Graco 3A2776D User Manual

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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

See page 3 for model information, including maximum working pressure and approvals.

WLD

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

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

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)

Component Identification

E, F

ti19927a

WLE

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)

FIG. 2

C1, A1

WLD

X (located between metering pumps, not visible in current view)

D1, A1

8 3A2776D

Fluid Control Assembly

Component Identification

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

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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

FIG. 5

Switch (only used if the water heater accessory has been added to the machine)

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

Component Identification

NOTE: Both valves shown open

. 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

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

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

RAM Blowoff Valve (DD)

To minimize material splatter, use the minimum air pressure required to remove platen from pail.

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.

ti13365a

. 7: User Interface

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

• 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.

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

. 8: Main Display Screen Components (shown with all display features enabled)

Remaining Potlife Time

Function Display

Go back one screen

3A2776D 13

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

. 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

Choose one of the configurations shown in F

. 9 then bolt together the three modules on a flat surface. See F

. 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

. 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

. 11. These are not used in the side-by-side module configuration.

3.5 in. long

ti20197a

10x

FIG. 11: Bolt Locations (Front to Back)

5.5 in. long

1.5 in. long

. 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.

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

)

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

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.

. 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.

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;

/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

/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

. 14.

ti20269a

. 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.

. 14.

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

WLD

. 15

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

. 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

. 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

. 18.

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. 16

ti20273a

. 18

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

. 20.

Material Inlets

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. 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

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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

. 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.

. 21.

. 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).

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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

. 23. Adjust knob until tank

heated fluid pump reaches approximately 2-3 cycles per second.

Adjustment Knob Location

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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

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. 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

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

If your A or B material will not function properly if it

. 1 on page 7.

mixes with a small amount of mineral oil,

. 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.

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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

. 25.

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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.

. 27: Feed Pump Controls

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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.

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

. 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.

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. 28

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

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. 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.

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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.

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

WLD

26 3A2776D

cavitation.

Initial Startup

NOTE: To run each side independently, press

repeatedly to set to

. 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.

WLD

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

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. 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.

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22. Repeat the previous step to prime the B sampling valve.

3A2776D 27

Initial Startup

23. Prime the A material hose:

a. Remove the outlet fitting from the mix manifold

so materials can be dispensed without mixing.

b. Place a waste pail under the mix manifold out-

let.

B Valve

A Valve

ti20088a

Outlet Fitting

c. Open the A side mix manifold inlet ball valve.

d. Press repeatedly to set to

Press . Slowly turn metering pump air regulator (CD) clockwise to increase air pressure until metering pump A starts. Continue until clean material dis-

penses from the A material line then press to stop pump.

e. Close the A side mix manifold inlet ball valve

then reconnect to the mix manifold. Back out the metering pump air regulator.

f. Repeat for the B material line.

NOTE: Now all of the material lines are primed except for the section from the mix manifold to the gun.

24. Perform the Prime Solvent Flush Pump procedure on page 29 to flush out the oil from those lines, and to finish preparing for spraying.

28 3A2776D

Prime Solvent Flush Pump

• The equipment must be grounded to reduce the risk of static sparking and electric shock. Hold gun firmly to side of grounded pail when triggering into pail.

• Do not point gun at anyone or at any part of the body.

• Solvent can irritate eyes, nose, throat, and skin. Hot fluid and parts can burn skin. Wear appropriate protective wear when using flush solvents and/or if fluid temperature exceeds 110° F (43° C).

• Keep clear of moving parts.

1. Turn main power switch ON and verify the XM PFP air supply ball valve is open.

2. Fill grounded metal pail with solvent.

3. With the mix manifold inlet ball valves and the mix manifold solvent flush ball valves closed, trigger the gun into a grounded pail to remove any residual pressure.

4. Ensure trigger lock is engaged. Remove spray tip.

Prime Solvent Flush Pump

7. Open the solvent flush valves.

ti20110a

8. Disengage trigger lock and trigger gun into a grounded pail. Press gun against the grounded pail. Use a pail lid with a hole to dispense through. Seal around hole and gun with a rag to prevent splash back.

9. Open solvent pump air valve (CB). Pull out and slowly turn solvent pump air regulator (CG) clockwise until solvent pump begins to slowly cycle.

10. Continue to dispense until all air is purged.

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If the optional hot water flush kit is not used,

TI19266a

place

solvent flush pump siphon tube in the pail of solvent.

TI1953a

11.

If the optional hot water flush kit is used,

perform the

following steps:

NOTICE

If the optional hot water flush kit is used,

water hose connected to the water inlet. Do not turn on the water heater yet.

3A2776D 29

turn on the

To avoid burning out the heater element in the water heater, never turn on the water heater unless it is filled with water.

Prime Solvent Flush Pump

a. After water begins dispensing from the gun, turn

the water heater toggle switch located on the back of the heater ON.

b. Turn the water heater power switch on the sys-

tem junction box ON.

ti20101a

NOTE: The water heater must be filled with fluid and turned on at least 45 minutes prior to when flushing will be required.

12. Close solvent pump air valve (CB) to stop pump then trigger gun into grounded pail to relieve pressure. Engage gun trigger lock.

TI19265a2

13. Close the solvent flush ball valves on the mix manifold.

30 3A2776D

Adjust Ratio and System Settings

1. Turn key to right (setup position). Yellow LED will flash and the Setup mode Home screen will display.

2. Press and to change the volume ratio setting.

3. When desired ratio is displayed, turn key to left. Yellow LED will turn off.

4. Change all settings in the user-interface to the desired values. See Appendix A - User Interface Display on page 58 for detailed screens information, including navigation and instructions.

Temperature Settings

2. After the red light goes out, check the temperature on the gauge and adjust as needed to get desired temperature.

NOTE: Tank will not heat up faster by increasing the temperature setting.

A and B Material Temperature

There is one Viscon HF 5400 watt heater for heating material while in circulation or while dispensing. These heaters are digitally controlled to your specific setpoint temperature.

The Supply screen controls and displays the setpoint and actual temperature.

Set the desired A and B temperature. The box next to the target is the setpoint. The number next to the thermometer is the actual temperature.

Press and to turn on the A and B primary heaters.

See Spray procedure for pre-heating procedure to use prior to spraying.

Set all temperatures per your materials data sheet specifications.

Feed Tanks

Temperature is controlled by an adjustable thermostat on each tank heater. Power to the tank heaters is supplied from the power switches (BB, BC) next to the main power switch. Tank material temperature is displayed on the Supply screen under the tank icon. The circulating heated fluid temperature is displayed on the temperature gauge next to the heater.

1. Set heater control knob to 4. This is approximately 120°F (49°C).

Hose Bundle Temperature

Set the desired hose bundle temperature on the supply screen.

Be sure the knob on the Viscon HP hose heater (the middle of the three heaters on the front of the system) is turned fully clockwise (full ON position). Always leave in the full ON position. Heater has a separate digital control module in the junction box.

The heater will heat the water/glycol mixture to 180°F (82°C) as needed until the hose bundle gets up to the desired temperature. It will then run at whatever temperature is required to maintain the hose setpoint temperature.

Press to turn the hose bundle heater ON or OFF.

3A2776D 31

Spray

Do not point gun at anyone or at any part of the body. Solvent can irritate eyes, nose, throat, and skin. Hot fluid and parts can burn skin. Wear appropriate protective wear when using flush solvents and/or if fluid temperature exceeds 110° F (43° C).

This procedure includes steps ensure that any settled fillers are well-mixed with the material, the metering pump lines are fully primed, the metering pump check valves are operating smoothly, and materials are up to temperature prior to spraying the production surface.

When the temperatures displayed on the Supply screen reach operating temperature, the material is ready to spray.

After the first day of spraying follow Pressure Relief Procedure, page 38, then tighten packing nuts on pumps and dosing valves.

5. Open both ball valves on the feed module air controls.

FEED PUMP

BYPASS

ti20127a

FIG. 31

6. Close mix manifold flush valves.

1. If this is the Initial Startup or if system components have been replaced, follow the Initial Startup procedure beginning on page 24.

2. Turn main power switch ON and verify the XM PFP air supply ball valve is open.

3. Perform Prime Solvent Flush Pump, page 29 to ensure the solvent pump is prepared to quickly flush out mixed material when done spraying.

NOTE:

If the optional hot water flush kit is used,

the water heater must be filled with fluid then turned on 45 minutes prior to when flushing will be required.

4. If tank levels are low, fill them with material. See

step 7 on page 24.

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7. Close mix manifold ball valves.

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32 3A2776D

Spray

8. Open recirculation valves.

WLD

9. Ensure metering pump air supply is OFF.

pressure to the metering pumps until the enabled pump(s) begin running slowly.

13. Turn A and B tank fluid heaters ON.

10. At the main run (fluid control) screen, press to enter manual pump run mode.

11. Press repeatedly to select . Press to begin circulating.

NOTICE

Run metering pump as slowly as possible until it is fully primed to prevent pump damage due to pump cavitation.

12. Back out the metering pump air regulator (CD) then turn on the main air shutoff valve (CA). Use metering pump air regulator to slowly increase the air

ti20101a

14. To adjust tank fluid heater temperature, adjust the numbered knob on the heater.

15. Turn on the primary material heaters.

a. Navigate to the Supply screen. See Operator

Command Mode Screens on page 66.

b. Press and to turn on the A and B pri-

mary heaters, and press to turn on the hose bundle heater.

16. If desired, press to enable automatic tank filling. See page 73 for automatic tank filling details.

17. Run the metering pumps until the material has reached the desired temperature.

NOTE: If you circulate the A side metering pump at pressures greater than 3000 psi (21 MPa, 210 bar), an advisory is issued and the yellow LED on the display illuminates. This is a reminder to select Spray mode prior to spraying and to circulate at a lower pressure to avoid excessive pump wear.

3A2776D 33

Spray

NOTE: If you circulate the A side metering pump above 5200 psi (35.4 MPa, 354 bar), an alarm shuts down the pump to prevent accidentally spraying material while still in circulation mode.

18. Once the materials reach the desired temperature

as shown on the supply screen, press .

19. Turn off the main air shutoff valve (CA).

24. Open mix manifold ball valves.

ti20128a

25. Select .

20. Close recirculation valves.

WLD

21. Perform Pump and Metering Test on page 40.

22. Perform Ratio Test (Batch Dispense or Ratio Test) on page 42.

23. Perform Down Stream Valve Leak Test on page 43.

26. Press to start the metering pumps.

27. Disengage trigger lock and trigger gun into a grounded metal pail. Use a metal pail lid with a hole to dispense through to avoid splashing.

TI19265a1

TI1953a

28. Adjust metering pump air regulator (CD) to 30 psi (0.21 MPa, 2.1 bar).

29. Dispense until clean, well-mixed epoxy flows from the gun.

TI19265a1

TI1953a

30. Engage trigger lock.

34 3A2776D

31. Perform the Mix and Integration Tests on page 44. When necessary, engage trigger lock then install the tip on gun.

Spray

TI19265a2

NOTE: While spraying, it is best to continuously hold the trigger. Do not release the trigger unless necessary. This maximizes the material temperature consistency and minimizes fiber buildup.

32. Adjust air regulator (CD) to the necessary spraying pressure and trigger gun to spray material on a test panel. Look at ratio screen to ensure it is reading the correct ratio. Continue spraying on the test panel until the desired pattern results then begin spraying the production surface.

33. Follow Flush Mixed Material on page 36 when you are finished spraying if the potlife of the mixed materials in the system could expire before you spray again.

NOTE: Pot life of the mixed materials in the system is much shorter than the dry time of dispensed epoxy because mixed material potlife or working time decreases with increased temperature.

3A2776D 35

Flush Mixed Material

• The equipment must be grounded to reduce the risk of static sparking and electric shock. Hold gun firmly to side of grounded pail when triggering into pail.

• Do not point gun at anyone or at any part of the body.

• Keep clear of moving parts.

This procedure flushes out mixed material from system to prevent it from curing in the system.

NOTE: Pot life of the mixed materials in the system is much shorter than the dry time of dispensed epoxy because mixed material potlife or working time decreases with increased temperature.

7. Disengage trigger lock and trigger gun into a grounded pail. Use a pail lid with a hole to dispense through. Seal around hole and gun with a rag to prevent splash back.

8. Open solvent pump air supply valve. Pull out and slowly turn solvent pump air regulator clockwise to increase air pressure. Use lowest pressure needed to flush material out of hose.

9. Continue dispensing until clean flushing fluid is dispensed.

Follow this procedure when you are finished spraying if the potlife of the mixed materials in the system could expire before you spray again.

1. If necessary, Prime Solvent Flush Pump, page 29.

2. Press to stop the metering pumps.

3. Trigger gun into a waste container to relieve pressure then engage trigger lock.

4. Remove spray tip.

5. Close mix manifold ball valves.

ti20129a

TI19265a1

TI1953a

10. Close the open solvent flush valve. Open the other solvent flush valve. Continue dispensing long enough for any remaining mixed material

11. Close solvent pump air supply valve.

12. Trigger gun to relieve pressure in solvent lines then engage trigger lock.

TI19265a2

6. Open one of the solvent flush valves on the mix manifold.

36 3A2776D

Park Metering Pump Rods

13. Close solvent flush valves.

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14. Use a rag and solvent to clean spray tip then reinstall on gun.

15. Remove the static mixer. Clean the mix element then re-install the mixer.

Park Metering Pump Rods

2. Open fluid recirculation valves.

WLD

3. Close mix manifold material ball valves.

ti20129a

4. Open the metering pump air supply ball valve.

NOTE: This procedure is only necessary when the system will not be used for more than a few hours. The primary purpose of this procedure is to prevent material from hardening on the metering pump shaft by extending the pump so the portion of the shaft that is exposed to material is not exposed to the air.

1. Close metering pump air supply ball valve then back out the air pressure regulator.

5. Press then press to start metering

pumps. Slowly adjust air pressure regulator until pumps begin to move. Each metering pump will circulate materials until they reach the bottom of the stroke then will stop.

3A2776D 37

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

1. Engage trigger lock.

TI19265a2

If the system will be shut down for more than a few hours,

perform Park Metering Pump Rods proce- dure on page 37 to prevent fluid hardening on the metering pump shafts.

NOTICE

The material may expand when air pressure is removed. This can cause the tank to overfill and damage the parts attached to the tank lid. To prevent overfilling the tank, never relieve air pressure in the tank unless the tank is less than half full. Verify tank material level on the user interface, see Appendix A - User Interface Display section beginning on page 58.

If necessary to relieve tank air pressure:

close both feed system air control ball valves and back out the air pressure regulator. Open the brass valves on the tank lids for full tank de-pressurization. Pressure gauge should read 0 psi.

FEED PUMP

BYPASS

ti20127a

3. Press .

4. Slide the feed pump air supply valve (DF) and director valve air supply valve (DA) to the OFF position.

. 32: Feed Pump Air Controls

ti20104a

. 33

6. Open mix manifold ball valves.

ti20128a

38 3A2776D

Pressure Relief Procedure

7. Open recirculation ball valves.

WLD

8. Disengage trigger lock.

TI19265a1

9. Hold a metal part of the gun firmly to a grounded metal pail. Trigger gun to relieve pressure in material hoses. Use a pail lid with a hole to dispense through. Seal around hole and gun with a rag to prevent splash back.

11. Close mix manifold material ball valves.

ti20129a

12. Perform Flush Mixed Material procedure beginning on page 36 to prevent mixed material curing in the system and to relieve pressure in the solvent lines.

13.

If the system will be shutdown for more than a few hours,

fill metering pump A and B packing nuts with

throat seal liquid (TSL).

NOTE: Fluid pressure in the system is now relieved.

10. Engage trigger lock.

TI1953a

TI19265a2

3A2776D 39

System Verification

NOTE: Each sampling valve must be primed prior to

beginning this procedure to ensure best accuracy. If the clear tube connected to the sampling valve is not filled with material, prime the sampling valves.

Graco recommends running the following tests daily prior to spraying on the production surface.

Pump and Metering Test

This test checks the following five items and should be run every time a new job is started, or if there is a suspected problem.

• Verifies that the metering pumps installed match the metering pumps selected on the Setup screen by dispensing exactly 750 ml of each material.

• Verifies that each metering pump holds fluid against the metering pump inlet valve by stalling on the down stroke.

• Verifies that each metering pump holds fluid against the metering pump piston valve and packings by stalling on the upstroke.

• Verifies that each metering valve holds fluid and that there are no external leaks between the metering pump and metering valve.

• Verifies that the recirculation valves (AC, AD) are closed and do not leak.

This test will dispense 750 ml of component A, and then 750 ml of component B. Dispense into separate cups so the fluid can be returned to the supply tanks.

1. Verify the clear tube connected to each sampling valve is filled with material. If not, perform the following steps to ensure accuracy of the metering test.

a. Turn metering pump air supply valve on.

b. At the main run (fluid control) screen, press

to enter manual pump run mode.

c. Press repeatedly to select . Press

d. With a waste container beneath the sampling

valve, slowly open the valve until material begins to slowly dispense. Once clean material dispenses from the sampling valve, and the clear tube is completely filled with clean mate-

rial, press to stop dispensing. Repeat with

the other side if necessary.

NOTE: During each dispense the flow will stop once to stall the upstroke, once to stall the downstroke, and then it will finish the dispense. Do not close the sampling valve until the fluid flow stops and the blue metering pump light (DK) goes out.

NOTE: Material hoses from the system to the mix manifold must be filled with material and pressurized for testing to be successful.

40 3A2776D

2. Enter Test mode in the run (fluid control) screen.

See Test Screens on page 69. Select run pump test.

System Verification

3. Set metering pump air regulator (CD) pressure to zero. Open metering pump air valve (CA). Adjust metering pump air regulator (CD) pressure to 50 psi (0.35 MPa, 3.5 bar).

4. Dispense fluid A:

a. Close recirculation valves, mix manifold inlet

ball valves, and sampling valves.

b. Place a clean 1 quart (1000 cc) container under

sampling valve A.

5. Dispense fluid B as follows:

a. Place a clean 1 quart (1000 cc) container under

sampling valve B.

ti20112a

b. Slowly open and adjust sampling valve B to

achieve desired flow. Metering pump stops automatically; twice during test and again when dispense completes. Metering pump B light (DK) turns off.

ti20111a

c. Press . Metering pump A light (DK) comes

on.

d. Slowly open sampling valve A until material

begins to dispense. Metering pump stops automatically; twice during test and again when dispense completes. Metering pump A light (DK) turns off, metering pump B light (DK) turns on.

e. Close sampling valve A (AE).

c. Close sampling valve B.

6. Compare fluid amounts in containers; they should each equal 750 ml (25.3 fl. oz.). Repeat test if fluids are not equal. If problem persists, see Alarm Code Troubleshooting, page 79.

7. Return fluid used in test to corresponding fluid supply container.

Confirm Pump and Metering Test

The Confirm Pump and Metering Test screen displays when the pump and metering test completes without error. This screen displays the target weight of material dispensed into each beaker from each metering pump. To have your test results entered in the downloadable USB log files, enter the two weights.

3A2776D 41

System Verification

Batch Dispense or Ratio Test

NOTE: This test dispenses a calculated volume of each

fluid based on ratio. The two fluids combined equal the batch size selected.

Follow this procedure to dispense a batch (into one container) for touch-up work or to verify the dispensed ratio (use separate containers for fluids A and B).

When checking the ratio, use a scale to tare the two containers then weight the dispensed materials.

1. Close mix manifold material ball valves.

e. At the main run (fluid control) screen, press

to enter manual pump run mode.

f. Adjust metering pump air regulator pressure to

50 psi (0.35 MPa, 3.5 bar).

ti20129a

2. Close recirculation ball valves.

WLD

3. Pressurize the material lines:

d. Set metering pump air regulator pressure to

zero. Open metering pump air valve.

g. Press .

h. When both the A and B metering pumps stall,

press .

4. Enter Test mode in the run (fluid control) screen.

See Test Screens on page 69. Select

to run

batch dispense test.

5. Adjust dispense amounts from 500 ml to 2000 ml (in

250 ml increments) by pressing to open the

drop-down box. Then press and to select

the desired value. Press to select that value.

6. Close recirculation valves, mix manifold inlet ball valves, and sampling valves.

42 3A2776D

System Verification

7. Place a clean container under sampling valve A.

ti20111a

8. Press . Metering pump A light comes on.

9. Dispense fluid A. Slowly open and adjust sampling valve A (AE) to achieve desired flow. The metering pump stops automatically when dispense completes and metering pump A light (DK) turns off and metering pump B light (DK) turns on.

Batch dispense:

12.

Ratio check

als dispensed.

stir material until mixed.

: compare net weight of A and B materi-

Confirm Batch Dispense Test

The Confirm Batch Dispense Test screen displays when the batch dispense test completes without error. This screen displays the selected ratio between the metering pumps and the weight of material dispensed from each metering pump.

The gray at the bottom of the beaker represents the volume of material dispensed by metering pump A and the black at the top of the beaker represents the volume of material dispensed by pump B.

Enter the weight of each sample in the A and B input boxes. The system will calculate the ratio and display a check in the box if it is within tolerance. The result of the test is also entered in the USB log.

10. Close sampling valve A (AE).

11. Dispense fluid B as follows:

Batch dispense:

pling valve B (AF).

Ratio check

pling valve B (AF).

b. Slowly open and adjust sampling valve B (AF)

to achieve desired flow. The metering pump stops automatically when dispense completes. Metering pump B light (DK) turns off.

move container under sam-

: place clean container under sam-

ti20112a

Down Stream Valve Leak Test

This test confirms or troubleshoots leaks in components located down stream of the dosing valves. Use this test to detect closed or worn valves, and to detect leaks in circulation valves installed at a remote mix manifold.

1. Close both mix manifold valves downstream of the dosing valves.

2. Close recirculation valves (AC, AD).

c. Close sampling valve B (AF).

3A2776D 43

System Verification

3. Enter Test mode in the run (fluid control) screen.

See Test Screens on page 69. Select run down stream valve leak test.

4. Select (AA, AB) are open by verifying blue LEDs are illumi-

nated for both dosing valves.

5. If test is successful, both metering pumps will stall against the downstream valves when the dosing valves (AA, AB) are open. If any movement is detected in the metering pumps after stalling, an alarm is issued indicating which side has a leak.

Press . Ensure dosing valves

Mix and Integration Tests

Use the following tests to check for proper mix and integration.

Butterfly Test

At low pressure, normal flow rate, and without a spray tip installed, dispense a 1/2 in. (12.7 mm) bead of material onto foil until multiple changeovers of each metering pump have occurred. Fold the sheet of foil over the fluid then peel it back and look for unmixed material (appears marble-like).

Curing Test

Spray a single continuous pattern on foil at typical pressure setting, flow rate, and tip size until multiple changeovers of each metering pump have occurred. Trigger and de-trigger at typical intervals for the application. Do not overlap or cross over your spray pattern.

Check curing at various time intervals, listed on the material data sheet. For example, check for dry to touch by running your finger along the test pattern’s entire length at the time listed on the data sheet.

NOTE:

Spots that take longer to cure indicate insufficient integration.

Appearance Test

Spray material onto metal substrate. Look for variations in color, gloss, or texture that may indicate improperly catalyzed material.

44 3A2776D

Empty and Flush Entire System

a. With director valve (DC) in the neutral position

• Running solvent through heaters can cause a fire or explosion. Turn off heaters and allow to cool before flushing. Do not turn on heaters until fluid lines are clear of solvent.

• Splashing fluid can land on exposed body parts and irritate the skin. Cover fluid container and use the lowest possible pressure when flushing to avoid splashing.

Empty and Flush Entire System

and the RAM air regulator (DB) backed out, slide main air slider valve (DA) ON.

Only perform this procedure when:

• The system will not be used for more than one month.

• Changing to a new material in the A or B side.

To flush a new system, see Initial Startup on page 24.

To flush only the mix manifold to the gun, see Flush

Mixed Material, page 36.

NOTE: While hot water is sometimes used to flush

mixed material from the system, it is not recommended for flushing the entire system. When flushing the entire system, use a solvent the dissolves the material.

This procedure is designed to minimize the volume of discarded A and B material when emptying and flushing the entire system.

1. Flush Mixed Material, page 36.

If applicable,

remove the feed pump from pail:

ti20104a

FIG. 34: Feed Pump Air Controls

b. Lift the director valve to the UP position, the

press and hold the blowoff button (DD) while increasing the air pressure using the RAM air regulator. When the feed pump exits the pail, move the director valve to the neutral position and release the blowoff button.

3. Empty the feed pump outlet material lines to the tank:

a. Slide the air motor slider valve (DF) ON.

b. Rotate air motor regulator (DE) to increase air

pressure until feed pump begins to cycle. Continue until all material from outlet line to the tank have been pushed into the tank. This will be noticeable by an increase in feed pump cycle rate.

4. Make sure all heaters are off and cool.

3A2776D 45

Empty and Flush Entire System

5. Close the circulation valves.

WLD

6. Empty the A material tank:

a. Close the A side mix manifold inlet ball valve.

b. Disconnect the A material hose from the mix

manifold at the fitting between the ball valve and check valve.

f. Close the A side mix manifold inlet ball valve.

g. Close the tank air supply ball valve then open

the brass valve on the top of the tank to relieve tank air pressure.

FEED PUMP

BYPASS

ti20127a

FIG. 35

The tank lid assembly is heavy. To prevent crushing your fingers if the tank lid is accidentally dropped, exercise caution while lifting the tank lid.

ti20088a

c. Place the A material hose in a clean container

to salvage the dispensed material. Make sure to have enough clean containers within reach to switch to as each container is filled.

d. Open the A side mix manifold inlet ball valve.

e. Press repeatedly to set to

Press . Slowly turn metering pump air regulator (CD) clockwise to increase air pressure until metering pump A starts. Continue pumping until the metering pump speed increases on its own which signals that the tank is now empty and there is air at the metering pump inlet. Press

to stop metering pump then back out the

air pressure regulator.

NOTICE

The level sensor is very sensitive. Be careful not to damage it while lifting the tank lid.

h. Remove the tank lid assembly.

i. Scrape remaining material from the walls of the

tank into the tank outlet.

j. Re-install the tank lid assembly.

k. Close the brass valve on the top of the tank

then open the tank air supply ball valves to pressurize the tank.

l. With selected, press . Slowly turn

metering pump air regulator (CD) clockwise to increase air pressure until metering pump A starts. Wait until the metering pump speed decreases, meaning that it is now primed with the new material from the tank inlet. Continue pumping until the metering pump speed increases, which means all of the material has

46 3A2776D

Empty and Flush Entire System

been pumped and there is air at the metering

pump inlet. Press to stop metering pump then back out the air pressure regulator.

7. Add solvent to the A material tank:

a. On the A side feed module, close both feed sys-

tem air control ball valves and back out the air pressure regulator. Open the brass valve on the top of the tank to fully relieve tank air pressure.

FEED PUMP

BYPASS

ti20127a

. 36

b. Remove the platen from the A side feed pump

by loosening the two setscrews and the air tube.

c. Place a pail of solvent under the feed pump

then slowly insert feed pump into the pail. The feed pump should rest on the bottom of the pail.

d. Slide the air motor slider valve (DF) to ON.

Adjust the air regulator (DE) so the feed pump runs very slowly.

e. Continue adding solvent to tank until enough

solvent is in the tank to expel the remaining material from the hose bundle material line.

8. Salvage the A material from the hose bundle material line then flush the hose bundle material line:

a. Press . Slowly turn metering pump air

regulator (CD) clockwise to increase air pressure until metering pump A starts. Continue until the material appears to be thinner, which is a sign that the solvent is mixing with the material,

then press to stop the metering pump.

Back out the air pressure regulator.

b. Cover the material container and store for later

use.

c. Move the A material line to a waste container.

d. Press . Slowly turn metering pump air

regulator (CD) clockwise to increase air pressure until metering pump A starts. Continue until

clean solvent is dispensed, then press to

stop the metering pump. Back out the air pressure regulator.

e. Reconnect hose bundle material line to the mix

manifold.

f. Disengage trigger lock then trigger gun into the

waste container and press . Slowly turn

metering pump air regulator (CD) clockwise to

increase air pressure until metering pump A starts. Continue until clean solvent is dis-

pensed, then press to stop the metering pump. Back out the air pressure regulator.

ti20104a

. 37: Feed Pump Air Controls

3A2776D 47

Empty and Flush Entire System

9. Verify tank air pressure is still relieved, then purge the material from the tank return line.

a. Open the circulation valves.

WLD

b. Disconnect the tank return line from side of the

tank.

c. Place the return line in a waste container.

d. Press . Slowly turn metering pump air

regulator (CD) clockwise to increase air pressure until metering pump A starts. Continue until

clean solvent is dispensed, then press to

stop the metering pump. Back out the air pressure regulator.

10. Repeat this entire procedure for the B material side. Leave solvent in the lines to prevent scale buildup which could flake off.

11. Adjust Packing Nuts, see page 52.

48 3A2776D

Prepare Level Sensor for Shipping

NOTICE

To prevent damage to the level sensor probe, do not ship the feed module with the tanks empty and the level sensor probe installed. This can cause the probes to vibrate severely and damage the level sensor head.

If possible, transport the tanks with at least 5 gallons (19 liters) of viscous material in the tanks, which is enough for the material level to be above the probe end and will prevent the probe from vibrating severely. If the tanks cannot be shipped with material, perform the following procedure.

1. Disconnect the 3/4 in. union below the level sensor head. The level sensor head will be loose but will not be removed. It is not necessary to remove the level sensor cable.

Prepare Level Sensor for Shipping

WLD

. 38

2. Use a pliers to grasp the flat on the rod and unscrew it out of the sensor head.

3. Pull the probe up out of the tank and tape it to the square tube frame securely to prevent vibration.

4. Replace the 3/4 in. union and level sensor head on the tank lid. Tighten securely for shipping.

5. After shipment, see Install Level Sensor Probes on page 19 to re-install.

3A2776D 49

Download Data from USB

USB Logs

By default, the ratio spray logs record data every 60 seconds. This 60 second interval will record about 32 days of data if spraying 8 hours per day, 7 days per week. To change the default, see Download Setup, page 50. This log can hold up to 18000 lines of data.

Ratio Log 1

(Default log for download.) The ratio log records date, time, machine number, job number, ratio, and batch volume while the system is in Spray mode.

Spray Log 2

The spray log records key data while the system is in spray mode. It records A and B temperature, A and B pressure, A and B flow, A and B batch totals, ratios, restrictor adjustments, alarm codes, and commands.

NOTE: Once the ratio or spray log is full, new data automatically overwrites old data.

NOTE: After data in the ratio or spray log is downloaded it remains in the USB module until it is overwritten.

Download Setup

Navigate to the System Setup screen. Change the number of hours of recorded data to download (default is

768 hours), by pressing and to move

to . Press to make the field selectable.

Press to scroll through each digit. Press

to save the new digit. Follow the same procedure to change the time interval at which data will record (default is 60 seconds). Exit the System Setup screen.

Download Procedure

Alarm Log 3

The alarm log records all alarm codes generated over a two year period. This log should be used for troubleshooting purposes and cannot be deleted. This log can hold up to 73000 lines of data.

Data Log 4

The data log records (every 120 seconds) all data that occurs during spray mode over a two year period. This log should be used for troubleshooting purposes and cannot be deleted. This log can hold up to 43000 lines of data.

NOTE: The 120 second recording period cannot be adjusted.

1. Insert USB flash drive into USB port (DR). Use only

Graco-recommended USB flash drives; see Rec-

ommended USB Flash Drives, page 74.

NOTE: Inserting the USB flash drive while the sprayer is

running will stop sprayer operation.

50 3A2776D

2. The USB download screen automatically displays, and the selected log(s) automatically downloads. The USB symbol flashes to indicate download is in process.

NOTE: To cancel download, press while in pro- cess. Wait for USB icon to stop flashing, and then remove USB flash drive.

3. The USB icon stops flashing when download com-

pletes. The box below displays , which indicates the download was successful

4. Remove USB flash drive from USB port (DR).

5. Insert USB flash drive into USB port of computer.

6. The USB flash drive window automatically opens. If it does not, open USB flash drive from within Win-

dows

Explorer.

Download Data from USB

7. Open Graco folder.

8. Open sprayer folder. If downloading data from more than one sprayer, there will be more than one sprayer folder. Each sprayer folder is labeled with the corresponding USB serial number.

9. Open DOWNLOAD folder.

10. Open folder labeled with the highest number. The highest number indicates the most recent data download.

11. Open log file. Log files open in Microsoft

Excel® by

default. However, they can also be opened in any

text editor or Microsoft

Word.

NOTE: All USB logs are saved in Unicode (UTF-16) format. If opening the log file in Microsoft Word, select Unicode encoding.

3A2776D 51

Maintenance

See the following table for maintenance tasks and frequency. See the following sections for details for each task.

Frequency Task

• Before first use

• After first hour of operation

• After first day of operation

• Whenever TSL is discolored or has seeped over the packing nut, and after sprayer has been transported

Weekly Filters

As Needed Add oil to agitator

Adjust packing nuts

Seals

motor lubricators. Use 10W or 10W-30 detergent oil.

Clean the system

5. After TSL is added, tighten dosing valve packing nuts 1/4 turn after nut contacts packings; about 145-155 in-lb (16-18 N•m).

TSL

ti20107a

Filters

Once a week check, clean, and replace (if needed) the following filters.

• Main air inlet manifold filter; see XM PFP Repair Parts manual 3A2989, Replace Air Filter Element section, for instructions.

Adjust Packing Nuts

NOTE: There must be no pressure when adjusting the

packing nuts. Air pressure in the feed tanks is too much.

1. Follow Pressure Relief Procedure, page 38, including relieving air pressure in the tanks.

2. Fill A and B metering pump packing nuts with throat seal liquid (TSL

3. After TSL is added, torque metering pump packing nuts to 50 ft-lb (67.5 N•m). Follow instructions in Xtreme Lowers manual 311762.

4. Fill A and B dosing valves packing nuts with throat seal liquid (TSL).

™

• Air regulator filter (5 micron) on air control assembly; see XM PFP Repair - Parts manual 3A2989, Replace Air Filter Element section, for instructions.

Seals

Once a week, check and tighten throat seals on metering pumps and dosing valves. Be sure to follow the Flush Mixed Material, page 36, prior to tightening seals.

52 3A2776D

Clean the System

1. Ensure all equipment is grounded. See Grounding, page 16.

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

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

4. Flush mixed material. See Flush Mixed Material, page 36.

5. Perform Pressure Relief Procedure, page 38. This includes flushing the system and parking the metering pumps.

6. Turn main power switch OFF.

Maintenance

7. Clean external surfaces only using 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.

3A2776D 53

Troubleshooting

Alarms

See Appendix B - Alarms, starting on page 76.

General Tips

The following information will help ensure the system is set up properly.

Grounding

• 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 air pressure supply gauge stays above 80 psi (0.55 MPa, 5.5bar) while spraying.

• Ensure that the metering pump air 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.

• Check that the main inlet air filter is clean.

Calibration

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

Motor Icing

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.

• 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

• Check that the static mixer and whip hose are clean.

• Check the check valves for build up if spraying fiber-filled material.

Mix Manifold

• 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 PFP Mix Manifold manual.

• If less integration and mix hose is used than what is recommended, ensure that “Fast Dosing” is selected in the setup screens.

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.

• 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.

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

54 3A2776D

Troubleshooting

Individual Control Module LED Diagnostic Information

The following LED signals, diagnosis, and solutions are the same for the display module, advanced fluid control module (AFCM), fluid control cube, high power temperature control module (HPTCM), and USB module. LEDs are located next to the module power cable.

Module Status LED Signal Diagnosis Solution

Green on System is powered up and power

--supply voltage is greater than 11 Vdc.

Blue

Voltage is being sent to the heater ---

(HPTCM only)

Yellow Internal communication in progress ---

Red solid Hardware failure Replace module.

Red flashing fast Uploading software ---

Red flashing slow Token error Remove token and upload software

token again.

Troubleshooting Table

NOTE: The sprayer operates using air pressure. Many problems are caused by inadequate air supply. The inlet air

pressure gauge cannot drop below 80 psi (0.5 MPa, 5.5 bar) while running.

Problem Cause Solution

Display not lit. No green light present on back of display module.

Display not lit on system. Green light is present on back of display module.

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

Voltage jumpers not installed or configured in power junction box.

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

No display power through CAN cable. Green light in present on AFCM, but is not present on USB module.

Green light is present on USB module. Check CAN cable. Replace if necessary.

Display module failed. Replace display module. See the XM

Reset main disconnect and breaker.

Install red jumpers in junction box terminal blocks. See Connect Power on page 16.

Check for 24 Vdc on J1, pins 2 and 3, of power supply. See Electrical Schematics in the XM PFP repair manual. If there is not 24 Vdc, replace power supply module. See XM PFP repair manual.

Check CAN cable. Replace if necessary. See the XM PFP repair manual.

See the XM PFP repair manual.

PFP repair manual.

3A2776D 55

Troubleshooting

Problem Cause Solution

Metering 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 at rod. Loose or worn packings. Tighten packing nut. If leak continues,

Fluid valve leaking between main and outlet housings.

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

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

3.5 bar) or greater.

Air pressure to metering valves is too low. Check air regulator behind main air

panel. Should be 80-85 psi (0.55-0.59 MPa, 5.5-5.9 bar).

Circulation valves or mix manifold ball valves are not open.

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

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

Air pilot valve(s) to motor stuck. Replace valve(s). See XM PFP repair

Metering valve(s) not opening. Service or replace valve(s). See XM PFP

Air motor stalled. See manual 311238.

Incorrect metering 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

O-ring on seat has failed. Replace both o-rings on that seat.

Material not mixing correctly. Test metering pump. Make sure mixer is

Material not properly conditioned before it was added to sprayer.

Not using enough integration hose. Add more integration hose.

Open ball valves.

operate, replace solenoid. See the XM PFP repair manual.

manual.

repair manual.

See Appendix A - User Interface Dis- play beginning on page 58.

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 in the XM PFP repair manual.

continuity; stop switch is normally closed circuit. See Electrical Schematics in the XM PFP repair manual.

replace packings.

volume.

clean; flush as needed.

Position mixer after integrator hose.

Mix material thoroughly.

Select “fast dosing” in setup.

56 3A2776D

Troubleshooting

Problem Cause Solution

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

System runs erratically. Air filter(s) clogged. Clean. Replace element(s).

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

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

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.

Fluid pressure too low. Increase metering pump pressure.

Fluid temperature too low. Increase fluid temperature.

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

Follow gun manual instructions.

Mix manifold, mixer, swivel, gun, or hoses partially plugged or too restrictive.

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.

Metering pump is binding. Repair lower. See XM PFP repair man-

Inadequate air supply. Use larger CFM compressor.

Air pressure to metering pumps too low. Increase metering pump air pressure.

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

Mix manifold, mixer, swivel, gun, 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.

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

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.

ual.

See Technical Data, page 85.

gun manual instructions.

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

Pressurize outlet hoses in manual A/B pump mode. Then start spray mode.

Select correct hose size to balance your volume ratio. See XM PFP Mix Manifold manual.

Pressurize outlet hoses in manual A/B pump mode. Then start spray mode.

Select correct hose size to balance your volume ratio. See XM PFP Mix Manifold manual.

Change pressure slowly while spraying.

3A2776D 57

Appendix A - User Interface Display

The user interface display is divided into three main functions: Setup, Command, and Automatic.

Setup Mode Screens (key to right)

Use these screens to:

• set desired mix ratio by volume

• set weight ratio and tolerance for ratio checks

• configure system settings

• set potlife parameters

• enable/disable functions, displays, and display components

• set which USB logs to download

• schedule maintenance parameters for alarms and advisories

• set pressure and temperature limits

• set tank “fill” and “full” levels

NOTE: Some setup functions must be enabled from the Enable Setup screens before users can change or set configurations. See Enable Setup Screens, page 63, for instructions.

• download USB logs.

Change a Setting

All settings are changed in the same manner:

1. Navigate to the desired screen. See Operator

Command Mode Screens on page 66, or Setup Mode Screens on page 59.

2. Once in the desired screen, use the arrow keys to navigate to the item that you wish to change.

3. Press enter to enter editing mode.

4. Use the arrow keys to change the selection or value.

5. Press enter again to save the change or press to cancel the change.

Alarms

Operator Command Mode Screens (key to left or removed)

Use these screens to:

• run pumps, including flush, circulate, and prime procedures

• park metering pumps so pump rods are down when not in use

• mix and spray

•view mix ratio

• run pump tests

• run batch dispense ratio tests

• run valve leak checks

• view dispense totals

•view alarms

• diagnose alarms

• clear alarms

• set and view A heater, B heater, and hose bundle temperatures

• view tank temperatures and levels

Automatically Displayed Screens

See Appendix B - Alarms, starting on page 76.

These screens are shown when

• The potlife timer alarms to notify the user that material is about to cure in the system.

58 3A2776D

Appendix A - User Interface Display

Setup Mode Screens

To enter the Setup Mode screens, turn the setup key lock (DJ) to the right. The key cannot be removed when in Setup Mode. See F

Setup Mode Screens Navigation Diagram

Software VersionsHome / Volume Mix Ratio

. 7 on page 12. Some setup screens can be disabled, see Enable Setup Screens on page 63.

Ratio Test

Temperature

Pressure

Tank Fill

Enable Options 3

Maintenance 2Maintenance 1

Enable Options 2Enable Options 1

Date/Time/Units System/USB

(From All Screens)

Potlife/Hose Length

3A2776D 59

Appendix A - User Interface Display

Home Setup Screens

Home

Home is the first screen that displays in Setup mode. It shows the current metering pump ratio and enables users to change the mix ratio and access the following screens: system setup, enable/disable functions, maintenance setup, and limits. Refer to the following table for more details.

Icon Function

Increase or decrease mix ratio. Press

and to change the mix ratio.

Navigate to jump to system setup screens.

Software Versions

This screen displays the versions and part number of the system components. Refer to the following table for

details. To access this screen, press from the

Home Setup screen.

Icon Function

Display module version (Vs) and part number

Advanced fluid control module version (Vs) and part number

USB version (Vs) and part number USB Configuration (Vc) and part number

Fluid control cube version and part number

Navigate to enable/disable options

B, and Hose version and part number (Vs)

screens.

Navigate to maintenance setup screens.

Navigate to pressure and temperature limits setup screens.

High power temperature control module A,

60 3A2776D

Appendix A - User Interface Display

System Setup Screens

System Setup enables users to configure system settings for fluid control and operator interaction. Refer to the following table for details.

NOTE:

Some system settings must be enabled from the Enable Setup screens before users can change or set configurations. See Enable Setup Screens, page 63, for instructions.

Icon Function

Set number of minutes before mixed material will set in hose. Resets after material volume set by user is passed through hose.

Indicates total hose volume. Always displayed in cc units.

Set length of hose after mix manifold. Used to indicated total hose volume.

Set calendar date and format.

Set time.

Potlife/Hose Length

This screen enables users to set the potlife timer, and length of each mixed material hose specific to the system. The total mixed material volume is then calculated and displayed on the page. The potlife time displays in the upper right corner.

When the fluid flow stops the displayed potlife time counts down in one minute intervals. The timer automatically resets when the calculated mixed fluid volume is dispensed.

Set USB language.

Set units of measurement desired for display, such as fluid and temperature.

Set sprayer number if using more than one sprayer.

Set how often data will record to USB ratio and spray logs.

Set number of hours of recorded data to download to USB flash drive.

Set the A and B side metering pump sizes.

Volume ratio reference

Weight ratio reference

Ratio Pass Tolerance

3A2776D 61

Appendix A - User Interface Display

Date/Time/Units

Use this screen to set day, time, and units that will be displayed on each screen. The selected language is used in each USB log. The following USB languages are supported: English, French, German, Spanish, Russian, Italian, Chinese, Japanese, Korean, Norwegian, and Polish.

System Number and USB Settings

Tank Fill

Graco recommends leaving all of the settings on this screen at the factory defaults.

This screen can be used to adjust tank level settings. The default settings from the top of the screen to the bottom are 20, 13, 11, and 4, when gallons is the selected unit of measure on the system. The level sensors cannot detect fluid under the four gallon level.

The top and bottom settings are used for maximum and minimum settings for the tanks on this machine and should not be changed. If the tank level goes beyond one of these settings, an alarm will result. See Alarm Code Troubleshooting on page 79.

Use this screen to set the sprayer number if using more than one sprayer, and to configure the number of hours downloaded to external USB flash drive and how often the data will record, and set the A and B side metering pump size. This system uses a 220 cc pump on the A side and a 180 cc pump on the B side.

The middle two settings are for maintaining the tank level when automatic tank filling is on. Automatic tank filling will maintain the fluid level in the tank to between these two levels. Changing these levels will move the arrows shown next to the tanks on the Supply screen. When using fiber-filled or compressible fluids, do not set the high arrow too high. When the tank is depressurized with too much fluid in the tanks, the fluid can expand and rise up into the tank lid air passages.

Each value must be larger than the value below it.

Ratio Test

Use this screen to set the ratio by weight (middle number), and the ratio by weight tolerance (bottom number). The ratio by volume (top number) is displayed but cannot be changed on this screen. These values determine whether the ratio test passes. See Home screen, on page 60, to change the ratio by volume.

62 3A2776D

Appendix A - User Interface Display

Enable Setup Screens

Use these screens to enable and disable functions, screens, and USB download log files. Checked boxes indicate the function, screen, or log file is enabled. Refer to the following table for details.

To enable and disable functions, screens, and USB log

files, press from the Home Setup screen. Once

in the Enable Setup screen, press and to

scroll through each subscreen. Press and to scroll through each field within the subscreens, and

press to enable or disable each. Press to return to the Home Setup screen.

Icon Function

USB data download function. Disable this function to prevent operators from changing USB settings. NOTE: Even if this function is disabled, selected USB logs will still be downloaded.

Enable or disable totalizer screens.

Enable or disable batch totalizer clear function.

Display potlife timer on all screens. Enable or disable potlife timer setup screen.

Display flow rates on run screens

Display A and B pressures on run screens.

Icon Function

Enable or disable dosing valve maintenance setup screen.

Enable or disable incoming air filter maintenance setup screen.

Enable or disable limits (pressure and temperature) screens.

Fast dosing function. Enable function to minimize B side dose size and increase dosing rate. See table below.

Use this function with short integration hose. The system will attempt to hold the dosing sizes below the advisory level.

Display time on all screens.

Enable or disable downloading individual USB log files (1-4).

Enable or disable the A or B feed system. When disabled, that feed system will not be shown on the user interface and no alarms will be generated for that feed system. This enables the user to use the air shutoff valve on the feed pump to turn on and off the feed pumps if there is a problem with the feed system.

Fast Dosing Function

Fast Dosing Advisory QTAE Alarm QDAE

ON 20 cc 30 cc

OFF 35 cc 45 cc

Display A and B heater outlet temperatures on run screens.

Enable or disable ability to change metering pump size in system setup screens.

Enable or disable ratio screen. If enabled, ratio screen will automatically display after sprayer runs for 10 seconds.

Enable or disable pump maintenance setup screens.

3A2776D 63

Enable Setup Screen 1

(Shown with factory default settings.)

Appendix A - User Interface Display

Enable Setup Screen 2

(Shown with factory default settings.)

Enable Setup Screen 3

(Shown with factory default settings.)

Maintenance Setup Screens

Use these screens to set maintenance setpoint amounts for pumps and dosing valves. The maintenance setup 2 screen enables users to schedule the number of days between changing the main incoming air filter before a reminder advisory will sound.

The number displayed below each selectable field indicates the amount of material dispensed, counting up to the setpoint requiring maintenance.

Icon Function

Set amount of material moved through pump that will result in a maintenance warning.

Set amount of material moved through dosing valve that will result in a maintenance warning.

Set number of days between changing the main incoming air filter before a reminder advisory is issued.

Maintenance Setup 1

Maintenance Setup 2

64 3A2776D

Appendix A - User Interface Display

User Limits Setup Screens

Use these screens to set and adjust pressure and temperature limits for both metering pumps, including limits that will issue advisories and alarms. Refer to the following table for details.

The allowable range for the temperature setpoint is 34° 160°F (1° - 71°C). If the temperature or pressure setpoint is zero, pressure limits and alarms are disabled.

NOTE: The B metering pump pressure always runs 10-20% higher than the A metering pump pressure.

Icon Function

Set and adjust pressure limits for both metering pumps during spray mode.

Set and adjust high and low temperature limits for both fluid heaters during spray mode.

Set target pressure or temperature.

Set and adjust limits above or below target value that if exceeded will issue an advisory. Used with pressure and temperature limits.

Set and adjust limits above and below target value that if exceeded will issue a alarm. Used with pressure and temperature limits.

Process Pressure Limits (for spray mode)

Process Temperature Limits (for spray mode)

3A2776D 65

Appendix A - User Interface Display

Operator Command Mode Screens

To enter the Operator Command Functions screens, turn the setup key lock (DJ) to the left. See F

. 7 on page 12.

Operator Command Mode Screens Navigation Diagram

Supply Screen

in each section

Go to primary screen

Maintenance 2

Maintenance 1

Totalizer

Information Screens

Alarm Information

Alarm Log

Valve Test

Test Screens

(Pump Volume Test shown)

Park Pump

(Spray Mode shown)

Run (Fluid Control) Screens

66 3A2776D

Pump Mode

Batch Test

Pump Test

Ratio

Spray Mode

Weight/Volume

Restrictor

Appendix A - User Interface Display

Run (Fluid Control) Screens

Run (fluid control) is the first screen displayed at power on. It enables users to spray material, and operate and park metering pumps. Run consists of two screens: power on/enter and ratio mode.

The power on/enter screen cycles through power on mode, spray mode, pump mode, and park mode. It displays the current ratio setpoint when in spray mode and may also display: pressure, temperature and flow rate if these options are enabled.

The ratio screen displays the current ratio and monitors the B side restriction adjustment.

Icon Function

Spray:

proportion and spray material.

Icon at bottom of screen:

metering pumps are active. Press repeatedly to cycle through metering pump A, metering pump B, and both metering pumps.

Icon in rectangle:

pumps. Operate the A metering pump only (prim-

ing, flushing).

Operate the B metering pump only (priming, flushing).

Operate both metering

Park Metering Pumps:

to bottom of the stroke.

Ratio:

jump to ratio screen.

Select which

run metering pumps

Spray Mode

Users must be in this mode to spray or proportion material. Press the button below the spray icon to enter this mode.

Pump Mode

Users must be in this mode to operate metering pumps for priming or flushing. Press the button below the metering pump icon to enter this mode. Continue pressing the metering pump icon button to cycle through metering pump A, metering pump B, and both metering pumps.

Power On/Enter Mode

Power On/Enter Mode is the default screen when users enter Fluid Control.

NOTE: This screen remains blank until a mode is selected.

3A2776D 67

Appendix A - User Interface Display

Park Mode

Users must be in this mode to park the metering pump fluid rods to the bottom of their stroke. Press the button below the park icon to enter this mode.

Ratio Mode

This screen displays the current ratio or the adjust

restriction screen. To access this screen, press .

NOTE: If the field is enabled on the Enable Setup screen, the Spray Mode screen will be replaced by the bar graph screen after 10 seconds of spray time.

Adjust Restriction Screen

This screen shows the balance of the A and B fluid sides. If the bar graph remains all the way to the right, there is not enough restriction on the B side and adding more restriction will lower the dosing size. If the bar graph remains all the way to the left, there is too much restriction on the B side. Reducing restriction will reduce dosing size.

Press to return to the Spray Mode screen.

Icon Function

Display Ratio:

fluid mix ratio.

Display Adjust Restriction Screen

show the accuracy of the

68 3A2776D

Appendix A - User Interface Display

Test Screens

Use this screen to run batch dispense tests, pump tests, and down stream valve leak tests.

Icon Function

Pump Test:

B; verifies pump selection, operation, and metering.

Batch Dispense:

amounts of A and B with a selectable total.

Down Stream Valve Leak Test:

valves after the dosing valves hold pressure.

Pump Test

Use this screen to dispense a fixed 750 ml volume of material from each metering pump. When the metering pump is active it flashes in black on the screen. When the metering pump completes dispensing it displays gray on the screen. This test will stall the A and B metering pumps on each stroke to verify they hold pressure. See Pump and Metering Test procedure on page 40.

dispenses 750cc of each A and

dispenses proportioned

test if

If weight mode is used, enter the net weights of each dispensed material in the respective input boxes on this screen. If they are within the ratio tolerance set on the Setup Mode Ratio Test screen, a check will appear in the box. The results are entered into the USB logs.

Confirm Pump and Metering Test

This screen displays when the pump test completes without error. This screen displays the target weight of material dispensed into each beaker from each metering pump.

3A2776D 69

Appendix A - User Interface Display

Batch Dispense or Ratio Test

Use this screen to dispense a selected total volume of material on ratio. For example, 1000 ml at 4:1 = 800 ml of A + 200 ml of B. The total batch volume can be selected from the drop down menu. The dispense material can be used to check the ratio or to mix together and use in production. See Batch Dispense or Ratio Test procedure on page 42.

When the metering pump is active it flashes in black on the screen. When the metering pump completes dispensing it displays in gray on the screen.

Confirm Batch Dispense Test

Down Stream Valve Leak Test

Use this screen to test for closed or worn valves down stream of the A and B dosing control valves. It can be used to test the mix manifold shutoff/check valves or any remote circulation valves.

While running the test, if there is continuous metering pump movement on the A or B side, an error will be issued. The error indicates a leak in the valve.

Confirm Valve Leak Test

This screen displays when the valve leak test completes and indicates whether the test was successful.

This screen displays when the batch dispense test completes without error. This screen displays the selected ratio between the metering pumps and the desired weight of material dispensed from each metering pump. The gray at the bottom of the beaker represents the material dispensed by metering pump A. The black at the top of the beaker represents the material dispensed by metering pump B.

70 3A2776D

Appendix A - User Interface Display

Information Screens

Use this screen to view alarm diagnostic information, alarm logs, and pump batch and grand totals. These screens also enable users to view maintenance information for pump and check valves, including the maintenance schedule.

NOTE:

If the potlife timer is enabled, the Flush Confirm

icon displays.

Alarm

The Alarm screen displays the specific alarm code. There are two levels of error codes: alarms and advisories. A solid bell icon with an exclamation point and three audible alerts indicate a alarm. And an outlined hollow bell icon and a single audible alert indicate an advisory.

Additionally, this screen displays the location of the error with the top view and side view of the system. Refer to the following table and subsections for more details.

Icon Function

Go to maintenance screen. Allows user to view maintenance information.See Mainte- nance Setup 2, page 64.

Flush confirm. Use when the potlife timer is enabled. Press button to confirm flush before a potlife advisory is issued.

Amount of material moved through pump that will result in a maintenance warning.

Amount of material moved through dosing valve that will result in a maintenance warning.

Number of days between maintenance cycles that will result in a reminder advisory.

Clear batch totalizers or maintenance counters.

Alarm Log

Use this screen view details regarding alarms received, including the date, time, and alarm code for the last 16 alarms. Up to four pages of alarms are available.

Icon Function

Go to Alarm log. Use up and down arrows to scroll through list of the past 16 errors.

Go to totalizer screen. Allows users to view the grand and batch totals for each pump and both pumps combined.

Press to access the alarm log. The press and

to scroll through each page of alarms.

3A2776D 71

Appendix A - User Interface Display

Totalizers and Job Number

Use this screen view the grand and batch totals for each pump and both pumps combined. The units of measurement are displayed on the bottom of the screen and displayed in the units of measurement selected during setup.

Grand total is the amount of material the system has dispensed during its lifetime. Batch total is the amount of material dispensed since the last user reset.

A job number can be entered at the beginning of each spray job. This helps to organize the USB spray log.

Clear Batch Totalizer

To clear the batch totalizer values for A, B, and A+B,

press to set all values to zero.

Change Job Number

1. Press to highlight the first digit. Press and

to change the number and press and

to move to the next digit. Press to save

the number or to cancel.

Maintenance 1 Screen

Use this screen view setpoints for the amount of material that needs to move through both pumps and dosing valves that will result in a maintenance warning.

Icon Function

Displays batch total and grand total for pump A. The grand total is displayed at the top, and the batch total is displayed at the bottom.

Displays batch total and grand total for pump B. The grand total is displayed at the top, and the batch total is displayed at the bottom.

Displays batch total and grand total for both pumps combined. The grand total is displayed at the top, and the batch total is displayed at the bottom.

Displays job number for each spray period.

Number of hours system has been running

Maintenance 2 Screen

Use this screen view number of days between changing the main incoming air filter before a reminder advisory is issued.

Reset Maintenance Counter

1. Press and to scroll through and select the maintenance field to reset.

2. Press to reset the maintenance counter to zero.

72 3A2776D

Supply Screen

Use these screens to turn on and off automatic tank filling, turn on and off the fluid heaters and hose heat, and change temperature setpoints for each fluid heater and for the hose heat.

When automatic tank filling is on, the feed pump will begin pumping fluid into the tank when the fluid level goes below the bottom arrow. It will continue filling until the fluid level reaches the upper arrow. When the feed pump is running, the small circle on the screen next to the tank will have a black background. In order for automatic tank filling to run, the director valve (DC) must be in the DOWN position, and the RAM slider valve (DA) and air motor slider valve (DF) must both be in the ON position with proper air pressure air supplied to the RAM and air motor. See Feed Pump Air Controls on page 11.

Appendix A - User Interface Display

This screen also displays the current volume of each tank and the current temperature measured at each fluid heater, at the hoses, and in each tank.

Icon Function

Turn on and off automatic tank filling

Turn on and off the A fluid heater

Turn on and off the B fluid heater

Turn on and off the hose heat

3A2776D 73

Appendix A - User Interface Display

Automatically Displayed Screens

Potlife Screen

This screen automatically displays when a potlife advisory occurs. The screen automatically closes when the advisory ends or the user presses the flush confirm button. Refer to the following table for more details.

Icon Function

Advisory has been issued.

Potlife timer is enabled.

Time after potlife expires. Starts at 0.00 and counts down in negative one minute intervals.

Press to mute advisory buzzer.

Press to confirm that mixed hose has been flushed. Resets potlife timer.

Icon Function

Flashes while data download is in process.

Check mark appears after download completes. Indicates download was successful.

If download was not successful, appears.

Displays total memory to download and remaining memory left to download.

Displays time remaining for log download to complete.

Press to cancel download. If download is cancelled, remove USB flash drive.

Indicates which log(s) will be downloaded.

Recommended USB Flash Drives

It is recommended that users use the Diesel 4GB USB

USB Screen

This screen automatically displays and the selected log(s) automatically starts downloading when a USB flash drive is inserted into the control box. See F on page 75 to see an example of a downloaded log file.

Inserting the USB flash drive while the sprayer is running will automatically stop sprayer operation. Removing the USB flash drive automatically closes the USB screen.

The log selected for current download is displayed in the single box next to the USB icon. The other available logs are displayed in the boxes on the right side of the screen. Refer to the following table for more details.

74 3A2776D

. 39

flash drive (16A004) included with the PFP sprayer for data download. However, the following USB flash drives can also be used, but are not available through Graco.

• Crucial Gizmo! JDO4GB-730)

• Transcend JetFlash (model TS4GJFV30)

™

4GB USB flash drive (model

V30 4GB USB flash drive

Appendix A - User Interface Display

FIG. 39: Example Ratio and Spray Logs

3A2776D 75

Appendix B - Alarms

Alarms Overview

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

Both reed switches are active. Start of changeover or motor icing problem.

Blank: No reed switch signal - error

Diagnose Alarms

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

Clear Alarms

Press to clear alarms and advisories. From the

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

This screen also shows diagnostic information. There are three lines of data on the left side. The top line shows the power supply. This should be 23-25 Volts. The middle line shows the voltage supplied to all sensors connected to the Advanced Fluid Control Module. 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 metering pump moves. This bar graph should move from top to bottom to match each metering pump stroke.

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

76 3A2776D

Appendix B - Alarms

Alarm Code Key

Use the following table as a quick guide to determine alarm code meaning.

Digit 1 Digit 2 Digit 3 Digit 4

Code Event Code Mode (Char 2) Code Location (Char 3) Code Zone (Char 4)

A Current 1 Low Alarm A Material A 1 Tank A

F Flow 2 Low Deviation B Material B 2 Tank B

L Tank Level 3 High Deviation C Controller A Heater A

P Pressure 4 High Alarm D Output Discharge B Heater B

R Ratio 5 Calibration F Input Feed C Level Sensor A

T Temperature 6 Sensor Failure M Power Supply D Level Sensor B

V Voltage 7 Unexpected

Non-Zero Value

8 Unexpected

Zero Value

9 Unstable K Reed Switch

C Communication A Loss P Display

D Pump A Runaway X System

D Cavitation

E Time-out

F Stall Up

G Stall Down

J Linear Sensor

K Reed Switch

M Maintenance A Pump

EValve

GFilter

Q Proportioning D Overdose

PPotlife

T Dosing Time

P Pneumatic Supply E Hose

R Recirculation H Heater Hose

J Linear Sensor

3A2776D 77

Appendix B - Alarms

Possible Alarms by Mode

The following table outlines the alarms that you may receive while operating the system. The alarms are categorized according to each mode.

Mode Control Logic Alarms

Spray Dosing valves close for startup test; green light blinks. --

If fluid pressure is under 1000 psi (7 MPa, 70 bar), STOP. P1AX

If pumps move (indicating internal leakage), STOP. F7AX, F7BX

If fluid pressure is more than 103% of allowed maximum, air motor shuts off until fluid pressure drops.

If is pressure more than 110% of allowed maximum, STOP. P4BX

Dosing valve A opens, and dosing valve B cycles to maintain ratio. --

A and B blue lights illuminate when dosing valves are operating. --

If there is not enough B component to hold ratio, dosing valve A closes momentarily. R5BE

If A or B component is more than 5% off ratio setpoint, STOP. R1BE, R4BE

If A dose size is too large, STOP. QDAE

A and B dosing valves close momentarily at each pump changeover. --

Park Both dosing valves open; A and B blue lights turn on. --

User opens circulation valves or sprays gun. When pump reaches bottom stroke the blue light turns off.

If park does not complete in 10 minutes, turn off air to both motors. DEAX, DEBX

Circulation A and/or B dosing valves close and motor air turns on. --

If fluid pressure exceeds 3000 psi (21.0 MPa, 210 bar) on the A pump, receive yellow light advisory.

If fluid pressure exceeds 5600 psi (39.2 MPa, 392 bar) on the A pump, STOP. P4AX

If no movement in 10 minutes, turn off air to both motors. DEAX, DEBX

Pump Test Both dosing valves close; green light blinks. --

If fluid pressure is under 1000 psi (7.0 MPa, 70 bar), STOP. P1AX, P1BX

If pumps move (indicating leakage) STOP. F7AX, F7BX

Turn on A blue light, open A dosing valve, user opens sampling valve. --

Close A dosing valve on upstroke; check for no movement. DFAX

Close A dose valve on down stroke; check for no movement. DGAX

Open A dose valve and dispense total of 750 ml material, close valve, turn off blue light.

Repeat for B side. DFBX, DGBX

If both pumps pass pump test, display shows two beakers of 750ml each. --

Batch Dispense Test

Valve Test If fluid pressure is not 1000 psi (7 MPa, 70 bar), STOP. P1AX

User selects total volume desired. --

Open A dosing valve, turn on blue light, user opens sampling valve, turn off blue light when complete.

Open B dosing valve, turn on blue light, user opens sampling valve, turn off blue light when complete.

Display shows volume of A and B components at end of batch dispense test. --

Check for no movement of pumps (stall within 10 seconds). F7AX, F7BX

None

P4AX

78 3A2776D

Appendix B - Alarms

Alarm Code Troubleshooting

NOTE: See PFP Plural-Component Sprayers Repair-Parts manuals for non-alarm based troubleshooting.

* Indicates the alarm is user-defined.

Alarm

Code Alarm Problem

A4DA A4DB

A4DH Hose Heater Over-Current

A8DA A8DB

A8DH Hose Heater No Current

A9DA A9DB

A9DH Hose Heater Unexpected

CACA CACB

CACH Temperature Control Module

CACP Display Has No Signal Always No display communication signal. Check cable connections. Replace

DAAX DABX

DDAX DDBX

DEAX DEBX

A/B Material Heater Over-Current Alarm

Alarm

A/B Heater No Current Alarm Always Temperature Control Module is bad. Replace module.

Alarm

A/B Material Heater Unexpected Current Alarm

Current Alarm

Temperature Control Module Heater Loss Of Communication Alarm with A/B Material Heater

Loss of Communication Alarm with Hose Heater

Pump Runaway; Above 80 CPM For 10 Sec.

Pump Cavitation; Dives More Than 1/2 Of Stroke.

Pump Does Not Move In 10 Minutes.

When

Active Cause Solution

Always Temperature Control Module is bad. Replace module.

Heater is bad. Repair heater.

Always Temperature Control Module is bad. Replace module.

Heater is bad. Repair heater.

Heater wiring is bad. Fix heater wiring

Always Temperature Control Module is bad. Replace module.

Heater is bad. Repair heater.

Heater wiring is bad. Fix heater wiring

Always Temperature Control Module is bad. Replace module.

Heater is bad. Repair heater.

Always Temperature Control Module is bad. Replace module.

Heater is bad. Repair heater.

Always Network communication cable is

bad.

Temperature Control Module network address is wrong.

Temperature Control Module is bad. Replace module.

Always Network communication cable is

bad.

Temperature Control Module network address is wrong.

Temperature Control Module is bad. Replace module.

Machine powered down in spray mode.

Always No material in pump or lines; no fluid

restriction.

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

Material is too cold or thick. Increase material temperature to

Pump inlet check valve not closing. Clear debris from check valve. Or

Feed pump not providing material. Check feed pump (if used).

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

Park or

Pump Test

Recirculation valves were not opened to allow flow.

Replace communication cable.

Set module network address.

Replace communication cable.

Set module network address.

display.

See XM PFP Repair manual.

Press stop button before turning off power.

Refill material in tank or hoses; install fluid tip.

reduce viscosity. See Spray, page

32. Shear material with agitation to reduce viscosity.

replace ball, seat, and seal.

PFP repair manual.

Open recirculation valves.

3A2776D 79

Appendix B - Alarms

Alarm

Code Alarm Problem

DFAX DFBX

DGAX DGBX

DJAX DJBX

DKAX DKBX

F6AJ A Air Motor Linear Sensor

F6AK A Air Motor Reed Switch Sig-

F6BJ B Air Motor Linear Sensor

F6BK B Air Motor Reed Switch Sig-

F7AX F7BX

L2F1 L2F2

Pump Did Not Stall Against Fluid Pressure On Up Stroke Only.

Pump Did Not Stall Against Fluid Pressure On Down Stroke Only.

Pump Motor Linear Sensor Has No Signal.

Pump Motor Linear Sensor Is Out Of Range.

Pump Motor Reed Switch Failure; Missing Signals From One Or Both Switches.

Jump Advisory.

nal Missing Advisory.

Jump Advisory.

nal Missing Advisory.

System Detects Unexpected Pump Movement (Fluid Flow).

Tank Level Low Advisory Spray and

When

Active Cause Solution

Pump Test Pump piston check valve, piston

packings, or dosing valve are not holding fluid pressure.

Pump Test Pump inlet check or dose valve is

fouled, or damaged.

Always No linear sensor signal from motor. Swap A and B sensors. Replace

Linear sensor plugged in while power is on.

Bad connection inside fluid control module.

Always Linear sensor is beyond range. Replace sensor or sensor magnet.

Sprayer is not properly grounded. See Grounding, page 16.

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 System ran out of fluid. Add fluid to the system.

Linear sensor is bad. Replace linear sensor.

Always Reed switch does not see the air

motor magnet.

Reed switches are bad. Replace air motor reed switch. Pre-

Air motor is icing.

Always System ran out of fluid. Add fluid to the system.

Linear sensor is bad. Replace linear sensor.

Always Reed switch does not see the air

motor magnet.

Reed switches are bad. Replace air motor reed switch. Pre-

Air motor is icing.

Spray Recirculation valve or dosing valve

open or leaking for more than five seconds.

Tank level less than 10% below tank

Tank

empty setpoint for 3 seconds.

Air solenoid is bad. Replace air solenoid.

Flush pump. See General Tips, page 54. Recheck. Remove, clean, and repair lower. See XM PFP repair manual.

Remove inlet housing & clean and inspect. See XM PFP repair manual.

sensor if problem follows sensor. See XM PFP repair manual.

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

Replace fluid control module. See XM PFP repair manual.

See XM PFP repair manual.

Swap A and B motor cables. Replace cable if problem persists. Otherwise replace reed sensor assembly. See XM PFP repair manual.

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

Replace fluid control module.

Replace air motor reed switch magnet.

vent air motor icing. See advisory P9AX and P9BX.

Replace air motor reed switch magnet.

vent air motor icing. See advisory P9AX and P9BX.

Close or repair recirculation valve, and run Pump Test. See Metering Test, page 40.

Add material to tank.

Increase air pressure to solenoid.

Pump and

80 3A2776D

Appendix B - Alarms

Alarm

Code Alarm Problem

L3F1 L3F2

L4F1 L4F2

L6FC L6FD

*MAAX *MABX

*MEAX *MEBX

*MGPX Maintain Air Filter. Always, if

P1AX P1BX

*P2AX *P2BX

P4AX P4BX

P4RE Pressure High. Recircula-

P5RE Pressure High. Recircula-

*P5AX *P5BX

P6AX P6BX

P9AX A Pump Pressure is Abnor-

Tank Level High Advisory Spray and

Tank Level High Alarm Always Tank level greater than 90% of total

Tank Level Sensor Failure Alarm

Maintain Pump. Always, if

Maintain Dosing Valve. Always, if

Pressure Low. Spray,

Pressure Exceeded Advisory Limits.

Pressure High. Always Fluid pressure is above maximum. Decrease main air regulator.

Pressure Exceeded Alarm Limits.

Pressure Sensor Failure; No Signal.

mally Low Compared to B Pump Pressure.

When

Active Cause Solution

Tank

Always Cable is disconnected or bad Replace level sensor

enabled

Pump Test,

Leak Test

Spray Pressure exceeded high or low advi-

tion

Spray Pressure exceeded high or low

Always Pressure sensor or cable is bad on

Spray A air motor is icing causing restric-

Tank level greater than 10% above tank full setpoint for 3 seconds.

Air solenoid to feed pump is bad. Replace air solenoid.

Fluid expanded when air pressure was removed.

tank volume for 3 seconds.

Fluid expanded when air pressure was relieved.

Sensor rod is damaged. Replace sensor rod.

Pump usage exceeds user-set limit. Maintenance due.

Dosing valve usage exceeds user-set limit. Maintenance due.

Air filter exceeds user-set limit. Maintenance due.

Fluid pressure is below 1000 psi (7 MPa, 70 bar).

sory limits for more than 15 seconds.

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

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

alarm limits for more than 15 seconds.

the side indicated.

tion and lower fluid pressure.

A pump is binding. Repair lower. See XM PFP repair

A motor is binding. Repair air motor. See XM PFP

Lower the tank level.

Increase air pressure to solenoid.

Lower the tank level.

Lower the tank full setpoint.

Turn all sensor DIP switches to off

Connect level sensor cable to system

Service pump. See pump manual listed on page 3.

Service dosing valve. See pump manual listed on page 3.

Service main air filter and control filter regulator.

Increase main air regulator.

Same as P5AX or P5BX.

Decrease pump air regulator pressure.

Adjust pump pressure regulator, change tips, or adjust target set point.

Replace sensor and cable assembly. See XM PFP repair manual.

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

Use a smaller tip.

manual.

repair manual.

3A2776D 81

Appendix B - Alarms

Alarm

Code Alarm Problem

P9BX B Pump Pressure is Abnor-

mally Low Compared to A Pump Pressure.

QDAE Dosing Size A Alarm Spray The fluid dosing size is greater than

*QPDX Pot Life Timer Expired. Mixed

Fluid Will Cure in Hoses, Mixer, and Gun.

QTAE Dosing Size A Advisory Spray The fluid dosing size is greater than

R1BE Ratio Low B (Under Dose B);

System Delivering Not Enough B Component.

R4BE Ratio High B (Overdose B);

System Delivering Too Much B Component.

When

Active Cause Solution

Spray B air motor is icing causing restric-

tion and lower fluid pressure.

B pump is binding. Repair lower. See XM PFP repair

B air motor is binding. Repair air motor. See XM PFP

45 cc when fast dosing is turned off.

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

Spray Have not sprayed enough volume to

keep fresh mixed fluid in the integration hose, mixer, whip hose, and spray gun.

35 cc when fast dosing is turned off.

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

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. See

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

Pump filter plugged on A side. Clean filter. See manual 311762.

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)

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

Use a smaller tip.

manual.

repair manual.

Decrease the air motor velocity with a smaller tip or increase ‘B’ restriction.

Spray fluid, or flush. Resets when you leave spray mode. See Spray, page 32, or Flush Mixed Material, page 36.

Decrease the air motor velocity with a smaller tip or increase ‘B’ restriction.

manual 311762 for part number.

Clean B pump outlet filter. See manual 311762.

age. See Pump and Metering Test, page 40.

Loosen valve packing nut. See XM PFP repair manual.

Check air signal at valve top

Repair valve or air solenoid. See XM PFP repair manual.

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

Check air filters. See XM PFP repair manual.

Use larger air hose.

Use larger compressor.

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

Adjust air regulator.

82 3A2776D

Appendix B - Alarms

Alarm

Code Alarm Problem

R5BE Dosing Sizes Are Not Opti-

mized.

R9BE System detected five R4BF

(Ratio High B) or five R1BF (Ratio Low B) alarms within five minutes. Sprayer shuts down for five minutes for operator to resolve problem.

*T2DA *T2DB

T3CA T3CB

T3CH Hose Heater Temperature

T4CA T4CB

T4CH Hose Heater Temperature

T4DA T4DB

T4DE Hose High Temperature RTD

T4DH Hose Heater High Tempera-

*T5DA T5DB

T6DA T6DB

T6DE Hose RTD 1 Bad Alarm Always RTD bad. Replace RTD.

T6DH Hose Heater RTD 2 Bad

Temperature Exceeded Advisory Limits.

A/B Material Heater Temperature Control Module Over Temperature Advisory

Control Module Over Temperature Advisory

A/B Material Heater Temperature Control Module Over Temperature Alarm

Control Module Over Temperature Alarm

A/B Material Heater High Temperature RTD 1 Alarm

1 Alarm

ture RTD 2 Alarm

A/B Material Heater Temperature Exceeded Alarm Limits.

A/B Material Heater RTD 1 Bad Alarm

Alarm

When

Active Cause Solution

Spray Dosing valve is operating near high

or low timing limits.

Spray See R4BE or R1BE alarm causes. See R4BE or R1BE alarm solutions.

Spray Fluid temperature exceeded high or

low limits for more than four minutes.

Always Module is bad. Replace module.

Always Heater bad. Repair heater.

RTD bad. Replace RTD.

Always Heater bad. Repair heater.

Splitter cable bad. Replace splitter cable

RTD bad in hose bundle. Replace RTD in hose bundle.

Always Heater bad. Repair heater.

Splitter cable bad. Replace splitter cable

RTD bad in hose heater outlet. Replace RTD in hose water heater

Spray Fluid temperature exceeded high or

low alarm limits for more than four minutes.

Always RTD bad. Replace RTD.

RTD disconnected. Connect sensor to system.

Always RTD bad. Replace RTD in hose heater outlet.

RTD disconnected. Connect sensor to system.

Balance A and B fluid hoses. See XM PFP Mix Manifold manual.

Or change ‘B’ restriction. Check Restriction screen.

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

Same as T5DA or T5DB.

Cool system down.

outlet.

If fluid temperature is too low, return to circulation mode to increase fluid temperature. Adjust heater set point if needed. See Spray, page 32.

If fluid temperature is too high, lower heater set point, and return circulation mode to cool. See Spray, page 32.

Adjust temperature target setpoint. See Spray, page 32.

3A2776D 83

Appendix B - Alarms

Alarm

Code Alarm Problem

T6F1 T6F2

T8DA T8DB

T8DH Hose Temperature Not Ris-

V1MA V1MB

V1MH Hose Heater Low Line Volt-

V2MX Voltage Low Control Advisory Always Voltage dropping below 9 Vdc from

V4MA V4MB

V4MH Hose Heater High Line Volt-

Tank RTD Failure Advisory Always Temperature sensor is bad Replace temperature sensor

A/B Material Temperature Not Rising Alarm

ing Alarm

A/B Material Heater Low Line Voltage Alarm

age Alarm

A/B Material Heater High Line Voltage Alarm

age Alarm

When

Active Cause Solution

Cable is disconnected or bad Connect temperature sensor cable

Heater A/B Heater bad. Repair heater.

Heater voltage too low. Increase heater voltage to 200 - 240

Hose

Heater

Always Temperature Control Module power

Always Temperature Control Module is bad. Replace module.

Heater bad. Repair heater.

Heater voltage too low. Increase heater voltage to 200 - 240

cable is disconnected.

Heater circuit breaker is off Turn on heater circuit breaker.

cable is disconnected.

Heater circuit breaker is off Turn on heater circuit breaker.

power supply.

Heater is bad. Repair heater.

to system.

VAC.

Plug in module power cable.

Change air filter in control filter regulator. See XM PFP repair manual.

Check voltage on information screen.

84 3A2776D

Technical Data

XM PFP

US Metric

Mix Ratio Range 1:1-10:1 (in 0.01 increments) Ratio Tolerance Range (before alarm) +/- 5% Maximum Flow Rate (measured with oil) 3 gallons per minute 13.6 liters per minute Fluid Viscosity Range

Air Inlet 1 in. npt(f) Fluid Inlets Pail (Feed Pumps) Maximum Fluid Working Pressure for A and B

Materials Maximum Fluid Working Pressure for Flushing

Fluid Maximum Fluid Working Pressure for Heating

Fluid Maximum Fluid Temperature 160°F 70°C System Inlet Supplied Air Pressure Range 80-150 psi 0.5-1.0 MPa, 5.5-10.3 bar Maximum Pump Air Pressure 100 psi 0.7 MPa, 7 bar Maximum Tank Air Pressure 90 psi 0.6 MPa, 6 bar Air Filtration 40 micron main filter, 5 micron control air filter Ambient Operating Temperature Range 32 to 130°F 0 to 54°C Ambient Storage Temperature Range 30 to 160°F -1 to 71°C Environmental Conditions Rating Altitude up to 13,123 ft Altitude up to 4000 m Sound Pressure * 86 dBA at 100 psi 86 dBA at 0.7 MPa, 7 bar Sound Power ** 98 dBA at 100 psi 98 dBA at 0.7 MPa, 7 bar System Weight (empty, no fluid) 2175 lb 987 kg

Air Consumption

Minimum 100 scfm

Maximum 250 scfm

Typical Application 125-175 scfm

Power Requirements

Voltage (can be set with jumpers) Option 1: 220-240V, 3 phase DELTA (3 wire plus ground)

Wattage 18,400 watts (23,400 with optional flush water heater) Amps 240V, 3-phase models: 65 Amps per phase full load

Handles mastic materials which are loaded into heated tanks with ram-fed priming piston pumps

6000 psi 41 MPa, 414 bar

4500 psi 31 MPa, 310 bar

100 psi 0.7 MPa, 7 bar

2.8 meter

7.1 meter

3.5-5.0 meter

Option 2: 380-400V, 3 phase WYE (4 wire including neutral plus ground)

380V, 3-phase models: 38 Amps per phase full load

/min

Technical Data

3A2776D 85

Technical Data

XM PFP

US Metric

Wetted Parts

Suction Tube (Flush) Aluminum Tanks Stainless Steel Flush Pump Carbide, PTFE, stainless steel, UHMWPE Hoses Nylon A and B Metering and Feed Pumps Carbon steel, alloy steel, stainless steel, zinc and nickel plat-

ing, ductile iron, tungsten carbide, PTFE Dosing Valves Carbon Steel, nickel plating, carbide, polyethylene, leather Manifold Carbon steel, nickel plating, carbide, stainless steel, PTFE,

UHMWPE Mixer Stainless steel housing with stainless elements

Approvals

Machine CE, ETL Pressure Tanks ASME, CE

Notes

* Sound pressure measured 3.3 feet (1 meter) from equipment.

** Sound power measured per ISO-9614-2.

86 3A2776D

Dimensions

Technical Data

Min: 70 in.

(1780 mm)

Max: 84 in. (2130 mm)

ti20268a

52 in.

(1320 mm)

76 in.

(1930 mm)

Min: 70 in.

(1780 mm)

Max: 84 in.

(2130 mm)

ti20267a

104 in.

(2640 mm)

38 in.

(965 mm)

3A2776D 87

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to

the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com.

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505

All written and visual data contained in this document reflects the latest product information available at the time of publication.

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Graco reserves the right to make changes at any time without notice.

For patent information, see www.graco.com/patents.

Original instructions. This manual contains English. MM 3A2776

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revision D - September 2014

Graco 3A2776D User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Models

Related Manuals

Warnings

Keep Components A and B Separate

Changing Materials

Components A and B

Component Identification

Typical Setup (Front View)

Typical Setup (Back View)

Fluid Control Assembly

Main Power and Heater Controls

Sprayer and Flush Pump Air Controls

Feed Module Air Controls

User Interface

Setup

Location

Unboxing

Configuration Options

Grounding

Connect Power

Connect Air Supply

Connect Feed Module Lines to Sprayer Module

Install Level Sensor Probes

Level Sensor Calibration

Connect the Fluid Hose Bundle to the System

Connect the Fluid Hose Bundle to the Mix Manifold

Connect the Mix Manifold to the Gun

Prime Heated Fluid Circulation System

Initial Startup

Prime Solvent Flush Pump

Adjust Ratio and System Settings

Temperature Settings

Spray

Flush Mixed Material

Park Metering Pump Rods

Pressure Relief Procedure

System Verification

Pump and Metering Test

Batch Dispense or Ratio Test

Down Stream Valve Leak Test

Mix and Integration Tests

Empty and Flush Entire System

Prepare Level Sensor for Shipping

Download Data from USB

USB Logs

Download Setup

Download Procedure

Maintenance

Adjust packing nuts

Seals

Filters

Clean the System

Troubleshooting

Alarms

General Tips

Individual Control Module LED Diagnostic Information

Troubleshooting Table

Appendix A - User Interface Display

Change a Setting

Alarms

Setup Mode Screens

Operator Command Mode Screens

Automatically Displayed Screens

Appendix B - Alarms

Alarms Overview

Alarm Code Troubleshooting

Technical Data

Dimensions

Graco Standard Warranty

Graco Information