervious gloves when spraying or cleaning equipment.

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. Wait until equipment/fluid has cooled completely.

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, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

•Gloves

• Hearing protection

6 313289S

Models

XM sprayers 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.

Check the identification plate (ID) for the 6-digit part number of the sprayer. Use the following matrix to define the construction of the sprayer, based on the six digits. For example, Part XM1A00 represents an XM Plural-Component sprayer (XM); 5200 psi pump set with pump filters (1); wall power supply, no heaters, no junction box, and is not approved for hazardous areas (A); with no additional kits (00).

NOTE:

Some configurations in the following matrix cannot be built. Consult with distributor or Graco representative.

To order replacement parts, see Parts section in this manual. The digits in the matrix do not correspond to the Ref. Nos. in the Parts drawings and lists.

XM 1 A

First and

Second

Digits

(plural com-

ponent

sprayer

mounted

on a frame)

(See Table 1 for lower models) Kit Choice

Pump Set

(hose/gun)

1 5200 psi

2 5200 psi B

3 6300 psi

4 6300 psi D

5 5200 psi 6 5200 psi 7 6300 psi 8 6300 psi

Third Digit Fourth Digit

System Choice

Pump

Filters

✔

✔✔

Remote

Manifold

✔

Control

Box

Wall Power

Supply NE

Wall Power

Supply

Wall Power

Supply

IS/

Alternator EH

IS/

Alternator

Fluid

Heaters

Location Category Key:

Junction

Box

✔✔

✔

Location

Overview

XM sprayers 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 Models, page 7, to determine the appro- priate location for your particular model.

Isocyanate Hazard

Spraying materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates.

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

Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not available, a supplied-air respirator is required for everyone in the work area.

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

Moisture Sensitivity of Isocyanates

Isocyanates (ISO) are catalysts used in two component foam and polyurea coatings. ISO will react with moisture (such as humidity) to form small, hard, abrasive crystals, which become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts.

NOTE:

The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature.

To prevent exposing ISO to moisture:

• Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container.

• Keep the ISO lube pump reservoir filled with Graco Throat Seal Liquid (TSL), Part 206995. The lubricant creates a barrier between the ISO and the atmosphere.

• Use moisture-proof hoses specifically designed for ISO, such as those supplied with your system.

• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.

• Never use solvent on one side if it has been contaminated from the other side.

• Always park pumps when you shutdown.

• Always lubricate threaded parts with Part 217374 ISO pump oil or grease when reassembling.

Material Self-Ignition

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

313289S 9

Overview

Components A and B

IMPORTANT!

Material suppliers can vary in how they refer to plural component materials.

Be aware that in this manual:

Component A Component B

NOTE:

This equipment doses the B component into the A component flow. An integration hose must always be used after the mix manifold.

Follow these recommendations for reassembly and setup:

• use at least a 3/8 in. (10 mm) x 25 ft. (7 m) hose.

• install a 24-element static mix tube after the integration hose.

Keep Components A and B Separate

To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (resin) and component B (hardener) parts.

refers to resin or major volume. refers to the hardener or minor volume.

NOTICE

Changing Materials

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

• Always clean the fluid inlet strainers and outlet filter after flushing. See Flush on page 14.

• Check with your material manufacturer for chemical compatibility.

• Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the A (resin) side.

NOTE:

If the amine will switch between the two sides, see Flush on page 14.

10 313289S

Before Repair

Location

Grounding

Connect ground wire clamp (FG) to a true earth ground. If wall power is used to power controls or heaters, ground electrical connection properly according to local codes.

Proper Lifting of Sprayer

Follow instructions to avoid serious injury or damage to equipment. Never lift with the hopper(s) filled.

Lift Using a Forklift

Power must be off. Sprayer can be raised and moved using a forklift. Carefully lift the sprayer; make sure it balances evenly.

Lift Using a Hoist

Sprayer can also be lifted and moved using a hoist. Connect a bridle swing, hooking an end to each of the air motor lift rings. Hook the center ring to a hoist Carefully lift the sprayer; make sure it balances evenly.

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2.0 ft. (0.61 m) minimum

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313289S 11

Before Repair

Pressure Relief Procedure

Follow Pressure Relief Procedure when you stop spraying or dispensing; and before cleaning, checking, servicing, or transporting equipment.

Relieve A and B Fluid Pressure

1. Engage trigger lock.

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2. Press .

3. If fluid heaters are used, shut them off using the controls on the heater control box.

7. Hold a metal part of the gun firmly to a grounded metal pail with a splash guard in place. Trigger gun to relieve pressure in material hoses.

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8. Engage trigger lock.

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Relieve Pump Fluid Pressure

4. Shut off feed pumps, if used.

5. Remove spray tip and clean.

6. Disengage trigger lock.

Fluid Heater B

Fluid Heater A

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9. Close mix manifold valves (AH, AJ), then open solvent flush valve (AK) on mix manifold.

Replace with illustration

10. Open solvent pump air control (CB). Use lowest pressure needed to flush material out of hose.

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12 313289S

r_312359_313289_14

Before Repair

11. Disengage trigger lock.

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12. Hold a metal part of the gun firmly to a grounded metal pail with a splash guard in place. Trigger gun to flush mixed material out of line with clean solvent.

13. Shut off solvent pump on air control panel.

14. Repeat steps 11 and 12. Then continue to step 15.

15. Close solvent flush valve (AK) on mix manifold.

Flush Before Using Equipment

The equipment was tested with lightweight oil, which is left in the fluid passages to protect parts. To avoid contaminating your fluid with oil, flush the equipment with a compatible solvent before use. See Flush on page 14.

Replace with illustration

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16. Release any residual gun pressure and engage trigger lock.

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313289S 13

Flush

Flush Mixed Material

Flush Mix Manifold

Use Solvent Pump

1. Press to turn off system. Follow Pressure Relief Procedure, page 12. Engage trigger lock.

Remove spray tip.

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4. Open solvent pump air control (CB). Pull out and slowly turn solvent pump air regulator (CG) clockwise to increase air pressure. Use lowest possible pressure.

r_312359_312359_3

5. Disengage trigger lock. Hold a metal part of the gun firmly to a grounded metal pail with a splash guard in place.Use a pail lid with a hole in it to dispense through. Be careful to keep fingers away from the front of the gun. Trigger gun until solvent appears.

4)!

2. Close sampling valves (AE, AF) and mix manifold valves (AH, AJ).

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3. Open solvent shutoff valve (AK) at mix manifold.

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6. Engage trigger lock.

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14 313289S

Flush

7. Close solvent pump air valve (CB) and solvent shutoff valve (AK) at mix manifold.

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8. Follow Pressure Relief Procedure, page 12.

9. Engage trigger lock.

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10. Disassemble and clean spray tip with solvent by hand. Reinstall on the gun.

313289S 15

Flush

Empty and Flush Entire System (new sprayer or end of job)

NOTE:

• If system includes heaters and heated hose, turn them off and allow to cool before flushing. Do not

turn on heaters until fluid lines are clear of solvent.

• Use the lowest possible pressure when flushing to avoid splashing.

• Before color change or shutdown for storage, flush at a higher flow rate and for a longer time.

• To flush only mix manifold, see Flush Mix Manifold procedure page 14.

Guidelines

Flush new systems if coating materials will be contaminated by 10W oil.

Flush system when any of the following situations occur. Flushing will help prevent materials from clogging the line between hoppers and pump inlets.

• anytime sprayer will not be used for more than

one week

• if materials used will settle

• if using thixotropic resins that require agitation

Procedure

1. Follow Pressure Relief Procedure, page 12, and Flush Mixed Material, page 14, as required.

Engage trigger lock. Turn main pump air regulator (CD) fully counter-clockwise to shut off.

air regulator

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r_312359_313289_13

NOTE:

When flushing coating materials remove pump fluid filters, if installed, and soak in solvent to decrease cleaning time. Proceed with Step 2. If flushing a new system, leave filters in place.

2. Move circulation return lines to separate fluid containers to pump remaining fluid out of system.

3. Increase main pump air regulator (CD) pressure to 30 psi (21 kPa, 2.1 bar).

4. Select . Press .

NOTE:

When running pumps independently set to or

. Press and as needed to clean.

NOTE:

If sprayer does not start with static pressure, increase air pressure by 10 psi (69 kPa, 0.7 bar) increments. To avoid splashing do not exceed 40 psi (28 kPa, 2.8 bar).

16 313289S

Flush

5. Open recirculation valves (AC, AD) for respective pump dispense side. Run pumps until the A and B reservoirs are empty. Salvage the material in separate, clean containers.

r_312359_313289_6

NOTE:

When priming or flushing the pumps, it is normal to get cavitation or pump runaway alarms. Clear the alarms

9. Close recirculation valves (AC, AD) and open mix manifold valves (AH, AJ). Dispense fresh solvent through mix manifold valves and out gun.

r_312359_313289_7

10. Close mix manifold valves (AH, AJ).

, and press again as necessary. These alarms prevent excessive pump speeds that can damage pump packings.

6. Wipe the reservoirs clean, then add solvent to each.

Move circulation lines to waste containers.

7. Repeat Step 4 to flush through each side until clean

solvent exits recirculation hose.

8. Stop and move recirculation hoses back to reser-

voirs. Continue recirculating until machine is thoroughly flushed.

11. Slowly open sampling valves (AE, AF) to flush solvent through until clean. Close sampling valves.

Press .

12. Follow Pressure Relief Procedure, page 12.

13. Remove pump fluid filters, if installed, and soak in solvent. Clean and replace filter cap. Clean filter o-rings and leave out to dry. Do not leave o-rings in solvent.

14. Close main air valve (E).

NOTE:

Always leave some type of fluid, such as solvent or oil, in the system to prevent scale build up. This build up can flake off later. Do not use water.

313289S 17

Shutdown Entire System

Follow this procedure before prolonged shutdown or before servicing equipment.

1. Follow Pressure Relief Procedure, page 12. Place gun over pail. Trigger gun; wait until pumps are down.

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2. Engage trigger lock, turn off air regulator, and close main air shutoff valve. Remove spray tip.

Cleaning Procedure

1. Ensure all equipment is grounded. See Grounding, page 11.

2. Turn off all heaters and allow equipment to cool.

3. Flush mixed material. See Flush Mixed Material, page 14.

4. Relieve pressure. See Pressure Relief Procedure, page 12.

5. Shutdown sprayer and turn off all power. See Shut- down Entire System, page 18.

6. Ensure the area where the sprayer will be cleaned is well ventilated; and remove all ignition sources.

7. Clean external surfaces using only a rag soaked in solvent that is compatible with the spray material and the surfaces being cleaned.

8. Allow enough time for solvent to dry before using sprayer.

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4)!

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3. Follow flushing procedure, see Flush on page 14.

4. Follow Pressure Relief Procedure, page 12. Engage trigger lock.

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For prolonged shutdown (one week or longer):

• Follow flushing procedure, see Empty and

Flush Entire System (new sprayer or end of job) on page 16.

• Cap fluid outlets to keep solvent in the lines.

• Fill pump A and B packing nuts with throat seal

liquid (TSL).

18 313289S

XM Setup and Troubleshooting Guide

The following setup information will help ensure the system is setup properly. See the XM repair-parts manual for troubleshooting and repair instructions.

Grounding

• Ground system to a true earth ground.

• Ensure incoming power is grounded.

Air Supply

• Use at least a 3/4 in. (19mm) ID air hose, no longer than 50 feet (15m).

• Ensure the first gauge (supply) stays above 80 psi (0.55 MPa, 5.5bar) while spraying.

• Ensure that the pump spray pressure regulator is set to at least 35 psi (2.4 bar) for spraying.

• Ensure that the solenoid air filter/regulator behind the air panel is set to at least 80-85 psi.

• Check that the air filter element in the solenoid air filter/regulator behind the air panel is clean.

Calibration

• Adjust the B side fluid restrictor so that the calibration bar graph averages center to right middle. This means that the “B” dosing valve is open 25% to 75% of the time.

• Ensure dosing valve needle packing nuts are not adjusted too tight. They should be snug when there is no fluid pressure on the valve.

• If feed pumps are used, don’t use more than 250psi (17 bar). Excess pressure adds double the amount of pressure on only the upstroke of the XM metering pump.

Motor Icing

• Ensure that the NXT motor De-Ice bleed valves are open to bleed warm air across the ice.

• Ensure that the motor is left active when not spraying to keep the internal bleed air working. Leave the motor active in Spray mode or Manual mode to keep the bleed air on.

Restrictions or Lost Pressure

• Always use filter screens in the XM pump lowers. Filter style pumps come with 60 mesh screens. Optional 30 mesh elements are also supplied.

• Always use a gun filter. 60 mesh is provided in the gun. Check that the static mixer is clean.

• Early mix manifolds (2009) had a 40 mesh screen on the B side. The screen could plug with materials that have filled ‘B’ side fluids.

Remote Mix Manifold Applications

Ensure remote mix manifold outlet kit is installed. See XM Repair parts manual. The kit includes outlet check valves which isolate the pump pressure sensors from the outlet hoses, and includes a ‘B’ side restrictor valve for the machine outlet.

NOTE: Early remote manifold machines didn’t include the ‘B’ restrictor valve from the factory.

• Ensure that the ‘A’ and ‘B’ outlet hose sizes volume balanced close to the mix ratio. Unbalanced hose sizes can cause off ratio slugs at the mix manifold during pressure and/or flow transitions. See XM Mix Manifold Kits manual.

• If a minimum of integration and mix hose is used, ensure that “Fast Dosing” is selected in the setup screens.

Air motors accumulate ice in the exhaust valving and muffler under hot and humid conditions or under cold ambient conditions. It can cause pressure loss or motor stalling.

• The ‘B’ fluid pressure should always be 15% to 30% higher than ‘A’ pressure.

•

A larger pressure difference indicates ‘A’ motor icing.

• A smaller or negative pressure difference indicates ‘B’ motor icing.

313289S 19

Software Version

• Ensure all modules in the system use software from same token. Different software versions may not be compatible.

• The latest software version for each system can be found at Tech Support at www.graco.com.

Troubleshooting

NOTE:

The sprayer operates using air pressure. Many problems are caused by inadequate air supply. The inlet air pressure gauge cannot drop below 50 psi (0.35 MPa,

3.5 bar) while running.

Problem Cause Solution

Display not lit on system with alternator power supply.

No electric power.

Display not lit on system with alternator power. Green light is present on FCM (218) and USB (219), but no green light is present on back of display module (204).

Display not lit on system with wall power supply. No green light present on back of display module (204).

Display not lit on system with wall power supply. Green light is present on back of display module (204).

Air valve not turned on. Turn on main air valve to system.

Air supply pressure too low. Increase pressure to 30 psi (0.21 MPa,

Air supply filters plugged. Inlet manifold filter (604) or air regulator (344) filter plugged.

Turbine air regulator (277) set too low. Adjust to 18 +/- 1 psi (12.6 +/- 10 kPa,

Alternator turbine failure. Repair or replace turbine. Page 38.

Power supply not connected to main board.

Display board failure. Replace display board. Page 36.

Faulty CAN cable (268). Or CAN cable is disconnected.

Faulty display module. Replace display module. See User Inter-

No electric power. Disconnect “off” or breaker “open.”

No green lights present on display, FCM, or USB module.

No display power through CAN cable (266). Green light in present on FCM (218), but is not present on USB module (219).

Green light is present on USB module (219).

Display module failed. Replace display module. See User Inter-

NOTE:

If an error code displays, see Alarms on page 23.

2.1 bar) or greater.

Clean filter bowls; replace filter elements. Page 31.

1.26 +/- 0.07 bar).

Check power connections to main board. See Electrical Schematics, starting on page 47.

Check cable and replace. See Alternator

Assembly, page 72.

face/Control Box, page 32.

Reset main disconnect and breaker.

Check for 24 Vdc on J1, pins 2 and 3, of power supply. See Electrical Schemat- ics, starting on page 47. If there is not 24 Vdc, replace with 15V747.

Check CAN cable. Replace if necessary. See Wall Power Supply Assembly, page 73.

Check CAN cable (274). Replace if necessary. See Wall Power Supply Assem-

bly, page 73.

face/Control Box, page 32.

20 313289S

Troubleshooting

Problem Cause Solution

Pumps do not run when Run Mode is selected and the blue LED is illuminated.

Pump Test completes without error, but A or B component has more than 750cc of fluid in beaker.

Batch Test completes without error, but A or B component has more fluid in beaker than displayed on screen.

Sprayer does not start when start button is pressed.

Fluid valves leaking. Loose or worn packings. Tighten packing nut. If leak continues,

Paint does not cure consistently. Ratio not set correctly. Check that correct ratio is set and set by

Air pressure to pumps too low Increase pressure to 50 psi (0.35 MPa,

3.5 bar) or greater.

Air pilot lines are obstructed Check pilot lines for kinks or pinches.

Solenoid valve stuck. Actuate solenoid manually, if it does not

operate, replace solenoid. Page 32.

Air pilot valve(s) to motor stuck. Replace valve(s). Page 42.

Metering valve(s) not opening. Service or replace valve(s). Page 42.

Air motor stalled. See manual 311238.

Incorrect pumps were selected in System Setup screens.

Air is trapped in fluid due to excessive agitation, circulation, and heat. Fluid is measured by volume when it is compressed under pressure.

See causes for previous pump test problem.

Faulty start switch or wire harness. Check start switch and wiring harness

Faulty stop switch or wiring harness. Check stop switch and wiring harness

See Appendix A in manual 312359.

Repeat Pump Test with fresh fluid.

If the specific gravity of each fluid is known, check samples by weight (750cc x specific gravity equals weight in grams). If weight is correct, extra volume in beaker is air.

See solutions for previous pump test problem.

continuity; switch is normally open circuit. See Electrical Schematics, starting on page 47.

continuity; stop switch is normally closed circuit. See Electrical Schematics, starting on page 47.

replace packings.

volume. See manual 312359.

Material not mixing correctly. Test pump. Make sure mixer is clean;

flush as needed. See manual 312359.

Position mixer after integrator hose.

Poor spray pattern. Also, see “System runs erratically” below.

Material not properly conditioned before it was added to sprayer.

Not using enough integration hose. Add more integration hose.

Fluid pressure too low. Increase pump pressure.

Fluid temperature too low. Increase fluid temperature.

Spray tip dirty or worn. Relieve pressure. Clean or replace tip.

Fluid A or B filters plugged. Clean filters. See pump manual.

Mixer or hoses partially plugged or too restrictive.

Mix material thoroughly.

Select “fast dosing” in setup.

Follow gun manual instructions.

Inspect parts for cured material. Clean or replace, or use larger hoses and mixer.

313289S 21

Troubleshooting

Problem Cause Solution

System runs erratically. Air filter(s) clogged. Replace elements. Clean. Replace element(s). See page 31.

Air supply hoses undersized. Replace hoses with appropriate size.

Air compressor undersized. Use larger air compressor.

Air supply pressure tank undersized. Use larger pressure tank.

Inlet air pressure gauge drops below 50 psi (0.35 MPa, 3.5 bar) while spraying.

A and/or B air motor has ice. Open air motor de-ice bleed air control.

Pump is binding. Repair lower. See Remove Displace-

Air supply relief valve opens. Air regulator set too high. Lower setting.

Turbine alternator makes high-pitched whining noise, or quits.

Display module cycles on and off. Turbine is not supplying enough power to

Flow rate too low. Air supply hose is too small or too long. Use 3/4 in. (minimum) ID hose. See

Receive ratio alarm after starting in spray mode while using remote mix manifold.

Receive ratio alarm while using remote mix manifold after a significant change in pressure.

Erratic pressure at spray gun when using feed pumps.

Turbine bearings worn. (Setting turbine air regulator too high, wears bearings.)

board.

Inadequate air supply. Use larger CFM compressor.

Air pressure to pumps too low. Increase pressure.

Fluid A or B filters plugged. Clean filters. See pump manual.

Spray tip too small. Relieve pressure. Install larger tip. Follow

Mixer or hoses partially plugged or too restrictive.

A and B hoses do not fill to correct pressure ratio simultaneously. Therefore, spray time increases in order to balance pressure. Ratio screen bar graph stays to one side until pressure balances.

Feed pressure is too high. Feed pressure at metering pump is too high on up stroke. Doubles the feed pressure to outlet pressure on up stroke only.

See solutions above for system runs erratically problem.

Allow ice to melt. Dry the compressed air. Heat the compressed air. Use a smaller tip and lower flow rate.

ment Pump, page 44.

Replace turbine cartridge. See Alterna-

tor Power Supply Control Components, page 38.

Increase turbine regulator setting to 18 +/- 1 psi (12.6 +/- 10 kPa, 1.26 +/- 0.07 bar). Check voltages on information screen. 10-14 Vdc when spraying.

Check turbine and electrical control exhaust air for restrictions.

Replace turbine cartridge. See Alterna-

tor Power Supply Control Components, page 38.

Technical Data, page 85.

gun manual instructions.

Inspect parts for cured material. Clean or replace, or use larger hoses and mixer.

While in circulation mode, close circulation valves and increase pressure in hoses until correct spray pressure is achieved.

Select correct hose size to balance your volume ratio. See manual 312749.

While in circulation mode, close circulation valves and increase pressure in hoses until correct spray pressure is achieved.

Select correct hose size to balance your volume ratio. See manual 312749.

Change pressure slowly while spraying.

Use lowest feed pressure needed to maintain feed.

22 313289S

Alarms

View Alarms

When an alarm occurs the alarm information screen automatically displays. It shows the current alarm code along with a bell icon. It also shows the alarm location with top and side views of the sprayer.

There are two levels of alarms: warnings and advisories. A bell icon indicates an alarm. A solid bell icon with an exclamation point and three audible alerts indicate a warning. And an outlined hollow bell icon and a single audible alert indicate an advisory.

Advisories are notifications that require attention but not immediately. Alarms require immediate correction; therefore, sprayer operation automatically stops.

Icon Function

Moving up

Moving down

Top changeover

Bottom changeover

One reed switch signal is missing

Blank: No reed switch signal

Diagnose Alarms

See Alarm Codes and Troubleshooting for causes and solutions to each alarm code.

Clear Alarms

Press to clear alarms and advisories. From the

This screen also shows diagnostic information. There are three lines of data on the left side. The top line shows the power supply or alternator power supply. This should be between 23-25 Volts for power supply systems and 10-14 Volts for alternator systems. The middle line shows the sensor voltage. This should be between

4.9-5.1 Volts.

The center of the screen shows linear sensor vertical bar graphs and reed switch information. The A side information is on the left and the B side information is on the right. Linear sensor position is displayed on the bar graph that goes up and down when the pump moves. This bar graph should move from top to bottom to match each pump stroke.

The state of the two reed switches in each air motor are shown with the arrow above each vertical bar graph.

alarm information screen, press to return to the run (fluid control) screen.

313289S 23

Alarms

Alarm Codes and Troubleshooting

Alarm

Code Alarm Problem When Active Cause Solution

General Performance Alarms

R4B Ratio High B (Overdose B),

system delivering too much B component.

R1B Ratio Low B (under dose B);

system delivering not enough B component.

REC System detected five R4B

(ratio high B) or five R1B (ratio low B) alarms within five minutes. Sprayer shuts down for five minutes to resolve problem.

FHA FHB

R2D Dosing sizes are not opti-

System detects pump movement (fluid flow) when valves are closed.

mized.

Spray B Dosing valve not closing. Perform Pump Test to test for

leakage. See Pump and Metering test in manual 312359.

Loosen valve packing nut.

Check air signal at valve top

Repair valve or air solenoid. See Replace Solenoid Mod- ule, page 32.

No B restriction at mix manifold. Increase B Restriction by turn-

ing B restrictor stem clockwise. See Adjust B Mix Manifold Restriction in manual 312359.

Pump filter plugged on A side. Clean filter. See manual

311762.

Use alternate 30 mesh screen. See manual 311762 for part number.

Inlet air dropping below 80 psi (0.55 MPa, 5.5 bar) while spraying. B dosing valve not closing correctly.

Solenoid air regulator set below 80 psi (0.55 MPa, 5.5 bar)

Spray B dosing valve will not open. Check for air signal to valve.

B mix manifold valve closed. Open green mix manifold valve.

Pump filter plugged on B side. Use alternate 30 mesh screen.

Spray See R4B or R1B alarm causes. See R4B or R1B alarm solu-

Spray Recirculation valve or dosing

valve open or leaking for more than 5 seconds.

Spray Dosing valve is operating near

high or low timing limits.

Check air filters. See Air Con- trols, page 40.

Use larger air hose.

Use larger compressor.

Use smaller gun tips or less guns to reduce flow rate.

Adjust air regulator.

See manual 311762 for part number.

Clean B pump outlet filter. See manual 311762.

tions. Flush mixed material if necessary, and purge off-ratio mixed material in hose.

Close or repair recirculation valve, and run Pump Test. See Pump and Metering test in manual 312359. See Mix Manifold Assembly, page 42.

Adjust mix manifold B restrictor stem clockwise or counter clockwise as indicated by bar graph on restrictor screen. See Adjust B Mix Manifold Restriction in manual 312359.

24 313289S

Alarm

Code Alarm Problem When Active Cause Solution

P4A P4B

DAA DAB

DDA DDB

P1A P1B

P4R Pressure high. Recirculation Pressure is above maximum

P5R Pressure high. Recirculation Pressure is above maximum

P9A A pump pressure is abnor-

P9B B pump pressure is abnor-

B3A Dosing size A advisory Spray The fluid dosing size is greater

Pressure high Always Fluid pressure is above maxi-

mum.

Pump runaway, above 80 cpm for 10 sec.

Pump cavitation; dives more than 3/4 of stroke.

Pressure low. Spray, Pump

mally low compared to B pump pressure.

mally low compared to A pump pressure.

Always No material in pump or lines; no

fluid restriction.

Always No fluid or valve closed. Refill supply and open inlet

Material is too cold or thick. Increase material temperature

Pump inlet check valve not closing.

Feed pump not providing material.

Inlet strainer plugged (if used). Check and clean strainer. See

Fluid pressure is below 1000

Test, Leak Test

Spray A air motor is icing up causing

Spray B air motor is icing up causing

psi (7 MPa, 70 bar).

advisory limit of 3000 psi (21 MPa, 210 bar) on A side.

warning limit of 5200 psi (35.9 MPa, 359 bar) on A side.

restriction and lower fluid pressure.

A pump is binding. Repair lower. See Remove

A motor is hanging up. Repair air motor. See Remove

restriction and lower fluid pressure.

B pump is binding. Repair lower. See Remove

than 35 cc when fast dosing is turned off.

The fluid dosing size is greater than 20 cc when fast dosing is turned on.

Decrease main air regulator or feed pump pressure.

Refill material in tank or hoses; install fluid tip.

valve.

to reduce viscosity. (See Heat Fluid section in manual

312359.) Shear material with agitation to reduce viscosity.

Clear debris from check valve. Or replace ball, seat, and seal. See Pump Assembly, page

44.

Check feed pump (if used).

Pump Assembly, page 44.

Increase main air regulator.

Decrease pump air regulator pressure.

Open the air motor de-ice bleed air controls. Allow ice to melt. Dry compressed air. Heat compressed air.

Use a smaller tip.

Displacement Pump, page 44.

Air Motor, page 45.

Open the air motor de-ice bleed air controls. Allow ice to melt. Dry compressed air. Heat compressed air.

Use a smaller tip.

Displacement Pump, page 44.

Adjust the B side fluid restriction.

Decrease the air motor velocity with a smaller tip.

Alarms

313289S 25

Alarms

Alarm

Code Alarm Problem When Active Cause Solution

B4A Dosing size A alarm Spray The fluid dosing size is greater

than 45 cc when fast dosing is turned off.

The fluid dosing size is greater than 30 cc when fast dosing is turned on.

Adjust the B side fluid restriction.

Decrease the air motor velocity with a smaller tip.

Pump Test (Daily Check Recommended)

DFA DFB

DGA DGB

DEA DEB

Pump did not stall against fluid pressure on up stroke only.

Pump did not stall against fluid pressure on down stroke only.

Pump does not move in 10 minutes.

Pump Test Pump piston check valve, pis-

ton packings, or dosing valve are not holding fluid pressure.

Pump Test Pump inlet check or dose valve

is fouled, or damaged.

Park or Pump Test

Recirculation valves were not opened to allow flow.

Flush pump. See Flush, page

14. Recheck. Remove, clean, and repair lower. See Pump Assembly, page 44.

Remove inlet housing & clean and inspect. See Pump Assembly, page 44.

Open recirculation valves.

General System Component Alarms

DJA DJB

Pump motor linear sensor has no signal.

Always No linear sensor signal from

motor.

Swap A and B sensors. Replace sensor if problem follows sensor.

DKA DKB

P6A P6B

Pump motor linear sensor is out of range.

Pump motor reed switch failure; missing signals from one or both switches.

Pressure sensor failure; no signal.

Linear sensor plugged in while power is on.

Bad connection inside fluid control module.

Always Linear sensor is beyond range. Replace sensor or sensor mag-

Sprayer is not properly grounded.

Always Bad motor cable connections,

or bad reed switch.

Reed switch cable is plugged in while power is on.

Bad connection inside fluid control module.

Always Pressure sensor or cable is bad

on the A or B side.

Power sprayer off and back on. Do not plug in linear sensor while power is on.

Replace fluid control module. See page 34.

net.

See Grounding, page 11.

Swap A and B motor cables. Replace cable if problem persists. Otherwise replace reed sensor assembly.

Power sprayer off and back on. Do not plug in reed switch cable while power is on.

Replace fluid control module. See page 34.

Replace sensor and cable assembly. See Pump Assem- bly, page 44.

26 313289S

+ 60 hidden pages