Graco XM 24W626, XM 262869, XM 262945, XM 262943 Operation Manual

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Page 1

Setup - Operation

WLD

™

PFP

3A2776H

Plural-Component Sprayer

For spraying two-component passive fire protection (PFP) intumescent epoxies. For professional use only.

Importan t Safety Instru ct io n s

Read all warnings and instructions in this manual and in all related manuals. Save all instructions.

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

Page 2

Contents

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Keep Components A and B Separate . . . . . . . . . . . . .8

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Components A and B . . . . . . . . . . . . . . . . . . . . . . . . . .8

Component Identification . . . . . . . . . . . . . . . . . . . . . . . . .9

User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Unboxing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Ratio Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Configuration Options . . . . . . . . . . . . . . . . . . . . . . . . .17

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Connect Power Cord . . . . . . . . . . . . . . . . . . . . . . . . . .19

Set Power Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Connect Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Connect Feed Module Lines to Sprayer Module . . . . .21

Install Level Sensor Probes . . . . . . . . . . . . . . . . . . . .23

Level Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . .23

Connect the Fluid Hose Bundle to the System . . . . . . 24

Connect the Fluid Hose

Bundle to the Mix Manifold . . . . . . . . . . . . . . . . .25

Connect the Mix Manifold to the Gun . . . . . . . . . . . . .26

Connect Tank Heat Circulation Hoses . . . . . . . . . . . .26

Prime Heated Hose Bundle

Fluid Circulation System . . . . . . . . . . . . . . . . . . .26

Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Prime Flush Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Adjust Ratio and System Settings . . . . . . . . . . . . . . . . .38

Verify Desired Ratio Mode . . . . . . . . . . . . . . . . . . . . .38

Adjust Ratio Set Point . . . . . . . . . . . . . . . . . . . . . . . . .38

Temperature Settings . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Flush Mixed Material . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Park Metering Pump Rods . . . . . . . . . . . . . . . . . . . . . . .45

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . . .46

System Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Pump and Metering Test and Calibration for

Ratio by Weight Mode . . . . . . . . . . . . . . . . . . . . .48

Batch Dispense or Ratio Test . . . . . . . . . . . . . . . . . . .50

Down Stream Valve Leak Test . . . . . . . . . . . . . . . . . .52

Mix and Integration Tests . . . . . . . . . . . . . . . . . . . . . .53

Empty and Flush Entire System . . . . . . . . . . . . . . . . . . .54

Prepare Level Sensor for Shipping . . . . . . . . . . . . . . . .58

Download Data from USB . . . . . . . . . . . . . . . . . . . . . . . .59

USB Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Download Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Download Procedure . . . . . . . . . . . . . . . . . . . . . . . . .59

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Adjust Packing Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Clean the System . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Appendix A - User Interface Display . . . . . . . . . . . . . . . 68

Change a Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Test Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Information Screens . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Appendix B - Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

Alarms Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . 100

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

2 3A2776H

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Models

9902471

Certified to CAN/CSA C22.2 No. 88

Conforms to

UL 499

Not for use in explosive atmospheres or hazardous locations.

9902471

Certified to CAN/CSA C22.2 No. 88

Conforms to

UL 499

II 2 G Ex db ia pxb IIA T3 Gb

System Series Location

Models

Ratio

Range Approvals

24W626 B

262869 B

262945 A

262943 A

Non-Hazardous

Hazardous

1:1 to

1.5:1

1.5:1 to 4:1

1:1 to

1.5:1

1.5:1 to 4:1

ATEX Ratings: ATEX Certificate No. ITS15ATEX18241X

Maximum Fluid Working Pressure Maximum Air Working Pressure

A and B Materials:

6000 psi (41 MPa, 414 bar)

Flushing Fluid:

4500 psi (31 MPa, 310 bar)

3A2776H 3

Heating Fluid:

100 psi (0.7 MPa, 7 bar)

IECEx Ratings Ex db ia pxb IIA T3 Gb IECEx Certificate No. IECEx ETL 15.0020X Ta = 0°C to 54°C

See Technical Data, page 96, for additional information.

Supply:

150 psi (1.0 MPa, 10.3 bar)

Max. Setpoint:

100 psi (0.7 MPa, 7 bar)

Page 4

Related Manuals

Manuals are available at www.graco.com. Component manuals in English:

Manual Description

3A2989 XM PFP Repair 3A2988 XM PFP Mix Manifold Instructions - Parts 3A2799

Heaters

309524

3A2954

Pumps, Motors, Supply Systems

308652 311238

311762 312375

312376 312792

312794 Merkur Pump Assembly Instructions - Parts 312796 NXT Air Motor Instructions - 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 406691 Hose Rack Parts 334931 Caster Kit Instructions

Other

306861 Ball Valves Instructions - Parts 307005 High Pressure Swivel Instructions - Parts

308169 407061 Simulation XM PFP Display Module 3A1244

334939 1:1 Ratio Adapter Kit Instructions 3A3072 Heater Upgrade Kit Instructions

™

XHF

Spray Gun

Viscon Instructions - Parts

Viscon HF High Flow, High Pressure Fluid Heater Instructions - Parts

Husky Pumps Instructions - Parts

NXT Xtreme Check-Mate

Instructions - Parts Check-Mate Pump Packages Instructions -

Parts Merkur

Air Filters, Lubricators, and Kit s Instructions

- Parts

Graco Control Architecture Module Programming

HP High Pressure Fluid Heater

™

205 Air-Operated Diaphragm

Air Motor Instructions - Parts

Lowers Instructions - Parts

Displacement Pumps

Pump Repair - Parts

4 3A2776H

Page 5

Warnings

WARNINGWARNINGWARNING

WARNING

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.

SPECIAL CONDITIONS FOR SAFE USE

• Potential risk of electrostatic discharge. See instructions for guidance to minimize the risk of electrostatic discharge.

• The system must be earthed using copper conductors according to the installation instructions. All intrinsically safe circuits must be connected to ground at one point.

• For information on the required dimensions of the flameproof joints contact the holder of this certificate (Graco Inc.); Flame-path joints are not intended to be repaired.

• Special fasteners for securing equipments covers on the flameproof heaters shall have a minimum yield strength of 1,100 MPa and be corrosion resistant and sized M8 x 1.25 x 30.

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent flowing through the equipment can cause static sparking. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

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

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

• Never spray or flush solvent at high pressure.

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

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

• Use only gr ounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are anti-static or conductive.

• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

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.

3A2776H 5

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Warnings

WARNINGWARNINGWARNING

WARNING

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. 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.

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.

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 Safety Data Sheet (SDS) from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

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

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

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

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

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

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

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.

6 3A2776H

Page 7

Warnings

WARNINGWARNINGWARNING

WARNING

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.

3A2776H 7

Page 8

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

8 3A2776H

Page 9

Component Identification

WLE

B C D

E, F

ti19927a

Typical Setup (Front View)

Component Identifica tio n

FIG. 1 Key:

AFrame B Fluid Control Assembly (see page 11) C User Interface (see page 15) 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 13) H Viscon HP Heater for hose bundle J Main Power and Heater Controls (see page12) K Viscon HF Material Heater L Air Powe red Agita tor with Lub ric ato r M Feed Pump N Recirculation Control Valve P Pressure Tank, Double-Wall Temperature Conditioned R Remote Mix Manifold

S Static Mixer Assembly T Spray Gun U Air Motor V Feed Module Air Controls (see page 14) W High Pressure Fluid Metering Pump X 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) B1 TSL Supply Bottle and Bracket C1 Heated Fluid Circulation Pump for Hose Bundle D1 Insulation Jacket E1 Explosion Proof Box (Hazardous Location System only) F1 Junction Box Non-Hazardous Location System only) or

Purge Box (Hazardous Location System only)

3A2776H 9

Page 10

Component Identification

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

C1, A1

D1, A1

Hazardous Location Models only

Typical Setup (Back View)

WLD

FIG. 2

10 3A2776H

Page 11

Fluid Control Assembly

ti19928a

Component Identifica tio n

FIG. 3

AA Dosing Valve AC Recirc ulation 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

3A2776H 11

Page 12

Component Identification

ti26689a

Hazardous Location System

Non-Hazardous Location System

r_XM1A00_312359_313289_14A

Hazardous Location System

BD BA

Main Power and Heater Controls

FIG. 4

BA Main Power ON/OFF Switch (non hazardous loca tion) BB A and B Tank Water Heat ON/OFF Switch BD Optional Heated Water Flush Tank Accessory ON/OFF

Switch (only used if the water heater accessory has been added to the machine) (standard on hazardous location models

CA Main Power ON/OFF Switch (hazardous location)

12 3A2776H

Page 13

Sprayer and Flush Pump Air Controls

r_XM1A00_312359_313289_14A

FIG. 5

Component Identifica tio n

CA Metering Pump Air On/Off Control (non hazardous loca-

tion) Main Power On/Off Switch (hazardous location), see

Main Power and Heater Controls, page 12 CB Flush Pump Air On/Off Control CC Inlet Air Pressure Gauge CD Metering Pump Air Regulator CE Metering Pump Air Regulator Gauge CF Flush Pump Air Gauge CG Flush Pump Air Regulator

3A2776H 13

Page 14

Component Identification

FEED PUMP

BYPASS

NOTE: Both valves shown open

ti20127a

ti20104a

Feed Module Air Controls

. 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 Air Controls

Feed Pump Bypass Button

Use the feed pump bypass button (CU) 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 84.

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 the pail to push the pail off of the RAM.

DA RAM Air ON/Exhaust Slider Valve DB RAM Air Regulator

14 3A2776H

Page 15

User Interface

ti13365a

NOTICE

To prevent damage to soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails.

Component Identifica tio n

. 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 M ove between drop-down fields, option

DJ Setup Key

Lock

DR USB Port Connection for data download.

3A2776H 15

Use to view screens. See page 68.

rently selected in Run Screen.

currently selected.

options, and save values. Resets alarms and advisories.

modes.

the icon above ea ch o f t he fo ur butt ons 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

• On - dosing valve is active

• Off - dosing valve is not active

DM Green Spray mode active

• Spray mode is on (active)

• Spray mode is off (inactive)

DN Red Alarm

• On - alarm is present

• Off - no alarm

DP Yellow Warning

• On - is active.

• Off - no warning indicated. R atio and setup fields are not changeable.

• Flashing - key is present and turned. Ratio and setup fields are changeable.

Page 16

Component Identification

Current Date and Time

Go back one screen

Navigational Bar

Function Display

Remaining Potlife Time System Ratio Mode

(Volume/Weight)

User Interface Display

Main Display Screen Components NOTE: For detailed screens information, see Appendix A - User Interface Display beginning on page 68.

The following figure calls out the navigational, status, and general informational components of each display screen.

The system ratio mode shows if the mix ratio target is by volume or weight . If the weight is crossed out, the system must be calibrated before running. See Pump and Metering Test and Calibration for Ratio by Weight

Mode on page 48.

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

16 3A2776H

Page 17

Setup

Front to Back Configuration

Side by Side Configuration

ti20267a

ti20268a

Setup

Location

Select a location that complies with the approval rating for your model. For approval rating, see Models, page

3. The location must have the required power and air sup-

ply to set up your sprayer. See Technical Data, page 96, for Air Consumption and Power Requirements 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.

Ratio Configuration

Proportioners leave the factory set up for materials which are higher volume and/or viscosity on the “A” side, and lower volume and/or viscosity on the “B” side. 1:1 mix ratio machines will normally change the “B” side circulation return hose from 3/8 in. to 1/2 in. ID to balance the recirculation speeds.

1:1 mis ratio machines also use outlet hose bundles which are 3/4 in. on both sides. The outlet fittings on the machine and the inlet fittings on the mix manifold must be changed on the “B” side from 1/2 in. to 3/4 in.

1:1 Ratio Adapter Kit 24X461 is provided with your machine. Install the kit, if necessary, before screwing the modules together.

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

. 9

3A2776H 17

Page 18

Setup

ti20163a

5.5 in. long

2x (115211)

1.5 in. long

(16J674)

ti20197a

3.5 in. long

8x (124869)

5.5 in. long

(115211)

(16J674)

Horizontal Braces

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.

Frame Connection Parts Part Description Qty

115211 SCREW, cap, hex head; 5.5 in 2 16J674 SCREW, cap, flange hd; 1.5 in 8 124869 SCREW, cap, hex head; 3.5 in 8 109570 WASHER 20 112731 NUT 10

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

If the front-to-back module configuration is used, install the two supplied straight steel horizontal braces between each feed module and the sprayer module, see F

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

configuration.

FIG. 10: Bolt Locations (Side by Side)

Do not use motor 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.

. 11: Bolt Locations (Front to Back)

18 3A2776H

Page 19

Setup

ti27665a

Grounding

The equipment must be grounded to reduce the risk of static sparking and electric shock. All internal earth grounding must use only copper wires. See electrical schematics in systems repair manual for wire size. 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.

All components shipped from the factory are electrically bonded through ground wires. Ground the electrical connection properly according to local codes.

Connect Power Cord

Non-Hazardous Location Models

200-240 VAC, 3 Phase Delta, Non-Hazardous Location: 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).

350-415 VAC, 3 Phase WYE, Non-Hazardous Location: Use a 5/32 in. (4 mm) hex key to connect the

three power leads to the top terminals T4, L1, and L2. Connect neutral to L3. Connect green to ground (GND).

1 L1

8 T4

7 L4

2 T1

3 L2

5 L3

CT1

4 T2 6 T3

8 T4

7 L4

1 L1

2 T1

3 L2

5 L3

CT1

4 T2 6 T3

Power must be connected by a qualified electrician. Graco does not supply junction box power supply cords. Use the following chart to determine which power cord your system requires.

Power Cord Requirements

System Voltage Cord Specification AWG (mm

200-240 VAC, 3 PH 6 (13.3) 3 wire + ground 350-415 VAC, 3 PH 6 (13.3) 4 wire + ground

For Hazardous Location Models, use appropriate power cord. Follow all National, State, and Local electric codes.

1. Open junction box cover.

2. For non-hazardous location models, Insert power cord through the large empty strain relief in the bottom of the junction box. For hazardous location models, Insert power cord in the bottom of the explosion proof box. Use appropriate cable gland for the 1-1/4 npt port, the cable gland must be rated to ATEX II 2 G. Follow all National, State, and Local electric codes.

3. Connect power cord as follows.

Hazardous Location Models

200-240 VAC, 3 Phase Delta, Hazardous Location:

Use a screwdriver to connect the three power leads to the left side of terminals TB3, TB4, and TB5. Connect green to ground (TB1).

)

350-415 VAC, 3 Phase WYE, Hazardous Location:

Use a screwdriver to connect the three power leads to the left side of terminals TB2, TB3, TB4, and TB5. Connect neutral to N. Connect green to ground (TB1).

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3A2776H 19

Page 20

Setup

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Set Power Jumpers

1. Find the red power jumpers for the terminal blocks supplied in a plastic bag in the circuit box. For hazardous location models, are in the explosion proof box (E1).

For 200-240 VAC and 350-415 VAC, 3 Phase installations only,

jumpers into the terminal blocks in the correct positions as shown in the following illustration. Push jumpers firmly into position.

. 12: Non-Hazardous Location Models

use pliers to install the three red power

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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.

NOTE:

Air supply requirement:

maximum; 80 psi (552 kPa, 5.5 bar) minimum (while running).

Flow volume required:

250 scfm (7.1 m

sure 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

150 psi (1.0 MPa, 10.3 bar)

100 scfm (2.8 m3/min) minimum;

/min) maximum. Available fluid pres-

/min).

. 13: Hazardous Location Models

3. Close junction box cover.

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.

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20 3A2776H

Page 21

Setup

Connect Feed Module Lines to Sprayer Module

1. Connect Modules, page 18.

2. Connect the large diameter green hose from each tank bottom outlet to the respective metering pump inlet. Hose (1403) is for side by side setup and hose (1413) is for front to back configurations.

NOTE: There is a vertical swivel union at each end of the green hose assembly.

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

. 15.

. 14: Feed Module Lines

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).

FIG. 15

b. Connect the 1/4 in. OD air signal tube to the

tube that has 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

15.

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

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. 15.

3A2776H 21

Page 22

Setup

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e. For Non-Hazardous Location Models, Con-

nect heater power cables (e) for the tank heater and the flush heater to the terminal blocks. See

. 16.

For Hazardous Location Models, Connect heater power cables (e) for the tanks heater the flush heater to the terminal blocks. See F

. 17.

. 16

FIG. 17

4. Connect the fluid ci rcul ation re turn h oses .

• 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.

NOTE: Systems that will be used for 1:1 mix ratio materials need to change some fittings and circulation hoses. Use parts from kit 24X461 (supplied with your machine). See manual 334939 for instructions.

22 3A2776H

Page 23

Install Level Sensor Probes

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Each tank uses a 37 in (94cm) 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

. 18

Level Sensor Calibration

Level sensors are factory set to work with these tanks. Calibration is not necessary unless replacing a sensor. See repair manual for the XM PFP (3A2989).

3A2776H 23

Page 24

Setup

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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 (models 262869, 262945) one 3/4 in. ID B material hose (models 24W626, 262943), 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.

For models 262869 and 262945, use 1:1 Hose and Fitting kit 24X461 (supplied with your machine) to replace the fittings and B side circulation hoses. See supplied manual 334939 for instructions.

1. Position the hose bundle end with the four loose red and blue tubes at the machine outlet.

Systems 262869 and 262943: Connect the 3/4 in. A and 1/2 in. B hoses to the respective material outlet check va lves on t he f ron t of t he s yste m. S ee F

19. Systems 24W626 and 262945: Connect the 3/4 in.

A and 3/4 in. B hoses to the respective material outlet check va lves on t he f ron t of t he s yste m. S ee F

19.

2. Connect the short purple flush hose from the 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

. 20.

FIG. 20: 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

. 21.

. 19

. 21

24 3A2776H

Page 25

Setup

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Material Inlets

Flush Inlet

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4. Locate the 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.

Connect the Fluid Hose Bundle to the Mix Manifold

1. Unroll the hose bundle out to the spray area.

2. System 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

System 24W626: Change the B side inlet nipple and 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 id entifi cation on mix mani fold. S ee F

. 23.

. 22

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.

FIG. 23

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 flush hoses from the manifold underneath the manifold carriage and connect to the 1/4 in. flush hose in the hose bundle. See F

. 23.

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.

3A2776H 25

Page 26

Setup

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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.

. 24

. 24.

Prime Heated Hose Bundle 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.

See instructions on page 29.

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).

Connect Tank Heat Circulation Hoses

NOTE: The tank jacket heat circulation system was pre-filled at the factory.

The tank to tank circulation hoses use quick-disconnect fittings that were connected back to their own tank for shipping.

Disconnect these fittings and connect them back to the opposite tank as shown in F

. 25 or FIG. 26.

26 3A2776H

Page 27

Setup

Side By Side Configuration

See Front to Back Configuration, F

. 4, page 12.

FIG. 25: Heated Fluid Diagram For Tank Heat (Hazardous Location Shown)

3A2776H 27

Page 28

Setup

Front to Back Configuration

FIG. 26: Heated Fluid Diagram For Tank Heat (Hazardous Location Shown)

28 3A2776H

Page 29

Prime Heated Fluid Circulation System Continued

FEED PUMP

BYPASS

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Adjustment Knob Location

Setup

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.

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.

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

. 28. Adjust knob until tank

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

NOTE: On all models, there is only one pump and one heater, which is located on the “A” side feed module.

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.

. 27

FIG. 28

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.

NOTE: Re-tighten all heated fluid circulation tube fittings after the first time the system has been run at full temperature.

3A2776H 29

Page 30

Initial Startup

purge complete

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.

1. Verify all procedures in the Setup section beginning on page 17 have been properly performed.

2. Perform Adjust Packing Nuts on page 61.

Power On Machine

For non-hazardous location models:

power switch (BA) ON and verify the system air inlet ball valve (E) is open. See F

. 1 on page 9.

Turn main

c. While the system is in the purge sequence, wait

approximately 3 minutes until the right indicator light turns green. The system display will turn on when the purge complete indicato r turn s gree n after a 3 minute purge sequence.

NOTE: For hazardous location models, the syste m will turn off if the air is locked, turned off, or depressurized. Open the main power switch (CA) to turn on system and allow the purge controller to complete the 3 minute purge sequence.

For hazardous location models:

a. Open the air supply valve (E). See F

page 9.

b. Open the main power switch (CA). After approx-

imately 5 seconds the left indicator light on the purge controller will turn green.

. 1 on

Flush Machine (If Required)

If your A or B material will not function properly if it mixes with a small amount of mineral oil,

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 96.

perform

30 3A2776H

Page 31

Initial Startup

FEED PUMP

BYPASS

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Return line port

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Load Machine (First Time)

6. 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.

. 29

7. 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

. 30.

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 84.

b. Remove the priming stick from the platen.

FIG. 31

c. Slide main air slider valve (DA) and air motor

slider valve (DF) to the OFF position. See F

32.

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.

. 30

8. Fill the tanks with material:

. 32: Feed Pump Controls

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.

3A2776H 31

Page 32

Initial Startup

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FEED PUMP

BYPASS

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h. Install pail of material beneath feed pump

platen.

. 33

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.

k. Ensure platen is centered on pail when it con-

tacts it. Repeat previous steps until platen is centered on pail.

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.

9. Open both ball valves (CS, CT) on the feed module air controls.

FIG. 34

l. Adjust air regulator (DB) 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 platen 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

. 32. 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

blow-off valve (DD) then lift the director valve. The feed pump will push pressurized air into the

To reduce the risk of explosion, never turn on heaters when solvent is in the system.

10. If not already set, adjust the feed module settings: 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.

32 3A2776H

Page 33

Initial Startup

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11. Open the circulation valves .

12. Verify the sampling valves are closed.

13. Open metering pump inlet ball valves.

NOTE: For hazardous location models, do not close the main power switch (CA). The system will turn off if the air is locked, turned off, or depressurized. Open the main power switch (CA) to turn on the system and allow the purge controller to complete the 3 minute purge sequence.

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

16. 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

14. For Non-Hazardous models: Turn on air supply (CA) and set metering pump air regulator to 20 psi (138 kPa 1.38 bar).

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 cavitation.

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.

17. 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, overflow the tank, and damage system components if there is too much fluid in the tank.

3A2776H 33

Page 34

Initial Startup

FEED PUMP

BYPASS

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Outlet Fitting

B Valve

A Valve

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18. Back out the tank air pressure regulator (CP) on the feed system air controls and open the brass valve on the tank lid.

. 35

19. With the tank air pressure relieved, remove tank port plugs and reconnect the tank return lines.

20. Adjust the tank air pressure regulator back to the desired pressure.

21. Close the circulation valves.

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.

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

22. Prime the A sampling valve:

a. Press repeatedly to set to

Slowly turn metering pump air regulator (CD)

Press .

24. 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.

34 3A2776H

Page 35

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.

Initial Startup

25. Perform the Prime Flush Pump procedure on page 36 to flush out the oil from those lines, and to finish preparing for spraying.

3A2776H 35

Page 36

Prime Flush Pump

TI19266a

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Hazardous Location Model

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Non-Hazardous Location Model

BDBB

Prime Flush Pump

Hazardous location models include the flush pump and a hot water supply kit. Hazardous location models can be setup to flush with either solvent or hot water.

Non-hazardous location systems only include a siphon flush pump meant for solvent pails. You can order the hot water flush kit accessory. See manual 332073 for complete hot water flush kit instructions.

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 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.

c. Turn on the heated water circulation pump 1-2

cycle/second.

If the hot water flush kit is used,

ing steps:

perform the follow-

NOTICE

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

a. After water begins dispensing from the gun, turn

the water heater knob to #6.

b. Turn the water heater power switch (BD) on the

system junction box ON.

If the hot water flush kit is not used,

pump siphon tube in the pail of solvent.

place flush

If the optional hot water flush kit is used,

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

a. Fill the tank.

b. Be sure that the flush pump siphon hose pick up

tube is latched in the water tank.

turn on the

36 3A2776H

Page 37

Prime Flush Pump

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TI19265a2

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

8. Open the flush ball valves.

9. 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.

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

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

11. Continue to dispense until all air is purged.

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

3A2776H 37

Page 38

Adjust Ratio and System Settings

Verify Desired Ratio Mode

The machine can be run in either Ratio by Weight Mode or Ratio by Volume Mode. Since PFP materials are blended by weight, normally have air mixed in the fluids, and are checked by weight, it is recommended that these materials be run in Ratio by Weight Mode. This calibrates the machine to the exact materials that you are pumping, and gives the most accurate ratio checks by weight.

Ratio by Weight Mode is indicated by a balance scale in the upper right corner of the screen. Ratio by Volume Mode is indicated by a beaker in the upper right corner. The mode can be selected in the Enable Setup Screen

3. See Enable Setup Screens, page 73. In Weight Mode, the scale in the upper right corner of

the screen will have an X through it until the machine is calibrated, and a ratio check is complete. Spray Mode can not be used until the X is cleared from the scale by doing a Pump Test Calibration, and performing a Ratio Check. See Batch Dispense or Ratio Test, page 50.

Temperature Settings

Set all temperatures per your materials data sheet specifications.

Feed Tanks

Temperature is controlled by an adjustable thermostat on the heater mounted on the “A” side feed module. Power to the tank heater is supplied from the power switch (BB) above the dosing valves. 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).

If you are running Ratio by Volume Mode, the mix ratio by weight still needs to be set on the Ratio Test Setup Screen. This allows ratio checks to be done by weight. See Appendix A, Ratio Test, page 72.

Adjust Ratio Set Point

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

2. Press and to change the volume or weight ratio setting. Current setting of volume or weight is

shown in the upper right corner.

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 68 for detailed screens information, including navigation and instructions.

NOTE: High mix or viscosity ratio (greater than 3:1) materials may require adding restriction to the B side outlet.

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.

38 3A2776H

Page 39

A and B Material Temperature

There is one Viscon HF 5400 watt heater for heating each 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.

Hose Bundle Temperature

Temperature Settings

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 c lockwi se (f ull ON p os iti on ). A lwa ys l eav e i n 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.

3A2776H 39

Page 40

Spray

Non-Hazardous

Location

Hazardous

Location

FEED PUMP

BYPASS

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Spray

This procedure includes steps to 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 46, then tighten packing nuts on pumps and dosing valves.

1. If this is the Initial Startup or if system components have been replaced, follow the Initial Startup procedure beginning on page 30.

NOTE:

If the 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.

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

step 8 on page 31.

6. Open both ball valves on the feed module air con-

trols.

FIG. 36

7. Close mix manifold flush valves.

2. Verify that the metering pump regulator (CD) is turned counterclockwise to 0 psi.

3. For non-hazardous location models: Turn the main power switch (BA) ON and verify the XM PFP air supply ball valve (E) is open. Open the pump air valve (CA).

For hazardous location models: Turn the main power valve (CA) ON and verify the XM PFP air supply ball valve (E) is open.

8. Close mix manifold ball valves.

4. Perform Prime Flush Pump, page 36 to ensure the flush pump is prepared to quickly flush out mixed material when done spraying.

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Hazardous

Location

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Non-Hazardous

Location

9. Open recirculation valves.

10. Ensure metering pump air regulator (CD) is turned counterclockwise to 0 psi.

NOTE: For hazardous location models, do not turn off the main power switch (CA). If air is blocked, turned off, or depressurized the system will turn off. To turn on system, open the main power switch (CA) and allow the 3 minute purge sequence to complete.

13. Use metering pump air regulator (CD) to slowly increase the air pressure to the metering pumps until the enabled pump(s) begin running slowly.

NOTE: For Hazardous Location Models: the system on/off valve is already open.

14. Turn A and B tank fluid heater (BB) ON if it isn’t already ON.

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

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

16. Turn on the primary material heaters. a. Navigate to the Supply screen. See Operator

Command Mode Screens on page 76.

12. 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.

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

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

17. If desired, press to enable automatic tank filling. See page 84 for automatic tank filling details.

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Page 42

Spray

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18. 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.

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.

NOTE: If the circulation valves are closed while circulating, but the control is left in Circulation Mode, the machine will alarm after 5 seconds and exit Circulation Mode. This is done to prevent spraying in Circulation Mode.

19. Once the materials reach the desired temperature as shown on the supply screen, press .

21. Close recirculation valves.

22. Perform Pump and Metering Test and Calibra tion for Ratio by Weight Mode on page 48.

23. Perform Ratio Test (Batch Dispense or Ratio Test) on page 50.

24. Perform Down Stream Valve Leak Test on page 52.

25. Open mix manifold ball valves.

20. Turn the metering pump air regulator (CD) counterclockwise to 0 psi.

26. Select .

27. Press to start the metering pumps.

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Page 43

Spray

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28. 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.

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

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

spraying on the test panel until the desired pattern results then begin spraying the production surface.

34. Follow Flush Mixed Material on page 44 when you are finished spra ying if t he p otli fe o f th e mix ed mat erials 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.

31. Engage trigger lock.

32. Perform the Mix and Integration Tests on page 53. When necessary, engage trigger lock then install the tip on gun.

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.

33. Adjust metering pump 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

3A2776H 43

Page 44

Flush Mixed Material

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Flush Mixed Material

To avoid fire and explosion:

• Flush equipment only in a well-ventilated area

• Ensure main power is off and heater is cool before flushing

• Do not turn on heater until fluid lines are clear of solvent

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.

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

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

9. Continue dispensing until clean flushing fluid is dispensed.

1. If necessary, Prime Flush Pump, page 36.

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.

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

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

11. Close flush pump air supply valve.

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

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.

44 3A2776H

Page 45

Park Metering Pump Rods

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13. Close flush ball valves.

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.

3. Close mix manifold material ball valves.

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. Turn the metering pump air regulator (CD) counterclockwise to 0 psi.

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.

6. Turn the metering pump air regulator (CD) counterclockwise to 0 psi

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Page 46

Pressure Relief Procedure

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FEED PUMP

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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.

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

perform Park Metering Pump Rods proce- dure on page 45 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 Supply Scr een, page 84.

If necessary to relieve tank air pressure:

close both feed system air control ball valves (CT, CS) and back out the air pressure regulator (CB). Open the brass valve s on t h e tan k li ds for full t a nk d e-p re ss u rization. Pressure gauge (CR) should read 0 psi.

3. Press .

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

. 37: Feed Pump Air Controls

. 38

6. Open mix manifold ball valves.

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Pressure Relief Procedure

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7. Open recirculation ball valves.

8. Disengage trigger lock.

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.

WLLD

11. Close mix manifold material ball valves.

12. Perform Flush Mixed Material procedure beginning on page 44 to prevent mixed material curing in the system and to relieve pressure in the flush 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.

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10. Engage trigger lock.

3A2776H 47

Page 48

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.

Pump and Metering Test and Calibration for Ratio by Weight Mode

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.

• If system Ratio Mode is set by weight, this test calibrates the weight ratio. Ratio Mode by weight is the standard setting.

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.

2. Enter Test Screens (see page 79).

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.

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.

48 3A2776H

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System Verification

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3. Select

to run pump test.

NOTE: These instr uct ions show run ning t he sys tem with ratio control by weight, which is standard and preferred for XM PFP systems. To control ratio by volume, see Test Screens (page 79).

4. Set metering pump air regulator (CD) pressure to zero. Verify metering pump air valve (CA) is open (horizontal). Adjust metering pump air regulator (CD) pressure to 50 psi (0.35 MPa, 3.5 bar).

d. Slowly open sampling valve A until material

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

e. Close sampling valve A (AE).

6. Dispense fluid B as follows: a. Tare and place a clean 1 quart (1000 cc) con-

tainer under sampling valve B.

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.

5. Dispense fluid A: a. Close recirculation valves, mix manifol d inlet

ball valves, and sampling valves.

b. Tare and place a clean 1 quart (1000 cc) con-

tainer under sampling valve A.

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

on.

c. Close sampling valve B.

7. Weigh the two samples with a gram scale and record the net weights.

8. 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. The screen displays the target weight of material dispensed into each beaker from each metering pump. The weights must be entered in grams to calibrate the machine.

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Page 50

System Verification

System Ratio Mode

by Weight

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NOTE: Calibration is not finished until a successful Ratio Test is performed. See Batch Dispense or Ratio

Test, page 50.

Batch Dispense or Ratio Test

This test dispenses a calculated volume of each fluid based on ratio. The two fluids combined equal the batch size selected.

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

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).

3. Pressurize the material lines: d. Set metering pump air regulator (CD) pressure

to 0 psi. Verify metering pump air valve (CA) is open.

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

to enter manual pump run mode.

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

1. Close mix manifold material ball valves.

2. Close recirculation ball valves.

f. Adjust metering pump air regulator (CD) pre s-

sure to 50 psi (0.35 MPa, 3.5 bar).

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

press .

4. Enter Test Screens (page 79).

50 3A2776H

Page 51

5. Select

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to run batch dispense test.

System Verification

10. 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.

11. Close sampling valve A (AE).

12. Dispense fluid B as follows: a.

Batch dispense:

move container under sam-

pling valve B (AF).

6. 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.

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

8. Place a clean container under sampling valve A.

Ratio check

: place clean container under sam-

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.

c. Close sampling valve B (AF).

Batch dispense:

13.

Ratio check

stir material until mixed.

: compare net weight of A and B materi-

als dispensed.

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.

9. Press . Wait until the Metering pump A light comes on.

3A2776H 51

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

Page 52

System Verification

Enter the weight (in grams) 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.

NOTE: If the test passes, the “X” will disappear in the top right corner and Spray Mode can be used. The system is now calibrated for use.

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.

detected in the metering pumps after stalling, an alarm is issued indicating which side has a leak.

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

2. Close recirculation valves (AC, AD).

3. Enter Test mode in the run (fluid control) screen. See Test Screens on page 79. Select

run down stream valve leak test.

4. Select

Press . Ensure dosing valves

(AA, AB) are open by verifying blue LEDs are illuminated 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

52 3A2776H

Page 53

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.

System Verification

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.

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Page 54

Empty and Flush Entire System

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Empty and Flush Entire System

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

To avoid fire and explosion:

• Flush equipment only in a well-ventilated area

• Ensure main power is off and heater is cool before flushing

• Do not turn on heater until fluid lines are clear of solvent

• Always ground equipment and waste container

• Always flush at the lower possible pressure

Only perform this procedure when:

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

FIG. 39: Feed Pump Air Controls

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

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

To flush a new system, see Initial Startup on page 30. To flush only the mix manifold to the gun, see Flush

Mixed Material, page 44. 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 that 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 44.

If applicable,

remove the feed pump from pail:

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

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.

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Empty and Flush Entire System

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5. Close the circulation valves.

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.

FIG. 40

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.

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 assem bl y.

i. Scrape remaining material from the walls of the

tank into the tank outlet.

j. Re-install the tank lid assem bly.

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

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Page 56

Empty and Flush Entire System

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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.

. 41

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 pres-

sure 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.

. 42: Feed Pump Air Controls

56 3A2776H

Page 57

9. Verify tank air pressure is still relieved, then purge

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the material from the tank return line. a. Open the circulation va lv es .

b. Disconnect the tank return line from side of the

tank.

Empty and Flush Entire System

c. Place the return line in a waste container.

d. Press . Slowly turn metering pump air

regulator (CD) clockwis e to increas e air pressure until metering pump A starts. Continue until

clean solvent is dispensed, then press to stop the metering pump. Back out the air pres-

sure 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 61.

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Page 58

Prepare Level Sensor for Shipping

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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.

. 43

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 23 to re-install.

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Page 59

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 59. 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 target, ratio, batch volume, and ratio type (volume/weight) 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 in the future (default is 60 seconds). Exit the System Setup screen.

Download Procedure

Event Log 3

The event log records all event 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 39000 lines of data.

Data Log 4

The data log reco rds (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.

To prevent fire and explosion, do not connect USB device in explosive atmosphere,

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

Graco-recommended USB flash drives; see Rec-

ommended USB Flash Drives, page 85.

NOTE: Inserting the USB flash drive while the sprayer is

running will stop sprayer operation.

3A2776H 59

Page 60

Download Data from USB

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 completes. The box below displays , which indi-

cates 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.

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 fold er.

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.

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Page 61

Maintenance

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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

Yearly or When Changing Materials

Adjust packing nuts

Seals

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

Clean the system Disassemble and

clean the A and B material heaters.

Adjust Packing Nuts

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).

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 .

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

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, p age 46, including relieving air pressur e 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).

™

Seals

Once a week, check and tighten throat seals on metering pumps and dosing valves. Be sure to follow the Flush Mixed Material, page 44, prior to tightening seals.

Battery

The front display battery must be changed in a nonhazardous location only. See XM PFP repair manual for instructions.

NOTE:

Use only Panasonic CR2032 batteri es for replacem ent.

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Maintenance

Non-Hazardous

Location

Hazardous

Location

Clean the System

1. Ensure all equipment is grounded. See Grounding, page 19.

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 44.

5. Perform Pressure Relief Procedure, page 46. This includes flushing the system and parking the metering pumps.

6. Turn main power switch OFF.

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.

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Troubleshooting

Alarms

See Appendix B - Alarms, starting on page 86.

General Tips

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

Troubleshooting

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.

• Clean the A and B heater cores.

Mix Manifold

• Ensure that the ‘A’ and ‘B’ outlet hose sizes are 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 checked 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.

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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 mod ule .

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

Voltage jumpers not installed or configured in power junction box.

No green lights present on disp lay , FC M, 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 Cor d on page 19.

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.

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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 met erin g va lves 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 valv e(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 star t 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 co nditioned bef ore 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 68.

Repeat Pump Test with fresh fluid. If the specific gravity of each flui d is

known, check samples by weight (750cc x specific gravity eq uals weigh t in grams). If weight is correct, extra volume in beaker is air.

See solutions for previous pump test problem.

continuity; switch is no rmally ope n circuit. See Electrical Schematics in th e 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.

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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 a larm after starting i n spr ay 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, mi xer, swiv el, 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. Insta ll larger tip. Foll ow

Mix manifold, mi xer, swiv el, 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 g raph 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 compr essed air. Heat the compressed air. Use a smaller tip and lower flow rate.

ual.

See Technical Data, page 96.

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.

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Problem Cause Solution

Purge Controller right indicator does not turn green. (Hazardous Location Models)

Purge Controller left indicator does not turn green. (Hazardous Location Models)

Both purge controller indicators are gree n but display screen does not turn on.

Troubleshooting

Leak in purge box or inadequate air supply.

Leak in purge box or obstructed purge exhaust.

Obstructed air line or loose wiring. Verify air line between purge controller

Check purge box for leaks. Make sure all cable glands are tight, sen-

sor and CAN cable glands include a rubber grommet. Verify mounting screws in purge controller are tight. Verify 8 mounting screw for explosion-proof box are tight. Verify door latches are tight and door mounting screws are tight.

Verify air regulator to purge controller-mounted in front sprayer air panel) is set to 80 psi. Verify no air blockage to purge controller. Verify flow control valve in purge controller is open. Verify bottom port closest to purge controller output is open. See Expo manual for additional troubleshooting.

Check purge box for le aks. See abov e for possible leak locations.

Verify pinch valves in pu rge controll er are all closed except for the 2 min pinch valve. Verify no obstruction on purge enclosure exhaust.

(through flame arrestor) and pressure switch in explosion proof box is not obstructed.

Verify wiring is secure in explosion proof box between the pressure switch terminals and the contactor. Verify wiring from explosion proof box to purge box (large explosion proof bushing ).

Ratio by Weight Mode

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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:

• change between volume and weight ratio

• set desired mix ratio by volume or weight

• set weight ratio and tolerance for ratio checks

• configure system settin gs

• 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 73, for instructions.

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

• 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 76, or Setup Mode Screens on page 69.

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.

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/calibrate weight mode

• 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

Alarms

See Appendix B - Alarms, starting on page 86.

These screens are shown when

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Appendix A - User Interface Display

Software VersionsHome / Volume Mix Ratio

Maintenance 2Maintenance 1

Enable Op tio n s 2Enable Options 1

Potlife/Hose Length

Date/Time/Units System/USB

Tank Fill

Ratio Test

Temperature

Pressure

(From All Screens)

Enable Options 3

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

. 7 on page 15. Some setup screens can be disabled, see Enable Setup Screens on page 73.

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Appendix A - User Interface Display

Home Setup Screens (Key Switch On)

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, ena ble/disable functions, mai ntenance 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 fl ui d con trol mo dul e ver sion (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

part number (Vs)

screens. Navigate to maintenance setup screens.

Navigate to pressure and temperature limits setup screens.

Temperature control module version and

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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 73, for instructions.

Icon Function

Set number of minutes before mixed material will set in hose. Resets after material volume set by us er is pa ssed th roug h ho se.

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 dow n in o n e m i nu t e in te r va ls . T h e ti m er au t o mat ically 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

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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

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 89.

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. The second settings (tank fill level) cannot be set above 85% of the tank size.

Ratio Test

Use this scree n t o set th e sp ra ye r nu mbe r if us in g m or e 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.

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.

For Ratio by Volume Mode, use this screen to set the ratio by weight (middle number), and the ratio tolerance (bottom number). The values determine whether the ratio test passes. The ratio by volume (top number) is displayed but cannot be changed on this screen. See Home screen on page 70 to change the ratio by volume.

For Ratio by Weight Mode, use this screen to set the ratio by weight tolerance (bottom number). The ratio by weight (top number) is displayed but cannot be changed on this screen. See Home screen, on page 70, to change the ratio by weight.

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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 use r in t e rf ac e a nd no al ar ms 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.

Selects system ratio by volume or ratio

by weight mode. Only one of these modes can be enabled at one time.

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.

3A2776H 73

Fast Dosing Function

Fast Dosing Advisory QTAE Alarm QDAE

ON 20 cc 30 cc

OFF 35 cc 45 cc

Enable Setup Screen 1

(Shown with factory default settings.)

Page 74

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

NOTE: The machine will be shipped in Weight Mode.

Maintenance Setup 2

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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)

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Appendix A - User Interface Display

Run (Fluid Control) Screens

Park Pump

Pump Mode

Spray Mode

(Spray Mode shown)

Restrictor

Ratio

Test Screens

Valve Test

Batch Test

Pump Test

Information Screens

(Pump Volume Test shown)

Weight/Volume

Alarm Information

Maintenance 1

Totalizer

Alarm Log

Maintenance 2

Supply Screen

Go to primary screen

in each section

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 15.

Operator Command Mode Screens Navigation Diagram

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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 both metering

Select which

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.

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

Park Metering Pum ps:

to bottom of the stroke.

Ratio:

jump to ratio screen.

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.

run meter ing pu mps

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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 .

The ratio displayed is the weight ratio if the machine is in Ratio by Weight Mode. The ratio displayed is the volume ratio if the machine is in Ratio by Ratio Mode.

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.

Press to return to the Spray Mode screen.

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 (smaller hose diameter) 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 (larger hose diameter) will reduce dosing size.

The first number below the date and time box is the A side pump dosing size. This value is displayed in volumes of cubic centimeters (cc) and is the volume pumped on the A side when the B side dosing valve is off. Optimizing the restriction of the system will keep this value small and ensure material is mixed well.

The second number below the date and time box is the material flow rate. Higher flow rates will cause larger dosing sizes and will require more optimized restriction. Set the restriction when the flow rate is at the maximum that will be seen in Spray Mode.

Press three times to display volume and weight ratio targets. The weight ratio target is only displayed in

weight mode.

Icon Function

Display Ratio:

fluid mix ratio.

Display Adjust Restriction Screen

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show the accuracy of the

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Test Screens

System Ratio Mode by Volume - Test by Volume

System Ratio Mode by Volume - Test by Weight

Appendix A - User Interface Display

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

Icon Function

Pump Test:

each A and B; verifies pump selection, operation, and metering. In System Weight Mode, this calibrates the system by entering weights.

Batch Dispense:

amounts of A and B with a selectable total.

Down Stream Valve Leak Test:

valves after the dosing valves hold pressure.

Test Mode Selection:

ume and weight test mode.

Pump Test/Calibrate

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 and Calibration for Ratio by Weight Mode procedure on page 48.

If the system ratio mode is by volume, pressing will allow the test to be run either by measuring volumes

or weights. If system ratio is by weight (standard on XM PFP systems), then the dispensed materials must be measured by weight.

(calibrate) dispenses 750cc of

dispenses proportion ed

test if

switch between vol-

Confirm Pump and Metering Test

This screen displays when the pump test completes without error. There are three variations that affect how the screen is used.

Ratio by Volume Mode - Test by Volume

Enter the volumes of each dispensed material in the respective input boxes on this screen. If the calculated ratio is within the ratio tolerance set on the Setup Ratio Test screen, a check will appear in the box. The results are entered into the USB logs.

The target ratio by volume for this test is set on the Setup Home screen on page 70. The tolerance is set on the Setup Ratio Test screen on page 72.

Ratio by Volume Mode - Test by Weight

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.

The target ratio by weight for this test and tolerance is set on the Setup Ratio Test screen on page 72.

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Appendix A - User Interface Display

System Ratio Mode by Weight

System Ratio Mode by Volume - Test by Volume

System Ratio Mode by Volume - Test by Weight

Ratio by Weight Mode

This screen displays two boxes where the A and B sample weights are entered to calibrate the machine to run in Ratio by Weight Mode. The weights must be entered in grams.

The target ratio by weight for this test is set on the Setup Home screen on page 70. The tolerance is set on the Setup Ratio Test screen on page 72.

Once entered, a check will appear in the box. There will still be an X through the scale in the upper right corner until a Ratio Test is performed successfully.

Confirm Batch Dispense Test

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.

There are three variations that affect how the screen is used:

Ratio by Volume Mode - Test by Volume

The target ratio by volume for this test is set on the Setup Home screen on page 70. The tolerance is set on the Setup Ratio Test screen on page 72.

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 50.

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.

If the system ratio mode is by volume, pressing will allow the ratio test to be run either by measuring vol-

umes or weights. If system ratio mode is by weight, then the dispensed materials must be measured by weight.

Ratio by Volume Mode - Test by Weight

Enter the weights of each dispensed material in the respective inp ut bo xe s on t h is sc reen . If ca lc ul a te d r ati o is within the ratio tolerance set on the Setup Ratio Test screen, a check will appear in the box. The results are entered into the USB logs.

The target ratio by weight for this test and tolerance is set on the Setup Ratio Test screen on page 70.

80 3A2776H

Page 81

Appendix A - User Interface Display

System Ratio Mode by Weight

Ratio by Weight Mode

Enter the weights of each dispensed material in the respective input boxes on this screen. The weights must be entered in grams. If calculated ratio is within the ratio tolerance set on the Setup Ratio Test screen (on page

72), a check box will appear in the box. The results are entered into the USB logs.

The target ratio by weight for this test is set on the Setup Home screen on page 70. The tolerance is set on the Setup Ratio Test screen on page 72.

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 di splays wh en the v alve l eak test comp letes and indicates whether the test was successful.

3A2776H 81

Page 82

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

The first number below the alarm code is the main power supply voltage used by the electronic modules. The voltage should read between 23 VDC - 25 VDC for non-hazardous location systems, and 10-14 VDC for the hazardous location systems.

The second number below the alarm code is the power supply voltage used by the system sensors. This voltage should read between 4.9-5.1 VDC.

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.

Go to maintenance screen. Allows user to view maintenance information.See Mainte- nance Setup 2, page 74.

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.

Press to access the alarm log. The press and

The third number below the alarm code is the A side pump dosing size. This value is displayed in volumes of cubic centimeters (cc) and is the volume pumped on the A side when the B side dosing valve is off. Optimizing the restriction of the system will keep this value small and ensure material is mixed well.

82 3A2776H

to scroll through each page of alarms.

Page 83

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.

3A2776H 83

Page 84

Appendix A - User Interface Display

1 2

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 (3DC) 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 14.

Press to three times display additional information.

Additional Information

1 Tank level sensor A (volts) 2 Tank level sensor B (volts) 3 Water/glycol mixture temperature at heater

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

84 3A2776H

Page 85

Automatically Displayed Screens

Appendix A - User Interface Display

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 do wnload 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 canceled, remove USB flash drive.

Indicates which log(s) will be downloaded.

Recommended USB Flash Drives

It is recommended that users use the USB flash drive

USB Screen

This screen automatica ll y dis pl ay s and the se lected log(s) automatically starts downloading when a USB flash drive is inserted into the control box.

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.

3A2776H 85

(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 Gizm o!

JDO4GB-730)

• Transcend JetFlash

(model TS4GJFV30)

™

4GB USB flash drive (model

V30 4GB USB flash drive

Page 86

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.

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.

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

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:

• Non-Hazardous PFP: 23-25 Volts

• Hazardous PFP: 10-14 Volts The middle line shows the voltage supplied to all sen-

sors connected to the Advanced Fluid Control Module. This should be between 4.9-5.1 Volts.

The third line shows the A side pump dosing size. This value is displayed in volumes of cubic centimeters (cc) and is the volume pumped on the A side when the B side dosing valve is off. Optimizing the restriction of the system will keep this value small and ensure the material is mixed well.

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.

86 3A2776H

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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 I Internal D Level Sensor B V Voltage 7 Unexpected

Non-Zero Value

8 Unexpected

Zero Value

9 Unstable K Re ed Swi tch C Communication A Loss P Display D Pump A Runaway T Temperature

D Cavitation X System

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

M Power Supply E Hose

P Pneumatic Supply H Heater Hose R Recirculation J Linear Sensor

Control Module

3A2776H 87

Page 88

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. -Spray mode turned on with system in weight mode and uncalibrated R5DX

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 exceed s 30 00 ps i (2 1.0 M Pa, 2 10 bar) on the A pump, receive ye llo w 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 did not move for 5 seconds while in circulation mode. F8RX

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

If fluid pressure is under 1500 psi (10.3 MPa, 103 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, P1BX

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

88 3A2776H

Page 89

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

CACT

DAAX DABX

DDAX DDBX

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

Temperature Control Module Loss of Communication

Pump Runaway; Above 80 CPM For 10 Sec.

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

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 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 net-

work address is wrong. Temperature Control Module is bad. Replace module.

Always Network communication cable is

bad. Temperature Control Module net-

work address is wrong. Temperature Control Module is bad. Replace module.

Machine powered down in spray mode.

Always

Always No material in pump or line s; no flui d

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

Network communication cable is bad.

restriction.

Material is too cold or thick. Increase material temperature to

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

Feed pump n ot providing material. Check feed pump (if used). Inlet strainer plugged (if used). Check and clean strainer. See XM

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. Check cable connections.

Refill material in tank or hoses; install fluid tip.

reduce viscosit y . See Spray, page

40. Shear material with agitation to reduce viscosit y .

replace ball, seat, and seal.

PFP repair manual.

3A2776H 89

Page 90

Appendix B - Alarms

Alarm

Code Alarm Problem

DEAX DEBX

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

F8RX No movement occurred in cir-

Pump Does Not Move In 10 Minutes.

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).

culation mode

When

Active Cause Solution

Park or

Pump Test Pump Test Pump piston check valve, piston

Pump Test Pump inlet check or dose valve is

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

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

Always Bad motor cable connections, or

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

Always Reed switch does not see the air

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

Always Reed switch does not see the air

Spray Recirculation valve or dosing valve

Circulation Pump did not move for 5 seconds

Recirculation valves were not opened to allow flow.

packings, or dosing valve are not holding fluid pressure.

fouled, or damaged.

Linear sensor plugged in while power is on.

Bad connection inside fluid control module.

Sprayer is not properly grounded. See Grounding, page 19.

bad reed switch.

Reed switch cable is plugged in while power is on.

Bad connection inside fluid control module.

Linear sensor is bad. Replace linear sensor.

motor magnet. Reed switches are bad. Replace air motor reed switch. PreAir motor is icing.

Linear sensor is bad. Replace linear sensor.

motor magnet. Reed switches are bad. Replace air motor reed switch. PreAir motor is icing.

open or leaking for more than five seconds.

while in circulation. User may have attempted to spray in circulation mode.

Open recirculation valves.

Flush pump. See General Tips, page 63. 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 senso r while power is on.

Replace fluid control module. See XM PFP repair manual.

See XM PFP repair manual.

Swap A and B mo tor 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 Pump and

Metering Test and Calibration for Ratio by Weight Mode, page 48.

Use spray mode for spraying.

90 3A2776H

Page 91

Appendix B - Alarms

Alarm

Code Alarm Problem

L2F1 L2F2

L3F1 L3F2

L4F1 L4F2

L6FC L6FD

*MAAX *MABX

*MEAX *MEBX

*MGPX Maintain A ir Filter. A lways, if

P1AX P1BX

*P2AX *P2BX

P4AX P4BX

P4RE Pressure High. Recircula-

P5RE Pressure High. Recircula-

*P5AX *P5BX

P6AX P6BX

Tank Level Low Advisory Spray and

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 D osing 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.

When

Active Cause Solution

Tank

Always Cable is disconnected or bad Replace level sensor

enabled

Pump Test,

Leak Test

Spray Pressure exceeded high or lo w advi-

tion

Spray Pressure exceeded high or low

Always Pressure sensor or cable is bad on

Tank level less than 10% below tank empty setpoint for 3 seconds.

Air solenoid is bad. Replace air solenoid.

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 u ser-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) for spray mode or below 1500 psi (10.3 M Pa, 1 03 bar) to test modes.

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.

Add material to tank.

Increase air pressure to solenoid. Lower the ta nk level.

Increase air pressure to solenoid.

Lower the ta nk level.

Lower the tank full setpoint.

Turn all sensor DIP switches to off Connect level sensor cable to sys-

tem Service pump. See pump manual

listed on page 4. Service dos ing valve. See pump

manual listed on page 4. Service main air filter and control fil-

ter 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.

3A2776H 91

Page 92

Appendix B - Alarms

Alarm

Code Alarm Problem

P9AX A Pump Pressure is Abnor-

mally Low Compared to B Pump Pressure.

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.

When

Active Cause Solution

Spray A air motor is icing causing restric-

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

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 flu id i n th e 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

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. 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.

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 40, or Flush Mixed Material, page 44.

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

manual 311762 for part number. Clean B pump outlet filter. See man-

ual 311762.

92 3A2776H

Page 93

Appendix B - Alarms

Alarm

Code Alarm Problem

R4BE Ratio High B (Overdose B);

System Deli vering Too Much B Component.

R5BE Dosing Sizes Are Not Opti-

mized.

When

Active Cause Solution

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

age. See Pump and Metering Test

and Calibration for Ratio by Weight Mode, page 48.

Loosen valve packing nut. See XM PFP repair manual.

Check air signal at valve top Repair valve or ai r solenoid. Se e XM

PFP repair manual.

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

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

Inlet air dropping below 80 ps i (0. 55 MPa, 5.5 bar) while sp rayi ng . B do sing valve not closing correctly.

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

Spray Dosing valve is operating near high

or low timing limits.

Check air filters. See XM PF P repai r manual.

Use larger air hose. Use larger compressor. Use smaller gun tips or less guns to

reduce flow rate. Adjust air regulator.

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

R5DX Uncalibrated system in

Weight Mode

R9BE System detected five R4BF

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

*T2DA *T2DB

T3CA T3CB

T3CH Hose Heater Temperature

T4CA T4CB

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

Or change ‘B’ restriction. Check Restriction screen.

Spray System was not ca librated. Run the Pump and Metering Test

and Calibration for Ratio by Weight Mode, page 48, and Batch Dispense or Ratio Test, p age 50 t o

calibrate system for weight mode . Run system in volume mode.

Run system in volume mode.

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

Flush mixed material if necessary, and purge off-ratio mix ed mat erial i n hose.

Spray Fluid temperature exceeded hig h or

low limits for more than four minutes.

Always Module is bad. Replace module.

Same as T5DA or T5DB.

Cool system down.

3A2776H 93

Page 94

Appendix B - Alarms

Alarm

Code Alarm Problem

T4CH Hose Heater Temperature

Control Module Over Temperature Alarm

T4CX Temperature Over Tempera-

ture Switch

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

T6F1 T6F2

T8DA T8DB

T8DH Hose Temperature Not Ris-

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

A/B Material Temperature Not Rising Alarm

ing Alarm

V1IT Low Voltage CAN Always

V1MA V1MB

V1MH Hose H eater Low Line Volt-

A/B Material Heater Low Line Voltage Alarm

age Alarm

When

Active Cause Solution

Always Module is bad. Replace module.

Cool system down.

Always Over temperature switch jumper

unplugged.

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 hig h 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.

Cable is disconnected or bad Connect temperature sensor cable

Heater A/B Heater bad. Repair heater.

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

Hose

Heater

Always Temperature Control Modul e po wer

Heater bad. Repair heater. Heater voltage too low. Increase heater voltag e to 200 - 240

24 VDC power supply. Check volta ge of pow er suppl y. Volt-

cable is disconnected. Heater circuit breaker is off Turn on heater circuit breaker.

Replace jumper.

outlet. If fluid temperatur e i s too l ow , re turn

to circulation mode to increase fluid temperature. Adjust h eate r se t point if needed. See Spray, page 40.

If fluid temperature is too h igh, lower heater set point, and return circulation mode to cool. See Spray, page 40.

Adjust temperature target setpoint. See Spray, page 40.

to system.

VAC.

age should be 23-25 VDC. If out of tolerance, adjust or replace power supply.

Plug in module power cable.

94 3A2776H

Page 95

Appendix B - Alarms

Alarm

Code Alarm Problem

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

V4IT High Voltage CAN

V4MA V4MB

V4MH Hose Heater High Line Volt-

A/B Material Heater High Lin e Voltage Alarm

age Alarm

When

Active Cause Solution

power supply.

Always

Always Temperature Control Module is bad. Replace module.

24 VDC power supply. Check volta ge of po wer suppl y. Volt-

Heater is bad. Repair heater.

Change air filter in contro l fil t er reg ulator. See XM PFP repair manual.

Check voltage on information screen.

age should be 23-25 VDC. If out of tolerance, adjust or replace power supply.

3A2776H 95

Page 96

Technical Data

XM PFP

US Metric

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, 3 micron purge con-

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

Mix Ratio Range

262869, 262943 1:1 to 1.5:1 24W626, 262945 1.5:1 to 4:1

Air Consumption

Minimum 100 scfm Maximum 250 scfm Typical Application 125-175 scfm

Power Requirements

Voltage (can be set with jumpers) Option 1: 200-240 VAC, 3 phase DELTA (3 wire plus ground)

Wattage 18,800 watts (non-hazardous location)

Amps 200-240 VAC, 3-phase models DELTA: 63 Amps per phase full

Handles mastic material s 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

troller filter (H azardous Location only)

2.8 meter

7.1 meter

3.5-5.0 meter

Option 2: 350-415 VAC, 3 phase WYE (4 wire including neutral plus ground)

18,900 watts (hazardous location) 22,900 watts (with hazardous location flush water heater) 23,400 watts (with optional non-hazardous flush water heater)

load 350-415 VAC, 3-phase models WYE: 40 Amps per phase full load

/min

96 3A2776H

Page 97

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 plating,

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

WPE Mixer Stainless steel housing with stainless elements

Purge Requirements (For Hazardous Models only. Purge air is filtered to instrumentation quality by filters listed above.)

Minimum Purge Time 3 minutes Minimum Purge Flow 4.8 scfm Maximum Air Temperature 104°F 40°C

Approvals

Non-Hazardous Location Models CE, ETL Hazardous Location Models CE, ETL, IECEx, ATEX Pressure Tanks ASME, CE (steel stamped on tanks under blue jacket)

Notes

* Sound pressure measured 3.3 feet (1 meter) from equipment. ** Sound power measured per ISO-9614-2.

3A2776H 97

Page 98

Technical Data

Min: 70 in.

(1780 mm) Max: 84 in.

(2130 mm)

76 in.

(1930 mm)

52 in.

(1320 mm)

ti20268a

Min: 70 in.

(1780 mm) Max: 84 in.

(2130 mm)

38 in.

(965 mm)

104 in.

(2640 mm)

ti20267a

Dimensions

98 3A2776H

Page 99

Notes

3A2776H 99

Page 100

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 workmans hip, 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 H - March 2017

Graco XM 24W626, XM 262869, XM 262945, XM 262943 Operation 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

Ratio Configuration

Configuration Options

Grounding

Connect Power Cord

Set Power Jumpers

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 Hose Bundle Fluid Circulation System

Connect Tank Heat Circulation Hoses

Initial Startup

Prime Flush Pump

Adjust Ratio and System Settings

Verify Desired Ratio Mode

Temperature Settings

Adjust Ratio Set Point

Spray

Flush Mixed Material

Park Metering Pump Rods

Pressure Relief Procedure

System Verification

Pump and Metering Test and Calibration for Ratio by Weight Mode

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

Battery

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

Test Screens

Information Screens

Automatically Displayed Screens

Appendix B - Alarms

Alarms Overview

Alarm Code Troubleshooting

Technical Data

Dimensions