Setup - Operation
WLD
™
XM
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.
EN
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
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)
Related Manuals
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
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
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
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
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
Component Identification
WLE
A
B
C
D
G
H
J
L
M
N
P
R
S
T
U
V
Y
X
K
E, F
C1
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
Component Identification
U
Z
X (located between
metering pumps, not
visible in current view)
W
A1
B1
C1, A1
D1, A1
Hazardous Location
Models only
E1
A1
F1
Typical Setup (Back View)
WLD
FIG. 2
10 3A2776H
Fluid Control Assembly
AA
AC
AG
AL
AE
AJ
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
Component Identification
ti26689a
BB
BD
Hazardous Location System
Non-Hazardous Location System
CA
r_XM1A00_312359_313289_14A
Hazardous Location System
BB
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
Sprayer and Flush Pump Air Controls
CA
CB
CC
CD
CE
CG
CF
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
Component Identification
FEED PUMP
BYPASS
CR
CP
CU
CS
CT
NOTE: Both valves shown open
ti20127a
DF
DB
DA
DC
DD
DE
ti20104a
Feed Module Air Controls
F
IG
. 6: Supply Controls
CP Tank Air Pressure Regulator
CR Tank Air Pressure Gauge
CS Tank Air Supply Valve
CT Agitator and Heated Water Circulation On/Off Valve
CU Feed Pump Bypass Button
Feed Pump 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
User Interface
DA
DB
DD
DE
DF
DG
DH
DK
DP
DN
DM
DC
ti13365a
DR
DJ
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
F
IG
. 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.
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.
F
IG
. 8: Main Display Screen Components (shown with all display features enabled)
16 3A2776H
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
F
IG
. 9
3A2776H 17
Setup
ti20163a
5.5 in. long
2x (115211)
8x
1.5 in. long
(16J674)
ti20197a
3.5 in. long
8x (124869)
8x
1x
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
IG
. 9 then
bolt together the three modules on a flat surface. See
F
IG
. 10 or FIG. 11 for bolt locations. The frame bolts are
included in a bag. Once connected, the assembly can
be moved as one piece with a fork-truck.
NOTICE
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
IG
. 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
IG
. 9 to ensure hoses and cables can reach their
connections.
IG
. 11: Bolt Locations (Front to Back)
F
18 3A2776H
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
2
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).
ti27666a
3A2776H 19
Setup
E
ti20105a
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).
2.
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.
IG
. 12: Non-Hazardous Location Models
F
use pliers to install the three red power
ti27667a
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
3
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-
3
/min).
IG
. 13: Hazardous Location Models
F
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.
ti27668a
20 3A2776H
Setup
a
b
c
e
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
IG
. 15.
d
IG
. 14: Feed Module Lines
F
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
WLE
IG
. 15.
IG
. 15.
IG
.
3A2776H 21
Setup
3UHVVXUH7DQN
6\VWHP)OXVK
+HDWHU
+HDWHU
PS1
TB8
TB9
TB10
TB11
TB12
TB9
TB10
TB11
TB12
&LUFXLW%UHDNHU
A
B
Hose
Tank
Flush
*URXQG
%DU
WLD
e
e
3UHVVXUH7DQN
6\VWHP)OXVK
*URXQG
%DU
&LUFXLW%UHDNHU
WLE
+HDWHU
+HDWHU
e
e
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
F
IG
. 16.
For Hazardous Location Models, Connect heater
power cables (e) for the tanks heater the flush heater to
the terminal blocks. See F
IG
. 17.
F
IG
. 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
Install Level Sensor Probes
WLD
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
IG
. 18
F
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
Setup
ti20106a
ti20272a
ti20273a
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.
IG
IG
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
IG
. 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
IG
. 21.
.
F
IG
. 19
IG
. 21
F
24 3A2776H
Setup
ti20274a
Material Inlets
Flush Inlet
ti20088a
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
IG
. 23.
IG
. 23.
F
IG
. 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
IG
. 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
Setup
ti20090a
R
S
T
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.
F
IG
. 24
IG
. 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
IG
. 25 or FIG. 26.
26 3A2776H
Setup
Side By Side Configuration
See Front to Back Configuration, F
IG
. 4, page 12.
FIG. 25: Heated Fluid Diagram For Tank Heat (Hazardous Location Shown)
3A2776H 27
Setup
Front to Back Configuration
FIG. 26: Heated Fluid Diagram For Tank Heat (Hazardous Location Shown)
28 3A2776H
Prime Heated Fluid Circulation System Continued
FEED PUMP
BYPASS
ti20127a
ti20126a
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
IG
. 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.
F
IG
. 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
Initial Startup
CA
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
3.
For non-hazardous location models:
power switch (BA) ON and verify the system air inlet
ball valve (E) is open. See F
IG
. 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:
4.
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.
IG
. 1 on
Flush Machine (If Required)
5.
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
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