Graco 3A1331C User's Manual
Contents
1. 10 Advisories and Alarms 11 Clear Alarms 11 View Current Alarms 11 View Error Log 12 Error Codes 13 Repair 16 Replace LCM Tear Off Sheet 16 Replace Switch Fuses 16 Replace Filter Element 16 Replace Alternator or Turbine Cartridge 17 Parts 18 Appendix A User Interface Display 22 Setup Mode Details 22 Changing Setup Parameters 22 Setup Screen 1 22 Setup Screen 2 23 Setup Screen 3 24 Set Password 24 Run Mode Details 25 Circulation Mode Active 25 Spray Mode Active 25 Alarm Active 25 Deviation Active 26 Information Screen2. 26 Appendix B Breakout Module Connections 27 Accessories 28 Technical Data 29 Graco Standard Warranty 30 2 3A1331C Overview Topics Covered in this Chapter Operating Window The purpose of the pressure monitor kit is to shutdown the sprayer if abnormal pressure conditions are detected to prevent spraying material that is not mixed on ratio Two pressure transducers are added to read the A and B uid pressures in the outlet manifold and send the readings back to the Local Control Module LCM The control watches the difference between the A and B pressures The control will alarm if the pressures split because of a plug leak or running out of uid When an alarm indicates that the sprayer may be off ratio the air solenoid shuts off the air supply to the proportioner motor The light tower will indicate an alarm has occurred and the alarm code will be on the LCM display For more information see Advisories and Alarms page 11 The following alarms can occur Differential Pressure B gt A Differential Pressure A gt B Pressure A High Pressure B High Air Solenoid Disconnected Pressure A Disconnected Pressure B Disconnected Operating Window Below Minimum Spray Pr
3. J4AX Differential Pressure A gt B Red Solid Improper con guration Adjust setpoints on setup screens See Setup Mode Details page 22 Ran out of A side material Re ll hopper or change drum Cavitating A side pump Warm material or add feed pressure A material leaking Follow pump troubleshooting in XP70 Sprayer manual Too much restriction on mix manifold B side restriction Reduce restriction to B side on mix manifold Bside hose is too small Change to larger diameter hose size No B side offset in control setup Adjust B side offset in setup screens if B normally runs at a higher pressure than A See Setup Mode Details page 22 J4BX Differential Pressure B gt A Red Solid Improper con guration Adjust setpoints on setup screens See Setup Mode Details page 22 Broken cable Replace transducer P6AX Pressure A Disconnected Red Solid Disconnected cable Connect cable 3A1331C 13 Code Icon Code Name Light Tower Code Cause Solution Alarms Broken cable Replace transducer P6BX Pressure B Disconnected Red Solid Disconnected cable Connect cable Broken cable Replace cable Disconnected cable Connect cable WJPX Air Solenoid Disconnected Red Solid Damaged solenoid Replace solenoid P4AX Pressure A High Red Solid A pressure exceeded maximum working pressure set point Reduce air pressure to motor or adjust setpoint
4. 1 56 195551 RETAINER plug adapter 1 57 245202 CORD SET USA 10 ft 3 m 13 AMP 120V 1 58 242001 CORD SET adapter Europe 8 in 20 mm 1 59 242005 CORD SET adapter Australia Asia 8 in 20 mm 1 61 113796 SCREW anged hex hd 3 62 115942 NUT hex ange head 3 63 121261 FUSE 250V 1 2A 2 65 114606 PLUG hole 1 67 113783 SCREW 1 4 20 pn hd 4 68 16H378 SHIELD membrane LCM pack of 10 1 69 114225 TRIM edge protection 0 6 ft 0 18 m 1 70 16J685 LABEL error codes 1 Replacement Danger and Warning labels tags and cards are available at no cost Base electronic components do not have Pressure Monitor speci c software installed Therefore use software upgrade token 21a to install software before use 3A1331C 19 262942 Air Turbine Pressure Monitor Kit Apply sealant to all non swiveling pipe threads Already included on new XP model sprayers 20 3A1331C Ref Part Description Qty 1 262457 BOX assembly 1 2 BRACKET top mount 1 4 15M669 SENSOR pressure uid outlet 2 5 16H600 LIGHT tower M12 12VDC 1 6 BRACKET mounting 1 7 258999 MODULE LCM breakout 1 8 157785 FITTING swivel 3 4 mxf 2 12 100016 WASHER lock 1 4 1 13 121399 O RING 012 solvent resistant 2 14 189930 LABEL caution 1 15 104371 SCREW cap sch 10 x 0 375 9 16 104472 SCREW
5. 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 All written and visual data contained in this document re ects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice Original instructions This manual contains English MM 3A1331 Graco Headquarters Minneapolis International Of ces Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 Copyright 2011 Graco Inc is registered to ISO 9001 Revised 04 2011
6. Already included on new XP model sprayers 18 3A1331C Ref Part Description Qty 1 262457 BOX weldment assembly 1 2 BRACKET top mount 1 3 15M293 POWER SUPPLY 24VDC 2 5A 60W gnd wire 1 4 15M669 SENSOR pressure uid outlet 2 5 15X472 LIGHT TOWER m12 1 6 BRACKET mounting 1 7 258999 MODULE LCM breakout 1 8 157785 SWIVEL 2 9 121254 SWITCH power 120V 1 11 102410 SCREW cap sch 4 12 100016 WASHER lock 1 13 121399 O RING 012 solvent resistant 2 14 189930 LABEL caution 1 15 104371 SCREW cap sch 10X 375 4 16 104472 SCREW cap 10 32 x 1 5 4 17 110755 WASHER plain 1 18 SCREW countersunk 6 32 x 38 2 20 110047 HOSE coupled 18 in 457 2 mm 1 21 24H286 MODULE LCM includes 21a and instructions 1 21a 16G728 TOKEN PM software not shown 1 21b MODULE LCM 1 25 121253 KNOB display adjustment 1 26 119992 NIPPLE 3 4 x 3 4 npt 1 27 111530 MUFFLER 1 28 16G901 VALVE 24VDC internal pilot 3 4 1 Ref Part Description Qty 29 15T859 CABLE assembly DB25 10 ft 3 m 1 30 COVER box 1 31 102063 WASHER lock ext 1 32 108865 SCREW cap button hd 1 33 121806 CABLE solenoid 1 43 122030 CABLE GCA M12 5P 1 47 16H323 GROMMET one slit 1 53 120206 MUFFLER sintered dia 1 8 1 55 116281 CORD SET IEC320 M F 6 ft 1 8 m
7. Icon Function Actual spray pressures Differential pressure alarm bar graph Selected pressure units Indicates that you are in spray mode Indicates that you are in circulation mode Indicates that there is an active alarm Indicates that there is an active deviation Table 7 Display Soft Key Icons Icon Function Enter Screen In screens that have editable elds press to access the elds and make changes Exit Screen In screens that have editable elds press to exit edit mode Enter In screens that have editable elds press to make data selections or to enter changes Right In screens that have editable elds press to move to the right while in a eld Cancel Cancel a selection or edited data Returns to the original data Clear Error Log Clear entire error log 3A1331C 7 Installation Topics Covered in this Chapter Location Install Air Solenoid Install Electronics Box and LCM Install Pressure Transducers Connect Air Hoses and Cables Shutdown the XP Sprayer before installing your pressure monitor kit Follow the Shutdown and Pressure Relief Procedure in the XP Sprayer operation manual All electrical wiring must be done by a quali ed electrician and comply with all local codes and regulations The procedures in this section are speci c to each component of the pressure monitor kit For sprayer installation instructions refer to the XP70 Spra
8. and deviations Icon System Status Indicates that you are in spray mode at least one of the pumps has pressure greater than the lower spray pressure limit and the differential pressure is less that the differential pressure deviation setpoint The green light on the light tower will be solid on Alarm Active This is the run screen that appears during an active alarm A and B pressure are shown The bar across the bottom indicates the magnitude of the differential pressure with respect to the alarm setpoint Refer to the following table for more information Icon System Status Indicates that there is an active alarm The red light on the light tower will be solid on and the system is disabled 3A1331C 25 Deviation Active This is the run screen that appears during an active deviation A and B pressure are shown The bar across the bottom indicates the magnitude of the differential pressure with respect to the alarm setpoint Refer to the following table for more information Icon System Status Indicates that there is an active deviation The yellow light on the light tower will be ashing The air to the motor is on Once the deviation condition no longer exists it automatically generates the Spray Mode Active Run Screen Information Screen The information screen is only available when an alarm deviation or advisory is active It shows the active alarm code and the A and B pressure conditions a
9. cap 10 32 x 1 5 4 17 110755 WASHER plain 1 18 108026 SCREW cap hex button hd 6 32 x 3 8 2 20 110047 HOSE coupled 3 4 npt x 18 in 457 2 mm 1 21 24H286 MODULE LCM includes 21a and instructions 1 21a 16G728 TOKEN PM software not shown 1 21b MODULE LCM 1 22 15B565 VALVE ball 1 23 114314 WASHER plain 2 24 172953 LABEL ground 1 25 121253 KNOB display adjustment 1 26 119992 NIPPLE 3 4 x 3 4 npt 1 27 111530 MUFFLER 1 28 16H550 VALVE 12VDC internal pilot 3 4 1 29 15T859 CABLE assembly DB25 10 ft 3 m 1 30 COVER box 1 31 C38163 WASHER lock ext tooth 1 32 103833 SCREW machined crbh 1 Ref Part Description Qty 33 121806 CABLE solenoid 1 34 262579 MODULE alternator M12 non IS 1 34a 193154 GASKET alternator 1 34e 257147 CARTRIDGE alternator 1 35 119644 FILTER REGULATOR 3 8 npt auto drain 1 35a 11228 ELEMENT lter 5 micron 1 36 108190 GAUGE pressure air 1 37 121858 ELBOW 3 8 nptm x 1 4 nptm 1 38 125385 VALVE safety regulator 1 39 114153 ELBOW male swivel 1 40 054175 TUBE nylon rd 1 4 0 6 ft 0 18 m 1 41 C12508 TUBING nylon round 3 8 4 ft 1 2 m 1 42 248208 HOSE coupled 6 ft 1 8 m 1 4 npsm 5 16 1 43 122030 CABLE M12 5P m x f 20 in 508 mm 1 47 16H323 GROMMET one slit 1 53 120206 MUFFLER
10. eld The following table explains the error type that is associated with the particular light tower LED Light Tower LED Description Green Solid System is powered up and monitoring pressure Yellow Solid In Circulation Mode or Manual Bypass Mode Yellow Flashing A deviation exists Red Solid An alarm exists and the system shuts down Clear Alarms Fore more information about the alarms see Information Screen page 26 To clear an error 1 Press to clear the alarm 2 Press to restart the air motor View Current Alarms From the Run screen press to navigate to the Information screen The Information screen displays current alarms or advisories Figure 11 3A1331C 11 View Error Log Setup Screen 3 is the error log screen It displays the most recent error on the top of the list with the past three errors below it This screen displays a list of advisory or alarm error codes and the time the error occurred since the kit was powered on 12 3A1331C Error Codes Code Icon Code Name Light Tower Code Cause Solution Alarms Ran out of B side material Re ll hopper or change drum Cavitating B side pump Warm material or add feed pressure B material leaking Follow pump troubleshooting in XP70 Sprayer manual No mix manifold B side restriction Add restriction to B side on mix manifold to balance pressures A side hose is too small Change to larger hose size
11. sintered dia 1 8 1 61 113796 SCREW anged hex hd 1 4 20 3 62 115942 NUT hex ange head 1 4 20 3 66 158962 ELBOW st pipe rdcg 1 67 113783 SCREW 1 4 20 pn hd 4 68 16H378 SHIELD membrane LCM pack of 10 1 69 114225 TRIM edge protection 0 6 ft 0 18 m 1 70 16J685 LABEL error codes 1 Replacement Danger and Warning labels tags and cards are available at no cost Base electronic components do not have Pressure Monitor speci c software installed Therefore use software upgrade token 21a to install software before use 3A1331C 21 Appendix A User Interface Display Topics Covered in this Chapter Setup Mode Details Run Mode Details Information Screen Setup Mode Details Setup mode screens enable user to view or modify system con guration data User can set Units of pressure Differential pressure warning value Differential pressure alarm value High pressure limit value Minimum spray pressure value Normal B pressure offset value Changing Setup Parameters 1 Navigate to a Setup screen by pressing Then use to select a screen 2 Press to access elds and make changes 3 Press to navigate to the eld that you want to change Press to edit data 4 Press to select digits 5 Press to accept the new values or press to cancel 6 Press to exit edit mode Setup Sc
12. two nuts 62 to mount the electronics box to the top of the cart b Use a marker to mark the bracket s third mounting hole c Loosen the nuts 62 below the cart shelf and remove the screws 61 and box bracket Center punch and drill a 5 16 in hole in the top of the cart 2 New XP carts with three mounting holes a Use three screws 61 and three nuts 62 to mount the box bracket to the cart b For power supply kits install the appropriate power supply cord s US European and Australia Asia cord adapters are supplied See Technical Data page 29 Early XP Cart Installation Figure 9 Install Pressure Transducers 1 Remove plugs from the circulation manifold Note Keep plugs if you will ever remove the pressure monitor kit 2 Connect pressure transducer 4 with blue 6 label with black o ring 13 to the A side of the circulation manifold Connect pressure transducer 4 with red 7 label with black o ring 13 to the B side of the circulation manifold Tighten to 40 50 ft lb 54 67 N m before applying uid pressure Pressure Transducers Figure 10 3A1331C 9 Connect Air Hoses and Cables Reference 262940 Line Power Kit page 4 and 262942 Air Turbine Kit page 5 for air hose and cable connections Use tie wraps provided to secure hose and cables For turbine kit 262942 route exhaust hose down cart leg and secure 262942 Secure solenoid cable F to air hoses with t
13. 2 In Manual Bypass Mode the system can never get into Spray Mode The event code EVC1 is displayed on the information screen and logged in the error log The yellow light is always on and all alarms are ignored b To exit Manual Bypass Mode set the mimimum spray pressure and maximum spray pressure to different spray pressures Event code EVC0 will log in the error log when Bypass Mode is disabled 6 Press to start the air motor The red LED will turn on and the motor will start Only spray when the green light on the light tower is on For more information about the LCM run screens see Run Mode Details page 25 Shutdown 1 Press The red LED will turn off and the motor will stop 2 Turn off the power switch or ball valve on the outside of the electronics box 10 3A1331C Advisories and Alarms Topics Covered in this Chapter Clear Alarms View Current Alarms View Error Log Error Codes There are three types of errors that can occur Errors are indicated by the light tower as well as on the display Alarms indicated by require immediate attention therefore the control disables the air motor and the Information screen automatically displays Deviations indicated by require attention but not immediately Advisories indicated by do not require attention Therefore if a deviation or advisory occur the system continues running and or displays next to the operation mode
14. 6 Blue C B Pressure Transducer 7 Red D LCM Cable 1 Blue E Solenoid Extension Cable 3 Red F Solenoid Cable 3 Red G Light Tower 4 Green Table 2 System Component Identi cation Table Ref System Component SA XP Motor Air Controls reference SB Local Control Module LCM SC Power Entry Fuses and Switch SD Motor Air Solenoid Valve 24 Volt SE Power Supply 24 Volt SF Light Tower 24 Volt SG XP Air Inlet Assembly reference SH Breakout Module SJ XP Fluid Manifold reference SL Motor Air Hose 4 3A1331C 262942 Air Turbine Kit SA SD SG SB SF F D SJ SH C B G SL J H SN E A H SM SK Figure 2 Table 3 Cable Identi cation Table Ref Cable Identi cation Label A Power Supply CAN B A Pressure Transducer 6 Blue C B Pressure Transducer 7 Red D LCM Cable 1 Blue E Solenoid Extension Cable 3 Red F Solenoid Cable 3 Red G Light Tower 4 Green H Air Tubing J Air Exhaust Table 4 System Component Identi cation Table Ref System Component SA XP Motor Air Controls reference SB Local Control Module LCM SD Motor Air Solenoid Valve 12 Volt SF Light Tower 12 Volt SG XP Air Inlet Assembly reference SH Breakout Module SJ XP Fluid Manifold reference SK Turbine Air Regulator SL Motor Air Hose SM Air Powered Alternat
15. A code Lamp 1 Green Digital Output 4 Phoenix Contact Part Number 1542761 Lamp 2 Yellow Digital Output 2 Not Used 1 Digital Output Ground 3 Lamp 3 Red Digital Output 5 A Pressure Transducer 6 Blue Pin Description Pin Number M12 Connector 5 pin Female B code Pressure Differential Analog Input 4 Phoenix Contact Part Number 1543650 Pressure Differential Analog Input 2 Pressure Power 5 volt 1 Pressure Ground 3 Shield Analog 5 3A1331C 27 B Pressure Transducer 7 Red Pin Description Pin Number M12 Connector 5 pin Female B code Pressure Differential Analog Input 4 Phoenix Contact Part Number 1543650 Pressure Differential Analog Input 2 Pressure Power 5 volt 1 Pressure Ground 3 Shield Analog 5 Accessories 16G410 Pressure Transducer Tee Adapter For using the pressure transducers on systems other than a XP Sprayer 303 stainless steel 7250 psi 50 MPa 500 bar 1 4 npt f x 3 8 npt f 11 16 24 transducer mount on branch of tee 16J717 Protective Bag If the pressure monitor kit will be outside use the protective bag for weather and over spray protection 28 3A1331C Technical Data Pressure Transducers Fluid pressure range 50 7250 psi 3 500 bar Power requirements for model 262940 Voltage 90 260 VAC Frequency 50 60 Hz Phase 1 Amps 1 Compressed air requirem
16. Instructions Parts 3A1331C XP Pressure Monitor Kit ENG Monitors pressures to provide ratio assurance on XP plural component sprayers For professional use only Not approved for use in explosive atmosphere locations Important Safety Instructions Read all warnings and instructions in this manual and the XP sprayer operation manual Save these instructions Models 262940 Line Power Pressure Monitor Kit with Light Tower 262942 Air Turbine Power Pressure Monitor Kit with Light Tower PROVEN QUALITY LEADING TECHNOLOGY Contents Overview 3 Operating Window 3 Component Identi cation 4 262940 Line Power Kit 4 262942 Air Turbine Kit 5 User Interface 6 Display Components 7 Installation 8 Location 8 Install Air Solenoid 8 Install Electronics Box and LCM 9 Install Pressure Transducers 9 Connect Air Hoses and Cables 10 Startup 10 Shutdown
17. Reduce air pressure to motor or adjust setpoint A pressure exceeded maximum working pressure set point Open down stream valve Reduce downstream restriction P4BX Pressure B High Red Solid Blockage in B line downstream Clean mix manifold Remote mix manifold applications only 14 3A1331C Code Icon Code Name Light Tower Code Cause Solution Deviations Ran out of B side material Re ll hopper or change drum Cavitating B side pump Warm material or add feed pressure B material leaking Follow pump troubleshooting in XP70 Sprayer manual No mix manifold B side restriction Add restriction to B side on mix manifold to balance pressures J3AX Differential Pressure A gt B Yellow Flashing A side hose is too small Change to larger hose size Ran out of A side material Re ll hopper or change drum Cavitating A side pump Warm material or add feed pressure A material leaking Follow pump troubleshooting in XP70 Sprayer manual Too much restriction on mix manifold B side restriction Reduce restriction to GB side on mix manifold B side hose too small Change to larger hose size J3BX Differential Pressure B gt A Yellow Flashing No B side offset in control setup Add B side offset in setup screen Events and Advisories EERX Under Minimum Spray Pressure Circulation Loading Yellow Under minimum spray pressure Normal for ci
18. SS 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 r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es 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
19. cond column lists the errors codes See Error Codes page 13 Maximum 99 Time The third column shows the time that the error occurred since the unit was last powered on The time will always start at 0 00 when the system is powered up This time will be logged as code ELCX Format Hours Minutes Maximum 999 59 Reset Press the Reset icon to clear the entire error log Set Password Note When the password is 0000 the setup screens can be accessed without entering a password 1 Navigate to setup screen 2 2 Press to access elds to make changes 3 Press to navigate to the password eld Press to edit data 4 Press and to increment or decrement to the desired digits of the password 5 Press to accept the password or press to cancel 6 Press to exit edit mode Note The password screen is shown when the setup screens are accessed and the password function has been enabled by changing the 0000 password Figure 18 If you set and forget the password please contact Graco Technical Assistance for a default password 24 3A1331C Run Mode Details There are four Run Screens Circulation Mode Active Spray Mode Active Alarm Active and Deviation Active Circulation Mode Active This is the run screen that appears after the power up screen A and B pressure are shown The bar across the bottom indicates the magnitude of the differential pressure with respec
20. ee Set Password page 24 Range 0 9999 Icon Function B Side Pressure Offset Default 0 psi Range 999 to 999 psi Only used for remote mix manifold applications where there is a normal difference in pressure between A and B Remote mix manifold applications should rst be balanced with proper hose sizing and adjusting the mix manifold B restrictor See manual 3A0590 Use if your differential alarm bar graph on the Spray screen is off to one side under normal spray conditions See B Side Pressure Offset Example B Side Pressure Offset Example In normal spray conditions the B pressure is 300 psi above the A pressure The bar graph is offset to one side Enter a B offset pressure of 300 psi Now the bar graph Is centered The differential pressure alarm now sees no differential when the B pressure is 300 psi higher than the A pressure If the B pressure was normally 300 psi lower than the A pressure you would enter 300 psi to balance the offset 3A1331C 23 Setup Screen 3 Setup screen 3 enables users to scroll through all errors and clear the entire error log The error log will display the most recent error on the top of the list Refer to the following table for more information Icon Function Error Number The rst column lists the error number Once the system has more than the maximum errors allowed then the oldest error will be over written Maximum 99 Error Code The se
21. ents for model 262942 Minimum air supply pressure 40 psi 2 75 bar Maximum air supply pressure 150 psi 10 3 bar Air Consumption 6 scfm Turbine air pressure set point pre set inside box 25 psi 1 72 bar Certi cation CE When an Electrostatic Discharge ESD is applied to the display the screen might clear Turn the power supply off and on or turn the turbine off and on 3A1331C 29 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 accessorie
22. er 30 3 Press silver tab in twist bowl to the left and pull down off of the regulator 4 Remove and replace element 5 Screw lter bowl on securely until the tab clicks Figure 14 16 3A1331C Replace Alternator or Turbine Cartridge For 262942 only Turbine alternator cartridge 257147 34e can be replaced in alternator 262579 34 1 Turn off air supply 2 Close ball valve 22 3 Remove box cover 30 Figure 15 4 Disconnect the alternator power supply cable A from the LCM 21 Disconnect ground wire Z 5 Disconnect air tube 40 from the alternator 34 6 Remove two screws 15 to remove alternator from the box 1 7 Remove four screws 34d to separate alternator housings 8 Disconnect turbine cartridge ribbon connector 34e from board AB 9 Replace gasket 34a if damaged Place between housings before securing with screws 34d 10 Reassemble Note Lightly lubricate turbine o ring before installing turbine in housing Align ribbon connector and rmly press the cartridge into the top housing Connect turbine to 3 pin connector on main circuit board Torque housing screws evenly to 18 in lbs 2 N m Reassemble into control box 1 A Z Figure 16 34d 34a 34e AB Z Figure 17 3A1331C 17 Parts 262940 Line Power Pressure Monitor Kit Apply sealant to all non swiveling pipe threads
23. essure The air motor is allowed to automatically operate in Circulation Mode with a yellow light anytime the uid pressures are below the minimum spray pressure This allows for loading the system and circulating the uids without alarms or shutdowns Above Minimum Spray Pressure When the control sees the uid pressures above the minimum spray pressure for 3 30 seconds and the pressures are balanced within the pre set limits it will automatically start the monitor mode and the green light on the light tower will change to solid on If the control does not see balanced pressures within 30 seconds of going above the minimum spray pressure it will alarm and shut off the air motor The default minimum spray pressure is 2000 psi 14 MPa 138 bar Enter Setup Mode to change the minimum spray pressure as necessary Maximum Spray Pressure The control will alarm and shutdown if it sees either A or B above the maximum working pressure of 7250 psi 50 MPa 500 bar Enter Setup Mode to reduce the maximum allowable pressure set point 3A1331C 3 Component Identi cation Topics Covered in this Chapter 262940 Line Power Kit 262942 Air Turbine Kit User Interface 262940 Line Power Kit SA SD SG SB SE SF SC F D A SJ SH C B G SL E Figure 1 Table 1 Cable Identi cation Table Ref Cable Identi cation Label A Power Supply CAN B A Pressure Transducer
24. ie wrap Route exhaust hose J down the inside of the cart leg and secure with tie wrap 262940 Route solenoid cable F behind the air hose and secure with tie wrap Startup 1 Refer to your XP Sprayer Operation manual for sprayer startup instructions Note The pressure monitor kit modi es XP sprayers However the operation procedures from the XP sprayer Operation manual still apply 2 Turn on power a For 262940 Turn on power switch 9 located on the electronics box b For 262942 Open ball valve 22 located outside of the electronics box 3 Wait for the power up screen to complete The Circulation Mode screen will display The light tower will brie y ash green yellow and red to verify the lights before staying on yellow Wait for the run screen to appear 4 Set system parameters before spraying These can be changed as necessary Press to enter Setup Mode For more information and default settings see Setup Mode Details page 22 5 In Circulation Mode all alarms are disabled except for the air solenoid detection pressure sensor failure and high pressure alarms Note In Manual Bypass Mode you can still spray when one pressure transducer fails but the control no longer monitors the pressures and will not shut off the sprayer This is for emergency only a To enter Manual Bypass Mode set the minimum spray pressure equal to the maximum spray pressure on setup screen
25. or 12 Volt SN Alternator Power Shutoff Valve 3A1331C 5 User Interface Figure 3 NOTICE To prevent damage to soft key buttons do not press the buttons with sharp objects such as pens plastic cards or ngernails Table 5 LCM Button Functions Button Function Mode Select between Run and Setup Modes Spray Start and stop the air motor The motor will stay on inde nitely if pressures are below minimum spray pressure Monitor mode will start within 30 seconds if the pressures are above the minimum spray pressure and no errors exist All errors are ignored for up to the rst 30 seconds Default is 2000 psi 138 MPa 138 bar Arrows Up Down Navigate up or down within a screen or to a new screen Soft keys activate the mode or action represented by the icon next to each soft key See Table 2 for soft key icons and actions Top Soft Key Edit data accept edited data or move right within a number eld Soft Keys Bottom Soft Key Enter a screen exit a screen or cancel edited data 6 3A1331C Display Components The following tables identify components shown on the spray mode active circulation mode active alarm active and deviation active run screens For more information see Run Mode Details page 25 Spray Mode Active Screen Figure 4 Circulation Mode Active Screen Figure 5 Alarm Active Screen Figure 6 Deviation Active Screen Figure 7 Table 6 Display Components
26. rculation mode EVC0 Manual Bypass Mode Enabled and Logged Minimum Pressure Maximum Pressure Yellow Manual Bypass Mode Reset minimum spray pressure and maximum spray pressure in Setup Mode EVC1 Manual Bypass Mode Disabled and Logged Event log only ELCX Control Power Up Timer set to zero in Log Event log only Remote mix manifold applications only 3A1331C 15 Repair Topics Covered in this Chapter Replace LCM Tear Off Sheet Replace Switch Fuses Replace Filter Element Replace Alternator or Turbine Cartridge For system speci c repair procedures refer to your XP Sprayer instructions parts manual Replace LCM Tear Off Sheet The LCM is supplied with 10 protective tear off sheets that prevent spray material from covering the LCM display 1 Peel away the dirty protective sheet 2 Install a new protective sheet 68 on the LCM display Figure 12 Replace Switch Fuses For 262940 only 1 Remove power inlet cord 55 or 57 2 Pry off small plastic cover above cord inlet 3 Pull fuses 63 out of power switch Replace and reassemble Figure 13 Replace Filter Element There is a 5 micron air lter used with the regulator on the alternator power kit 262942 Check the lter monthly and replace element as needed 1 Close main air shutoff valve on air supply line and on unit Depressurize air line 2 Remove box cov
27. reen 1 Setup screen 1 enables users to set units of measurement that will display on other screens differential warning and differential alarm Additionally this screen displays the software number and version Refer to the following table for more information Icon Function Warning Pressure Adjust the differential pressure deviation setpoint The yellow light on the light tower will be ashing Default 400 psi Range 0 2000 psi Alarm Pressure Adjust the differential pressure alarm setpoint The red light on the light tower will be solid on This is the main setting that determines how far apart your A and B pressures can be before shutting down the machine If the machine shuts down too easily increase this to a higher setpoint Default 600 psi Range 0 2000 psi 22 3A1331C Setup Screen 2 Setup screen 2 enables users to set the high spray pressure alarm limit value minimum spray pressure value and B pressure offset Refer to the following table for more information Icon Function High Pressure Limit Adjust the high pressure limit Default 7250 psi 14 MPa 138 bar Range 0 7250 psi 50 MPA 500 bar maximum Minimum Spray Pressure Limit Adjust the lower spray pressure limit Default 2000 psi 14 MPa 138 bar Range 0 7250 psi 50 MPA 500 bar maximum Password The setup screens can be protected by a password to restrict their accessibility To set the password s
28. s 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 veri cation of the claimed defect If the claimed defect is veri ed Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost pro ts 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 FITNE
29. t the time of the alarm if applicable If the alarm condition occurs while on the run screen the information screen is automatically generated The red light on the light tower will be solid on Refer to the following table for more information Icon System Status Indicates that there is an active alarm The red light on the light tower will be solid on and the system is disabled Indicates that there is an active deviation The yellow light on the light tower will be ashing Indicates that there is an active advisory The yellow light on the light tower will be solid on Active Alarm Code See Error Codes page 13 26 3A1331C Appendix B Breakout Module Connections The following provides descriptions and pins of all connectors used on the breakout module These can be used if the components are being wired directly to the breakout module LCM Power Cable 1 Blue Pin Description Pin Number M12 Connector 5 pin Female A code Shield 1 Phoenix Contact Part Number 1694224 Power 12 V or 24 V 2 Ground 3 CAN 4 CAN 5 Solenoid Air Connector 3 Red Pin Description Pin Number M12 Connector 5 pin Female A code Solenoid Air Digital Output 4 Phoenix Contact Part Number 1542761 Not Used 2 Not Used 1 Digital Output Ground 3 Not Used 5 Light Tower Connector 4 Green Pin Description Pin Number M12 Connector 5 pin Female
30. t to the alarm setpoint In Circulation Mode all alarms are disabled except for the Air Solenoid Detection High Pressure A and High Pressure B alarms If the user needs to spray with one of the above errors active set the Lower Spray Pressure Limit equal to the High Pressure Alarm Limit to enter Manual Bypass Mode Only use Manual Bypass Mode for emergency operation The control no longer monitors the pressures and will not shut off the sprayer Icon System Status Indicates that you are in Circulation Mode and the uid pressure is below the Lower Spray Pressure Limit All alarms are disabled except for Air Solenoid Detection High Pressure A and High Pressure B alarms The yellow light on the light tower will be solid on This screen will also be used when in Manual Bypass Mode Note All alarms and deviations are ignored in Bypass Mode You will be allowed to spray bad material The yellow light will be solid on Spray Mode Active This is the run screen that appears during spray mode A and B pressure are shown The bar across the bottom indicates the magnitude of the differential pressure with respect to the alarm setpoint When the pressure rst gets above the lower spray pressure limit the user has 30 seconds to balance the system differential pressure so it is less that the differential pressure deviation and alarm limits Then the system will automatically go into Spray mode and start monitoring all alarms
31. yer Operation manual Location These pressure monitoring kits are not approved for use in hazardous atmosphere locations Installing this kit on a XP Sprayer that is EX approved voids the approval The EX mark should be removed from the machine ID plate when this kit is installed NOTICE Do not store a XP Sprayer with a pressure monitor kit outside in the rain Use protective bag 16J717 to prevent damage to the electronic components used with the pressure monitor kit when stored outside Install Air Solenoid 1 Disconnect the upper swivel and remove the motor air line from the lower air manifold Note On early XP sprayers to remove the existing air hose it may be necessary to remove the air lter assembly from the XP and put it in a vice New models XP sprayers have an additional hose union 2 For the turbine powered kit 262942 remove a plug from the air manifold and install the 5 16 in x 4 ft 1 2 m air hose Figure 8 3 Connect the air solenoid valve and new motor air hose to the air inlet assembly Ensure that the air solenoid valve cable faces the back of the machine 8 3A1331C Install Electronics Box and LCM Early XP carts have two mounting holes and new XP carts have three mounting holes Complete steps 1 and 2 to drill a third mounting hole for the pressure monitor kit Complete step 2 if you have a new XP cart 1 Early XP carts with two mounting holes a Use two screws 61 and
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