Graco 3A2776D User Manual
Setup - Operation
XM PFP
For spraying two-component intumescent epoxies. For professional use only.
Not for use in explosive atmospheres or hazardous locations.
Important Safety Instructions
Read all warnings and instructions in all
supplied manuals. Save all instructions.
3A2776D
EN
See page 3 for model information, including
maximum working pressure and approvals.
WLD
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Keep Components A and B Separate . . . . . . . . 6
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 6
Components A and B . . . . . . . . . . . . . . . . . . . . . 6
Component Identification . . . . . . . . . . . . . . . . . . . . 7
Typical Setup (Front View) . . . . . . . . . . . . . . . . . 7
Typical Setup (Back View) . . . . . . . . . . . . . . . . . 8
Fluid Control Assembly . . . . . . . . . . . . . . . . . . . . 9
Main Power and Heater Controls . . . . . . . . . . . 10
Sprayer and Flush Pump Air Controls . . . . . . . 10
Feed Module Air Controls . . . . . . . . . . . . . . . . 11
User Interface . . . . . . . . . . . . . . . . . . . . . . . . . 12
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Unboxing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Configuration Options . . . . . . . . . . . . . . . . . . . . 14
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Connect Power . . . . . . . . . . . . . . . . . . . . . . . . 16
Connect Air Supply . . . . . . . . . . . . . . . . . . . . . . 17
Connect Feed Module Lines to Sprayer Module 18
Install Level Sensor Probe . . . . . . . . . . . . . . . . 19
Check Level Sensor Calibration . . . . . . . . . . . . 19
Connect the Fluid Hose Bundle to the System . 20
Connect the Fluid Hose Bundle to the
Mix Manifold . . . . . . . . . . . . . . . . . . . . . . . . 21
Connect the Mix Manifold to the Gun . . . . . . . . 22
Prime Heated Fluid Circulation System . . . . . . 23
Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Prime Solvent Flush Pump . . . . . . . . . . . . . . . . . . 29
Adjust Ratio and System Settings . . . . . . . . . . . . 31
Temperature Settings . . . . . . . . . . . . . . . . . . . . . . 31
Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Flush Mixed Material . . . . . . . . . . . . . . . . . . . . . . 36
Park Metering Pump Rods . . . . . . . . . . . . . . . . . . 37
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 38
System Verification . . . . . . . . . . . . . . . . . . . . . . . . 40
Pump and Metering Test . . . . . . . . . . . . . . . . . . 40
Batch Dispense or Ratio Test . . . . . . . . . . . . . . 42
Down Stream Valve Leak Test . . . . . . . . . . . . . 43
Mix and Integration Tests . . . . . . . . . . . . . . . . . 44
Empty and Flush Entire System . . . . . . . . . . . . . . 45
Prepare Level Sensor for Shipping . . . . . . . . . . . 49
Download Data from USB . . . . . . . . . . . . . . . . . . . 50
USB Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Download Setup . . . . . . . . . . . . . . . . . . . . . . . . 50
Download Procedure . . . . . . . . . . . . . . . . . . . . . 50
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Adjust Packing Nuts . . . . . . . . . . . . . . . . . . . . . 52
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Clean the System . . . . . . . . . . . . . . . . . . . . . . . 53
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
General Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Individual Control Module LED Diagnostic
Information . . . . . . . . . . . . . . . . . . . . . . . . . 55
Troubleshooting Table . . . . . . . . . . . . . . . . . . . 55
Appendix A - User Interface Display . . . . . . . . . . 58
Change a Setting . . . . . . . . . . . . . . . . . . . . . . . . 58
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Setup Mode Screens . . . . . . . . . . . . . . . . . . . . . 59
Operator Command Mode Screens . . . . . . . . . . 66
Automatically Displayed Screens . . . . . . . . . . . 73
Appendix B - Alarms . . . . . . . . . . . . . . . . . . . . . . . 75
Alarms Overview . . . . . . . . . . . . . . . . . . . . . . . . 75
Alarm Code Troubleshooting . . . . . . . . . . . . . . . 78
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 88
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 88
2 3A2776D
Models
Models
Models
Maximum Fluid
Working Pressure
Maximum Air Working
Pressure Approvals
A and B Materials:
6000 psi
(41 MPa, 414 bar)
Supply:
262869
24W626
Flushing Fluid:
4500 psi
(31 MPa, 310 bar)
(1.0 MPa, 10.3 bar)
Max. Setpoint:
(0.7 MPa, 7 bar)
Heating Fluid:
100 psi
(0.7 MPa, 7 bar)
Related Manuals
Manuals are available at www.graco.com. Component
manuals in English:
Manual Description
3A2989 XM PFP Repair
3A2988
3A2799 XHF Spray Gun
Heaters
309524
3A2954
3A2824
XM PFP Mix Manifold Instructions Parts
Viscon
®
HP High Pressure Fluid
Heater Instructions - Parts
Viscon HF High Flow, High Pressure
Fluid Heater Instructions - Parts
Viscon LT Fluid Heater Instructions -
Parts
150 psi
100 psi
Certified to CAN/CSA C22.2 No. 88
9902471
Conforms to
UL 499
Manual Description
Pumps, Motors, Supply Systems
™
308652
311238
311762
312375
312376
312792
312794
Husky
Pumps Instructions - Parts
NXT
Xtreme
Check-Mate
Instructions - Parts
Check-Mate Pump Packages Instructions - Parts
Merkur
Merkur Pump Assembly Instructions -
Parts
205 Air-Operated Diaphragm
®
Air Motor Instructions - Parts
®
®
312796 NXT Air Motor Instructions - Parts
Lowers Instructions - Parts
®
Displacement Pumps
Pump Repair - Parts
313526 Supply Systems Operation
313527 Supply Systems Repair - Parts
312374 Air Control Instructions - Parts
Accessories
332073 Hot Water Flush Kit Instructions
3A2987 Air Dryer Kit Instructions
Other
306861 Ball Valves Instructions - Parts
307005
308169
3A2776D 3
High Pressure Swivel Instructions Parts
Air Filters, Lubricators, and Kits
Instructions - Parts
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific
hazard symbols and warnings not covered in this section may appear throughout the body of this manual where
applicable.
WARNING
WARNINGWARNINGWARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause
electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
or installing 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.
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.
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. Do not use pail liners unless they
are antistatic 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.
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.
4 3A2776D
Warnings
WARNING
WARNINGWARNINGWARNING
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure and disconnect all power sources.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create
safety hazards.
• 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.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including
eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is
not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer
SPLATTER HAZARD
Hot or toxic fluid can cause serious injury if splashed in the eyes or on skin. During blow off of platen,
splatter may occur.
• Use minimum air pressure when removing platen from drum.
3A2776D 5
Warnings
Keep Components A and B Separate
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.
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.
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
This equipment doses the B component into the A component flow. An integration hose must always be used
after the mix manifold and before the static mixer.
refers to resin or major volume.
refers to the hardener or minor volume.
• Always clean any 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
6 3A2776D
Component Identification
Typical Setup (Front View)
Y
Component Identification
V
U
J
B
C
D
G
K
E, F
C1
T
ti19927a
WLE
L
P
M
A
N
X
H
S
R
FIG. 1
Key:
AFrame
B Fluid Control Assembly
C GCA Control Display
D Metering Pumps Control On and Off Buttons
E Main Air Supply Shutoff Valve, 1 in. npt(f) Inlet
F Air Filter, 1-1/4 in.
G Air Controls for Sprayer and Flush Pump (see page 10)
H Viscon HP Heater for hose bundle
J Junction Box/Heater Controls (see page 10)
K Viscon HF Material Heater
L Air Powered Agitator with Lubricator
M Feed Pump
N Recirculation Control Valve
P Pressure Tank, Double-Wall Temperature Conditioned
3A2776D 7
R Remote Mix Manifold
S Static Mixer Assembly
T Spray Gun
U Air Motor
V Supply Controls (see page 11)
W High Pressure Fluid Metering Pump
X Solvent Flush Pump (Merkur Pump)
Y Radar Fluid Level Sensor
Z Air Regulator for Feed Tanks and Pumps
A1 Heated Tank Circulation Components (uses a Viscon LT)
B1 TSL Supply Bottle and Bracket
C1 Heated Fluid Circulation Pump for Hose Bundle
D1 Insulation Jacket
Component Identification
Typical Setup (Back View)
U
B1
Z
FIG. 2
C1, A1
A1
WLD
W
X (located between
metering pumps, not
visible in current view)
D1, A1
8 3A2776D
Fluid Control Assembly
AA
AC
AL
Component Identification
AE
AG
AJ
FIG. 3
AA Dosing Valve
AC Recirculation Valve
AE Sampling Valve
AG Outlet Check Valve
AJ Hose Connection (Model 262869) - A side: 3/4 npt(m); B side: 1/2 npt(m)
Hose Connection (Model 24W626) - A side: 3/4 npt(m); B side 3/4 npt(m)
AL Pressure Sensor
ti19928a
3A2776D 9
Component Identification
Main Power and Heater Controls
BB BCBD BA
FIG. 4
ti20101a
BA Main Power ON/OFF Switch
BB A Tank Water Heat ON/OFF Switch
BC B Tank Water Heat ON/OFF Switch
BD Optional Heated Water Flush Tank Accessory ON/OFF
Sprayer and Flush Pump Air Controls
CA
CB
FIG. 5
Switch (only used if the water heater accessory has been
added to the machine)
CC
CD
CE
CF
CG
r_XM1A00_312359_313289_14A
CA Metering Pump Air On/Off Control
CB Solvent Pump Air On/Off Control
CC Inlet Air Pressure Gauge
CD Metering Pump Air Regulator
CE Metering Pump Air Regulator Gauge
10 3A2776D
CF Solvent Pump Air Gauge
CG Solvent Pump Air Regulator
Feed Module Air Controls
CR
Component Identification
CU
CP
NOTE: Both valves shown open
F
IG
. 6: Supply Controls
CP Tank Air Pressure Regulator
CR Tank Air Pressure Gauge
CS Tank Air Supply Valve
CT Agitator and Heated Water Circulation On/Off Valve
CU Feed Pump Bypass Button
FEED PUMP
BYPASS
ti20127a
CT
CS
Feed Pump Bypass Button
Use the feed pump bypass button to manually run the
feed pump when the automatic tank filling function is not
running the feed pump. See automatic tank filling details
on page 73.
Feed Pump Air Controls
DF
DA RAM Air ON/Exhaust Slider Valve
DB RAM Air Regulator
DC RAM Up/Down Director Valve
DD RAM Blowoff Valve
DE Air Motor Regulator
DF Air Motor ON/Exhaust Slider Valve
DE
RAM Blowoff Valve (DD)
DD
DC
To minimize material splatter, use the minimum air
pressure required to remove platen from pail.
DB
DA
To easily remove the RAM from the pail, press and hold
the RAM Blowoff Valve button while lifting the RAM
platen. A small amount of air pressure will be supplied to
ti20104a
3A2776D 11
the pail to push the pail off of the RAM.
Component Identification
User Interface
NOTICE
To prevent damage to soft key buttons, do not press the buttons
with sharp objects such as pens, plastic cards, or fingernails.
DJ
DR
DA
DG
DF
DD
ti13365a
DH
DE
DP
F
IG
. 7: User Interface
DM
DB
Buttons LEDs
Call
out Button Function
DA Display
Screen
DB Start Initiates Active Run Mode function cur-
DC Stop Terminates Active Run Mode function
DD Enter Press to open drop-down fields, select
DE Alarm
Reset
DF Left/Right Move between screens in run or setup
DG Function Activates mode or action represented by
DH Up/Down Move between drop-down fields, option
DJ Setup Key
Lock
DR USB Port Connection for data download.
Use to view screens. See page 58.
rently selected in Run Screen.
currently selected.
options, and save values.
Resets alarms and advisories.
modes.
the icon above each of the four buttons in
the LCD.
boxes, and selectable values within
Setup screens.
Change ratio or enter Setup mode.
There are four types of LEDs on the display.
Call
out LED Function
DK Blue Dosing valve active
DM Green Spray mode active
DN Red Alarm
DP Yellow Warning
DK
DC
• On - dosing valve is active
• Off - dosing valve is not active
• Spray mode is on (active)
• Spray mode is off (inactive)
• On - alarm is present
• Off - no alarm
• On - is active.
• Off - no warning indicated. Ratio
and setup fields are not changeable.
• Flashing - key is present and
turned. Ratio and setup fields
are changeable.
DN
12 3A2776D
Component Identification
User Interface Display
Main Display Screen Components
NOTE: For detailed screens information, see Appendix A - User Interface Display beginning on page 58.
The following figure calls out the navigational, status, and general informational components of each display screen.
Current Date and Time
Navigational Bar
F
IG
. 8: Main Display Screen Components (shown with all display features enabled)
Remaining Potlife Time
Function Display
Go back one screen
3A2776D 13
Setup
Setup
Location
Select a non-hazardous location with the required power
and air supply to set up your sprayer. Maintain access
from all sides.
Unboxing
The machine is shipped on two separate pallets, one
with the XM PFP and one with the two feed modules.
Each pallet is wrapped in heavy cardboard with a lid
secured with straps. Cut the lid straps then remove the
lids and cardboard.
Configuration Options
The system can be laid out two ways:
• Side by side: where the feed modules are on either
side of the system module
• Front to back: where the feed modules are behind
the system module
Front to Back Configuration
Side by Side Configuration
ti20267a
F
IG
. 9
14 3A2776D
ti20268a
Connect Modules
Regardless of the chosen module configuration, the A
feed module must be on the left and the B feed module
must be on the right when looking at the front of the system module. The A module has a blue A sticker on the
air control panel and a 1/2 in. return fitting into the tanks.
The B module has a green B sticker on the air control
panel and a 3/8 in. return fitting into the tanks.
Setup
5.5 in. long
1x
Choose one of the configurations shown in F
IG
. 9 then
bolt together the three modules on a flat surface. See
F
IG
. 10 or FIG. 11 for bolt locations. The frame bolts are
included in a bag. Once connected, the assembly can
be moved as one piece with a fork-truck.
NOTICE
Do not use lift rings to lift the entire assembly. This
will damage the system. The system must be lifted
from the bottom.
If the modules will not be connected, they must be within
12 in. of each other and in one of the two configurations
in F
IG
. 9 to ensure hoses and cables can reach their
connections.
If the front-to-back module configuration is used, install
the two supplied straight steel braces between each
feed module and the sprayer module, see F
IG
. 11.
These are not used in the side-by-side module configuration.
4x
3.5 in. long
ti20197a
10x
FIG. 11: Bolt Locations (Front to Back)
2x
5.5 in. long
8x
1.5 in. long
F
IG
. 10: Bolt Locations (Side by Side)
3A2776D 15
ti20163a
Setup
Grounding
The equipment must be grounded to reduce the risk
of static sparking and electric shock. Electric or static
sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock.
Grounding provides an escape wire for the electric
current.
Ground the electrical connection properly according to
local codes.
Connect Power
Power must be connected by a qualified electrician.
Graco does not supply heater junction box power cords.
Use the following chart to determine which power cord
your system requires.
380V, 3 Phase WYE: Use a 5/32 in. (4 mm) hex key to
connect the three power leads to the top terminals L1,
L2, and L3. Connect neutral to N. Connect green to
ground (GND).
7L4
N L1 L2 L3
1L1
ti8613a1
4. Find the red power jumpers in the terminal blocks
supplied in a plastic bag in the junction box.
5.
For 380V, 3 Phase installations only,
use pliers to
install the red power jumpers into the terminal
blocks in the correct positions as shown in the following illustration. Push jumpers firmly into position.
Power Cord Requirements
System
Voltage Cord Specification AWG (mm
2
)
240V, 3 PH 6 (13.3) 3 wire + ground
380V, 3 PH 6 (13.3) 4 wire + ground
1. Open junction box cover.
2. Insert power cord through the large empty strain
relief in the bottom of the junction box.
3. Connect power cord as follows.
230V, 3 Phase Delta: Use a 5/32 in. (4 mm) hex key to
connect the three power leads to top terminals L1, L2,
and L3. Connect green to ground (GND).
L1 L2 L3N
1L1
FIG. 12
6.
For 240V, 3 Phase installations only,
use pliers to
install the red power jumpers into the terminal
blocks in the correct position as shown in the following illustration. Push jumpers firmly into position.
F
IG
. 13
7. Close junction box cover.
ti8612a1
16 3A2776D
Connect Air Supply
Connect air supply line to the 1 in. npt(f) air supply ball
valve inlet.
NOTE:
Use a 3/4 in. (19.1 mm) ID minimum air hose.
E
ti20105a
NOTE:
Air supply requirement:
maximum; 80 psi (552 kPa, 5.5 bar) minimum (while
running).
150 psi (1.0 MPa, 10.3 bar)
Setup
Flow volume required:
250 scfm (7.1 m
100 scfm (2.8 m3/min) minimum;
3
/min) maximum. Available fluid pressure and flow rate are directly related to available air
volume. A typical single gun XM PFP application will use
125 to 175 scfm (3.5 to 5.0 m
3
/min).
NOTE:
Dosing valves are operated by air. The sprayer will not
operate correctly if the inlet air pressure drops below
80 psi (552 kPa, 5.5 bar) while spraying.
3A2776D 17
Setup
Connect Feed Module Lines to Sprayer Module
1. Connect Modules, page 15.
2. Connect the large diameter green hose from each
tank bottom outlet to the respective metering pump
inlet.
NOTE: There is a vertical swivel union at each end of
the green hose assembly.
NOTE: If desired, the green hose can be trimmed to fit
better.
a. Loosen the tank end of the hose before trying to
connect to the metering pump inlet.
b. Bend the hose as necessary to make it fit.
c. Once the vertical unions are tightened, check
that the hose clamps on the green hose are
tightened to approximately 90-100 in-lb
(10-11 N•m).
3. Connect the two hose bundles with a red air hose
on the sprayer module to the correct connection on
the respective feed module, as described below.
a. Connect the red 1/2 in. air hose to the swivel
union. See the ‘a’ in F
e
IG
. 14.
ti20269a
a
c
d
b
F
IG
. 14
b. Connect the 1/4 in. OD air signal tube to the
tube with a tube connector. This is the feed
pump pilot signal. See the ‘b’ in F
c. Connect the small cable with an M8 connector
to the mating M8 connector. See the ‘c’ in F
14.
d. Connect the larger cable with an M12 connector
to the mating M12 connector. This is the level
sensor connection. See the ‘d’ in F
e. Connect heater power cable to the mating
power connector. See the ‘e’ in F
4. Connect the fluid circulation return hoses.
• The 1/2 in. circulation hose from the dosing
valve connects to the side of the A tank.
• The 3/8 in. circulation hose from the dosing
valve connects to the side of the B tank.
IG
IG
. 14.
IG
. 14.
. 14.
IG
.
18 3A2776D
Install Level Sensor Probes
Each tank uses a 37 in (94 cm) stainless steel rod,
which functions as the level sensor probe, that mounts
into the level sensor head and extends down into the
tank. The level sensor probes are tie-wrapped to the
frame of each feed module at the factory prior to shipment. The level sensor probes must be mounted into the
level sensor heads before use.
1. Verify the main power switch is OFF.
2. Disconnect 3/4 in. union that holds the level sensor
on top of the tank.
3. Apply blue thread lock to the threads in the top of
the rod.
4. Feed the rod into the tank and screw the threaded
end up into the sensor head.
5. Use a pliers to grab the flat on the rod and tighten
the rod up into the sensor head. Do not over-tighten.
Setup
WLD
IG
. 15
F
Level Sensor Calibration
Level sensors are factory set to work with these tanks.
Calibration is not necessary unless replacing a sensor.
See manual 3A2989.
3A2776D 19
Setup
Connect the Fluid Hose Bundle to the System
The system is shipped with a 50 ft (15 m) hose bundle
for connecting the system to the mix manifold.
The bundle contains one 3/4 in. ID A material hose, one
1/2 in. ID B material hose (model 262869) one 3/4 in. ID
B material hose (model 24W626), one 1/4 in. ID flush
hose, and 1/2 in. OD heated fluid circulation tubes. The
hose bundle is insulated and wrapped inside a protective sheath which has a Velcro closure so it can be
opened to change hoses.
1. Position the hose bundle end with the four loose red
and blue tubes at the machine outlet.
Model 262869: Connect the 3/4 in. A and 1/2 in. B
hoses to the respective material outlet check valves
on the front of the system. See F
Model 24W626: Connect the 3/4 in. A and 3/4 in. B
hoses to the respective material outlet check valves
on the front of the system. See F
IG
IG
. 16.
. 16.
2. Connect the short purple flush hose from the solvent
flush pump to the 1/4 npsm hose in the bundle. Use
the 1/4 in. nipple included with the hose bundle to
connect the hoses. See F
IG
. 17.
ti20272a
FIG. 17: Solvent Flush Pump Connection
3. Connect the two red tubes in the bundle to the tube
tee on the red tube on the front of the machine. Do
the same for the blue tubes. See F
IG
. 18.
ti20106a
F
IG
. 16
ti20273a
IG
. 18
F
20 3A2776D
Setup
4. Locate the long temperature sensor with black heat
shrink sheath and a connected cable that is
tie-wrapped to the B heater power cable.
a. Cut the temperature sensor loose from the tie
wrap.
b. Insert the sensor down inside the hose bundle
so it is buried in the insulation and up against
the fluid hoses. Be sure the sensor cable will not
get pulled tight by the hose or catch on anything.
Connect the Fluid Hose Bundle to the Mix Manifold
1. Unroll the hose bundle out to the spray area.
2. Model 262869: Connect the 3/4 in. A and 1/2 in. B
hoses to the material inlet ball valves on the mix
manifold. See F
Model 24W626: Connect the 3/4 in. A and 3/4 in. B
hoses to the material inlet ball valves on the mix
manifold. Color code material hoses (green and
blue) with respective color identification on mix
manifold. See F
IG
. 20.
IG
. 20.
Material Inlets
ti20274a
F
IG
. 19
c. Use electrical tape to wrap the hose bundle
from where it connects to the system to the
hose sheath. This insulates and protects the
hose bundle.
Solvent Inlet
ti20088a
FIG. 20
3. Remove the U-shaped tube connectors only from
the end of the longer set of red and blue tubes. Trim
the excess tubing to fit the one set of the red and
blue tubes fully into the two brass compression fittings on the aluminum heat circulation plate under
the main manifold. Tighten the compression fittings.
4. Route the purple solvent flush hoses from the manifold underneath the manifold carriage and connect
to the 1/4 in. flush hose in the hose bundle.
See F
IG
. 20.
5. Use electrical tape to wrap the hose bundle from
where it connects to the system to the hose sheath.
This insulates and protects the hose bundle.
3A2776D 21
Setup
Connect the Mix Manifold to the Gun
The following parts are supplied loose. Connect them to
the mix manifold as follows. See F
1. Connect 1/2 in. ID x 2 ft hose to mix manifold (R)
outlet.
R
IG
. 21.
S
T
F
IG
. 21
2. Connect static mixer (S).
3. Connect 1/2 in. ID x 10 ft. hose.
4. Connect 1/2 in. x 3/8 in. nipple.
5. Connect 3/8 in. ID x 3 ft hose.
6. Connect 1/2 x 3/8 nipple.
7. Connect swivel.
8. Connect gun (T).
ti20090a
22 3A2776D
Setup
Prime Heated Fluid Circulation System
The heated fluid circulation system includes heated
hoses alongside the material hoses for the length of the
hose bundle, heated fluid circulation through the mix
manifold, and heated fluid circulation through the tank
double-wall which is insulated by a jacket.
Hose Bundle Heating System
1. Add a 50% water, 50% glycol anti-freeze mix to the
small translucent tank located at the bottom right
corner of the front of the sprayer module.
NOTE: Even in warm climates, a water/glycol mix
should be used to keep the circulation system clean and
working properly.
2. With air supply on, adjust the silver knob on top of
the diaphragm pump to start the small black diaphragm pump under the tank. Adjust pump to
approximately 2-3 cycles per second.
3. Continue to add the 50/50 fluid mixture as air is
purged from the fluid lines but make sure the tank is
no more than 1/4 to 1/3 full when cold.
3. Adjust the silver knob located just above the Feed
Module Air Controls. When looking at the Feed
Module Air Controls, the knob will be visible just
above them. See F
IG
. 23. Adjust knob until tank
heated fluid pump reaches approximately 2-3 cycles
per second.
Adjustment Knob Location
ti20126a
NOTE: Re-tighten all heated fluid circulation tube fittings
after the first time the system has been run at full temperature.
Double-Walled Tank Heating System
NOTE: The double-walled tanks are pre-filled with a
water/glycol mix at the factory. If your tanks are already
filled, skip this section.
1. Add a 50% water, 50% glycol anti-freeze mix to the
small translucent tank located between the tank and
feed pump on the feed module.
2. Turn the agitator and tank heated fluid pump air ball
valve ON.
FEED PUMP
BYPASS
ti20127a
F
IG
. 22
FIG. 23
4. Continue to add the 50/50 fluid mixture as air is
purged from the fluid lines but make sure the tank is
no more than 1/4 to 1/3 full when cold.
5. Repeat for other feed module.
NOTE: Re-tighten all heated fluid circulation tube fittings
after the first time the system has been run at full temperature.
3A2776D 23
Initial Startup
Initial Startup
Perform this procedure on new systems. Systems are
tested at the factory with mineral oil and there will be
residual oil in the material lines. Flush new systems if A
or B material will not function properly if it contacts mineral oil.
NOTE: If the tank return lines are not disconnected on
the initial priming of the system, all of the oil in the material lines will be pushed back into the tank and mixed
with the material, which will contaminate all of the fluid in
the tank.
1. Verify all procedures in the Setup section beginning
on page 14 have been properly performed.
2. Perform Adjust Packing Nuts on page 52.
3. Turn main power switch (BA) ON and verify the system air inlet ball valve (E) is open. See F
page 10 and F
4.
If your A or B material will not function properly if it
IG
. 1 on page 7.
mixes with a small amount of mineral oil,
IG
. 4 on
perform
the remainder of this Initial Startup procedure once
with grounded pails of solvent instead of A and B
material pails. After performing this entire procedure
once with solvent, perform it a second time with the
A and B materials. Be sure to choose a solvent that
is compatible with your material and with the wetted
parts in this system. See Technical Data on
page 85.
5. Close both feed system air controls ball valves then
open the brass valve on the tank lid air assembly.
Air pressure gauge should read 0 psi. Close the
brass valve.
FEED PUMP
BYPASS
Return line
port
ti20267a
FIG. 25
7. Fill the tanks with material:
NOTE: If adding flush solvent, remove the platen from
the feed pump by loosening the two setscrews and the
air tube. Drop the feed pump directly into the pail.
a. Navigate to the Supply screen then press
to activate automatic tank filling. See page 73.
b. Remove the priming stick from the platen.
ti20127a
FIG. 24
6. Disconnect the material circulation return line from
the side of each tank then cap the tank port. This
enables pushing the mineral oil out of the fluid lines.
Route the return lines into waste containers. See
F
IG
. 25.
ti20108a
FIG. 26
24 3A2776D
Initial Startup
c. Slide main air slider valve (DA) and air motor
slider valve (DF) to the OFF position. See F
27.
DF
DD
DA
F
IG
. 27: Feed Pump Controls
ti20104a
DE
DC
DB
d. Back out the air regulator (DB) then lift the RAM
director valve (DC).
e. Slide main air slider valve (DA) ON.
f. Slowly adjust the air regulator (DB) to increase
air pressure until the RAM begins to lift. Use air
regulator to adjust RAM speed.
g. Adjust director valve to the neutral position
when the platen is high enough to position the
pail beneath the platen.
h. Install pail of material beneath feed pump
platen.
IG
k. Ensure platen is centered on pail when it con-
.
tacts it. Repeat previous steps until platen is
centered on pail.
l. Adjust air regulator (CB) to increase air pres-
sure until the RAM presses into the pail. Install
priming stick once fluid begins exiting the priming stick hole.
NOTE: New platens components may be stiff and resist
entering the pail. Continue increasing pressure up to 80
psi until platen enters the pail. If it does not enter at 80
psi, the thick clear packing on the platen may need to be
flipped upside down so the wider diameter side is up
and the smaller diameter side is down.
Use the minimum pressure possible to lift the platen
out of the pail to minimize material splattering when
the platen exits the pail.
m. With the platen pressing into the fluid, slide the
air motor slider valve (DF) to the ON position.
See F
IG
. 27. Feed pump will start cycling. Continue pumping until pail is empty or desired
amount of fluid has been added to the tank.
Slide the air motor slider valve (DF) to the OFF
position to stop the feed pump.
n. To lift the platen out of the pail, press the
blowoff button (DD) then lift the director valve.
The feed pump will push pressurized air into the
pail to remove it from the platen. Do not let the
pail lift off of the frame. If it does, lower the
platen then retry.
o. Repeat the previous steps as necessary until
both tanks are filled to desired level. Do not
overfill the tank.
ti20108a
IG
. 28
F
i. Back out the air regulator (DB) then lower the
RAM director valve (DC).
j. Slowly adjust the air regulator (DB) to increase
air pressure until the RAM begins to lower. Use
air regulator to adjust RAM speed.
3A2776D 25
Initial Startup
8. Open both ball valves on the feed module air controls.
FEED PUMP
BYPASS
ti20127a
F
IG
. 29
To reduce the risk of explosion, never turn on heaters
when solvent is in the system.
9. If not already set, adjust the feed module settings:
11. Verify the sampling valves are closed.
12. Open metering pump inlet ball valves.
WLD
13. Turn on air supply and set metering pump air regulator to 20 psi (138 kPa 1.38 bar).
a. Use regulator on the feed module air controls to
set tank air pressure to 60 psi.
b. Adjust silver knob on agitator until it reaches
30 rpm.
c. Adjust silver knob on tank heated fluid circula-
tion pump until it reaches 60 cpm.
d.
If there is no solvent in the tanks,
adjust tank
water heater knob until the 4 is at the 12 o’clock
position then check temperature when the
heater indicator light turns off. Adjust setting
then repeat until desired temperature is
achieved.
10. Open the circulation valves.
14. At the main run (fluid control) screen, press to
enter manual pump run mode.
15. Press repeatedly to select Metering Pump
A . Press . Slowly turn metering pump air
regulator (CD) clockwise to increase air pressure
until metering pump A starts. Continue to run pump
slowly and dispense into pail until clean material
comes out of the return line. Press to stop
pump. Back out the metering pump air regulator.
NOTICE
Run metering pump as slowly as possible until it is
fully primed to prevent pump damage due to pump
WLD
26 3A2776D
cavitation.
Initial Startup
NOTE: To run each side independently, press
repeatedly to set to
or
. Press and as
needed to prime. Monitor containers to avoid overflow.
NOTE: When priming or flushing pumps, it is normal to
get cavitation or pump runaway alarms. Press to
clear alarms then press again as necessary.
These alarms prevent excessive pump speeds, which
will damage pump packings.
16. Repeat the previous step for the B side.
NOTICE
Prior to performing the following step, make sure
the tank is not more than half full. When the tank
pressure is relieved, the fluid will expand, and could
overfill the tank if there is too much in the tank.
17. Back out the tank air pressure regulator on the feed
system air controls and open the brass valve on the
tank lid.
20. Close the circulation valves.
WLD
21. Prime the A sampling valve:
a. Press repeatedly to set to
.
Press .
Slowly turn metering pump air regulator (CD)
clockwise to increase air pressure until metering
pump A starts.
b. With a waste container beneath the valve, open
the A sampling valve slowly until clean material
dispenses then close the sampling valve.
FEED PUMP
BYPASS
ti20127a
F
IG
. 30
18. With the tank air pressure relieved, remove tank
port plugs and reconnect the tank return lines.
19. Adjust the tank air pressure regulator back to the
desired pressure.
ti20109a
22. Repeat the previous step to prime the B sampling
valve.
3A2776D 27
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