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Graco 312359J User's Manual

1. 62 8 in 1595 1 mm 38 4 in 975 4 mm 56 2 in ti21283a 1427 5 mm 312359J 81 Dimensions System Dimensions with Hoppers One 20 Gallon Hopper and One 7 Gallon Hopper 1841 5 mm B s T d 70 0 in 1788 0 mm e oe TET 1094 7 mm as ce Two 7 Gallon Hoppers 70 0 in 1788 0 mm 33 4 in 848 4 mm Secr Mns gt ti21284a 1516 4 mm 82 312359J Pump Performance Charts Pump Performance Charts Calculate Fluid Outlet Pressure Calculate Pump Air Consumption To calculate fluid outlet pressure MPa bar psi ata specific To calculate pump air consumption m min or scfm at a spe fluid flow Ipm gpm and operating air pressure MPa bar psi cific fluid flow Ipm gpm and air pressure MPa bar psi use use the following instructions and pump data charts the following instructions and pump data charts 1 Locate desired flow along bottom of chart 1 Locate desired flow along bottom of chart 2 Follow vertical line up to intersection with selected fluid 2 Follow vertical line up to inte
2. 1 Insert USB flash drive into USB port DR Use only Graco recommended USB flash drives see Rec ommended USB Flash Drives page 75 NOTE Inserting the USB flash drive while the sprayer is run ning will stop sprayer operation 312359J 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 M while in process Wait for USB icon to stop flashing and then remove USB flash drive 3 The USB icon stops flashing when download com pletes The box below displays w which indi cates the download was successful 4 Remove USB flash drive from USB port DR Ww Never leave USB flash drive in 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 312359J Download Data from USB 7 Open Graco folder 8 Open sprayer folder If downloading data from more than one sprayer there will be more than one sprayer folder Each sprayer folder is labeled with the corresponding USB serial number 9 Open DOWNLOAD folder 10 Open folder labeled with the highest number The highest number indicates the most recent data download 11 Open log file Log files open in Microsoft Excel by default However they
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4. 38 Shutdown Entire System 39 System Verification 40 Mix and Integration Tests 40 Pump and Metering Test 40 Batch Ratio Dispense Test 43 Down Stream Valve Leak Test 44 XM Setup and Troubleshooting Guide 45 Empty and Flush Entire System new sprayer or end of job 46 Download Data from USB 48 USB LOGS uut ere DELE QUO EAE Jed an aes 48 Download Setup less 48 Download Procedure 0005 48 Maintenance uus ki cw ed pacc ORC rr C 50 PUOI S ciii be dictos aot acp a d ed Gre gets ae 50 zIII MMC P 50 Cleaning Procedure 000005 50 PIOUS et ctc dara oie ch bsec o AUR Et C mde 51 View Alarms cee ee eee 51 Diagnose Alarms eee 51 Clear Alarms llle 51 Alarm Codes and Troubleshooting 52 LED Diagnostic Information 58 Accessories and Kits 59 Appendix 2x4 xu nuUa RR ndn Inh peewee et 61 User Interface Display 61 Setup Mode Screens 00 02 eae 62 Operator Command Functions Screens 69 Auto Display Screens 75 APPENA B sedrer rubr incR x aW Pe Ra aS 77 Metering Diagrams LL 77 ADDendiX C uuo iuueni bu rion Sn ceed wt naa 79 Power Cord Guidelines 79 DIM
5. 09 16 11 14 59 Ss oO ag 250cc H FOUL qoe zn cc Tu E OO eer TE 65 Appendix A Enable Setup Screens Enable Setup allows users to enable and disable func tionalities screens and USB download log files Checked boxes indicate the function screen or log file is active Refer to the following table for details To enable and disable functionalities screen and USB log files press VN from the Home Setup screen Once in the Enable Setup screen press n and gt to scroll through each subscreen Press A and v to scroll through each field within the sub screens and press i to enable or disable each x Press to return to the Home Setup screen USB data download function Disable this function to prevent operators from chang ing USB settings NOTE Even if this function is disabled selected USB logs will still be downloaded Enable or disable totalizer screens LEEEE 5 E345 Enable or disable batch totalizer clear func pogga tion Display potlife timer on all screens fe Enable or disable potlife timer setup screen rt Display flow rates on run screens ivy O Display A and B pressures on run screens Display A and B temperatures on run l Screens Enable or disable ability to change pump t size in system setup screens Enable or disable ratio screen If enabled A B ratio screen will automatically display after sprayer runs for 10 seconds Enable or di
6. Press 2 and Y to select preferred units of mea surement for the potlife timer and length of each mixed material hose Press n and me to move to the next digit in each field Once the measurement unit in the field is correct press to save that measure ment When the fluid flow stops the displayed time counts down in one minute intervals The timer automatically resets when the calculated mixed fluid volume is dis pensed Date Time Units This screen enables users to set day time and units that will be displayed on each screen Mi DD E germis 03 16 09 t osi 13 30 t B 312359J System Number and USB Settings This screen enables users to set the sprayer number if using more than one sprayer It also enables users to configure the number of hours downloaded to external USB flash drive and how often the data will record See Set System Settings Optional page 24 for instruc tions 09 16 11 14 58 I oO 8 250cc H 2e aware d 312359J Appendix A Pump Configuration Users can change the pump size that is specific to the system if the pump box is selected on Enable Setup 1 page 66 NOTICE Changing the pump size settings may cause the system to spray off ratio Set Pump Sizes To change the pump size press and Y to select the field Press 4 to open the drop down field Press 2 and v to select the preferred pump size Press again to save the change
7. Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion point symbol alerts you to a general warning and the hazard symbol refers to procedure specific risk Refer back to these warnings Additional product specific warnings may be found throughout the body of this manual where applicable FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and explosion e Use equipment only in well ventilated area e Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present Ground all equipment in the work area See Grounding instructions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem Keep a working fire extinguisher in the work area Do not connect USB device in explosive atmospheres SPECIAL CONDITIONS FOR SAFE USE e To prevent the risk of electrostatic sparking the equipment s non metallic parts must be cleaned with only a damp cloth e Refer to the Viscon
8. aatis 12345 pono Maintenance 2 Screen View number of days between changing the main incoming air filter before a reminder advisory is issued Reset Maintenance Counter 1 Press 4 and v to scroll through and select the maintenance field to reset 12345 2 Press E2299 to reset the maintenance counter to Zero 312359J Auto Display Screens Potlife Screen The potlife screen automatically displays when a potlife advisory occurs The screen automatically closes when the advisory end or the user presses the flush confirm button Refer to the following table for more details 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 d Press to confirm that mixed hose has been Au flushed Resets potlife timer O04 4 09 Uga L OL um A USB Screen The USB screen automatically displays and the selected log s automatically starts downloading when the USB flash drive is inserted into the control box NOTE Inserting the USB flash drive while the sprayer is run ning automatically stops 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 fo
9. see Download Setup page 48 This log can hold up to 18000 lines of data NOTE Once the spray log is full new data automatically over writes old data NOTE After data in the spray log is downloaded it remains in the USB module until it is overwritten Alarm Log 2 The alarm log records all alarm codes generated over a two year period This log should be used for trouble shooting purposes and cannot be deleted This log can hold up to 73000 lines of data Data Log 3 The data log records every 120 seconds all data that occurs during spray mode over a two year period This log should be used for troubleshooting purposes and cannot be deleted This log can hold up to 84000 lines of data NOTE The 120 second recording period cannot be adjusted 48 Download Setup Navigate to the System Setup screen Change the num ber of hours of recorded data to download default is 768 hours by pressing A and v to move to rd Press to make the field selectable Press gt to scroll through each digit Press i to save the new digit Follow the same procedure to change the time interval at which data will record default is 60 seconds Exit the System Setup screen DS 15 11 14 58 kra Tm eel 00 060 sec lt mM COO vee hr i H a Ee Download Procedure Aw Remove sprayer from hazardous location or remove the hazard before inserting downloading or removing USB flash drive
10. Assembly cuo 14 312359J Fluid Control Assembly a Component Identification us Fic 3 Fluid Control Assembly AA Dosing Valve A AB Dosing Valve B AC Recirculation Valve A AD Recirculation Valve B AE Sampling Valve A 312359J AF AG AH AJ AK AM AK r XM1A00 312359 313289 18A Sampling Valve B Hestriction Valve Mix Manifold Shutoff Check Valve A Mix Manifold Shutoff Check Valve B Solvent Shutoff Valve Pressure Sensor Solvent Check Valve 15 Component Identification Junction Box Heater Controls BC BE BD Fic 4 Junction Box Heater Controls BA Main Power Disconnect Switch BD Hopper Heater A Control BB Fluid Heater A Control BE Hopper Heater B Control BC Fluid Heater B Control Air Controls
11. HP Heater manual for special conditions for safe use ELECTRIC SHOCK HAZARD 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 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 4 312359J 312359J Warnings INTRINSIC SAFETY Intrinsically safe equipment that is installed improperly or connected to non intrinsically safe equipment will create a hazardous condition and can cause fire explosion or electric shock Follow local regula tions and the following safety requirements e Only models with model number XM D or XM E _ and packaged models with part numbers ending in 00 13 17 23 27 29 31 utilizing the air driven alternator are approved for installation in a Hazardous explosive atmosphere Location see Approvals page 8 Only the models stated above meet all local safety fire codes including NFPA 33 NEC 500 and 516 and OSHA 1910 107 To help prevent fire and explosion e Do not install equipment approved only for a non hazardous location in a hazardous location See model ID label for intrinsic safety rating of your model e Do not substitute system components as this may impair intrinsic safety Equipment that comes in contact with the intrinsically safe terminals must be rated for Intrinsic
12. box to turn them on To adjust heater temperature refer to the Viscon HP manual for instructions and the Heat Fluid section page 31 IL TIL SED Fluid Heater B Fluid Heater A ti21275a 2 Close recirculation valves and mix manifold flush valve Open mix manifold valves A blue and B green Resin Hardener Circulate Circulate Resin Hardener Valve Valve Blue Green 32 3 Adjust pump air regulator to 30 psi 0 21 MPa 2 1 bar 4 Select p Press o 5 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 Dispense flush solvent out of mix hose until a well mixed coat ing flows from the gun T11950a T11953a Engage trigger lock Install tip on gun e gt T1949a 7 Adjust air regulator CD to the necessary spraying pressure and apply coating to a test panel Look at ratio screen to ensure it is reading the correct ratio Also look at bar graph to ensure mix manifold restriction adjustment is within optimal range Refer to Batch Ratio Dispense Test page 43 and Adjust B Machine Outlet Restriction page 33 8 Follow Flush Mix Manifold page 36 or Park Fluid Pump Rods page 38 when you are finished spray ing or before potlife expires NOTE Mixed material potlife or working time decreases with increased temperature Po
13. following table as a quick guide to determine alarm codes F Hw B Dein B MaeiB N Time 8 DeonHg C Cowoe P Pressue 4 Hm o D DesmgPoie R Rao S umtwanng M PowerorArsuply v ors 9 Unbatencea Sd LL D_ pump YA Pump unaway 1 p Pump divingicavitation SSS fe Pump timeout S SS YF Pump faitediostatup ie JPwwetieosaldu G YR jwetitsal YS esewohue YK Jeoniswehtue SPS LM dunearsensorjmp LLL Wo wantenance due A Pump a E Jsgwe e Be 1 1 LED Diagnostic Information The following LED signals diagnosis and solutions are the same for the display module fluid control module and USB module LEDs are located next to the module power cable System is powered up and power supply voltage is greater than 1 1 Vdc Yellow Internal communication in progress I Red solid Hardware failure Replace display module fluid control module or USB module Red flashing fast Uploading software BY Red flashing slow Token error Remove token and upload software token again 58 312359J Accessories and Kits iw A Not all accessories and kits are approved for use in hazardous locations Refer to the specific accessory and kit manuals for approval details 20 Gallon Hopper Kit 255963 One complete double wall 20 gallon hopper See man ual 312747 for more information Hoppe
14. indicating which side has a leak 312359J System Verification XM Setup and Troubleshooting Guide The following setup information will help ensure the system is setup properly See the XM repair parts manual for trouble shooting and repair instructions Grounding e Ground system to a true earth ground e Ensure incoming power is grounded Air Supply e Use at least a 3 4 in 19mm ID air hose no longer than 50 feet 15m e Ensure the first gauge supply stays above 80 psi 0 55 MPa 5 5bar while spraying e Ensure that the pump spray pressure regulator is set to at least 35 psi 2 4 bar for spraying e Ensure that the solenoid air filter regulator behind the air panel is set to at least 80 85 psi e Check that the air filter element in the solenoid air fil ter regulator behind the air panel is clean Calibration e Adjust the B side fluid restrictor so that the calibration bar graph averages center to right middle This means that the B dosing valve is open 25 to 75 of the time e Ensure dosing valve needle packing nuts are not adjusted too tight They should be snug when there is no fluid pressure on the valve e f feed pumps are used don t use more than 250psi 17 bar Excess pressure adds double the amount of pressure on only the upstroke of the XM metering pump Motor Icing Air motors accumulate ice in the exhaust valving and muf fler under hot and humid conditions or under cold amb
15. mT 1 1 16 ses O00 app caren O00 O00 o acer ooo Soo 0 000 roo 0 sn ud g o 000 000 0 i 000 0000 Y 20 000 S00 0 BEET TALI OOO OC U c 9oueuojurely eoueuojurely prar SFEZT Sree FEA ser aco OT D EDO OO Prom d O TO0 OU Sear V e0 OOO OLI rer TOO OLI ce Bl TLTI ASE BU J9ZI 610 BO 9T ED 60791 ED 60 91 E0 BO 9T E0 2019 TEET ET 490 10 ESOT 60 91 EO uoneunoju wey 1se duing apo Aeids SU9BINS O1 U0D UlJe V SU99J2S S L SU9919S jO1 U05 pinj4 ung 312359J Appendix A 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 pumps Run consists of two screens power on enter and ratio mode The power on enter screen cycles through power on mode spray mode and pump mode It always displays the current ratio setpoint and may also display pres sure temperature and flow rate if these functions are selected The ratio screen displays the current ratio and monitors the B side restriction adjustment Spray proportion and spray material E Run pumps operate both pumps or oper ate each pump independent from the other AFB ate each pump priming flushing P Park Pumps runs pump to bottom of the stroke F2 Hatio jump to ratio screen 1 0 1 Power On Enter Mode Power On Enter Mode is the default screen when users enter Fluid Control NOTE This sc
16. oafety This includes DC voltage meters ohmmeters cables and connections Remove the unit from the hazardous area when troubleshooting Do not connect download or remove USB device unless unit is removed from the hazardous explo sive atmosphere location If explosion proof heaters are used ensure wiring wiring connections switches and electrical distri bution panel all meet flame proof explosion proof requirements 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 e 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 Do not spray without tip guard and trigger guard installed Engage trigger lock when not spraying Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment PRESSURIZED EQUIPMENT HAZARD Fluid from the gun dispense valve leaks or ruptured components can splash in the eyes or on skin and cause serious injury e Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment e Tighten all fluid connections before operating the equipment e Check hoses tubes and couplings daily Replace worn or da
17. om A and B blue lights illuminate when dosing valves are operating oom If there is not enough B component to hold ratio dosing valve A closes R2D momentarily Rand B dosing valves close momentarily at each pump changeover User opens circulation valves or sprays gun When pump reaches bot tom stroke the blue light turns off If park does not complete in 10 minutes turn off air to both motors DEA DEB Circulation A and or B dosing valves close and motor air turns on If fluid pressure exceeds 3000 psi 21 0 MPa 210 bar on the A pump P4A receive yellow light advisory If fluid pressure exceeds 5600 psi 39 2 MPa 392 bar on the A pump P4A STOP If pumps move indicating leakage STOP FHA FHB DGA Open A dose valve and dispense total of 750 ml material close valve turn off blue light Repeat for B side DFB DGB DHB If both pumps pass pump test display shows two beakers of 750ml each Batch Dispense Test 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 Valve Test If fluid pressure is not 1000 psi 7 MPa 70 bar STOP P1A Check for no movement of pumps stall within 10 seconds FHA FHB 312359J 5 N Alarms Alarm Code Key Use the
18. recommendations for setup e use at least a 3 8 in 10 mm x 25 ft 7 m hose as the integration hose e install a 24 element static mix tube after the integra tion hose Keep Components A and B Separate NOTICE To prevent cross contamination of the equipment s wet ted parts never interchange component A resin and component B hardener parts 10 312359J Location iw A XM sprayers are not approved for use in hazardous locations unless the base model all accessories all kits and all wiring meet local state and national codes See ModelsModels page 7 to determine the appropriate location for your particular sprayer model Grounding Zw AN Connect the XM sprayer ground wire clamp FG to a true earth ground If wall power is used to power con trols or heaters ground electrical connection properly according to local codes EN FG E El o o ti21273a 312359J Location Proper Lifting of Sprayer DM Follow instructions to avoid serious injury or damage to equipment Never lift with the hopper s filled NOTICE Drain all fluid prior to lifting sprayer Lift Using a Forklift Power must be off Sprayer can be raised and moved using a forklift Carefully lift the sprayer make sure it balances eve
19. sec tion are viewable and configurable If they are not follow instructions in Enable Setup Screens to enable them NOTE For details regarding the user interface display screens see User Interface Display page 61 To set maintenance parameters for pumps and valves including maintenance schedules press a from the Home Setup screen Use the first screen to set maintenance setpoint amounts for pumps and dosing valves Use the second screen to set the maintenance schedule for changing the incoming air filter Set Maintenance Setpoints To set maintenance setpoint values press and Y to move through each field and press l to make a field selectable Press a to scroll through each setpoint digit Press 4 and v to scroll through the optional values Continue this process until the desired setpoint is reached Press i to save that setpoint LO 005 DOU amp 0 OG DICES Lo 005 000 0 O00 OU p EEE g Wy oos K 0 000 OWS 312359J Basic Operation Set Maintenance Schedule To set the number of days between changing the incom ing air filter that will result in a reminder advisory press gt to move to the Maintenance Setup 2 screen Press to make the field selectable Press gt to scroll through each digit and press A and v to scroll through the optional values Press to save the number of days value 25 Basic Operation Set Sprayer Limits Optional NOTE For details regardi
20. top view and side view of the system Refer to the following table and subsections for more details 0l 06 11 13 3 z3 84 VOC 497 VOC 14 cc E Je A Go to Alarm log Use up and down arrows to scroll through list of the past 16 errors amp Go to totalizer screen Allows users to view the grand and batch totals for each pump and both pumps combined 1234 al 312359J Appendix A Go to maintenance screen Allows user to view maintenance information but not make changes See Maintenance Setup 2 page 67 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 warn Number of days between maintenance cycles that will result in a reminder advi Clear batch totalizers or maintenance counters Alarm Log 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 Be to access the alarm log The press A and Y to scroll through each page of alarms D3 16 09 037 16 09 037 16 09 O3 156 09 73 Appendix A Totalizers and Job Number View the grand and batch totals for each pump and both pumps combined The units of measurement are dis played on the bottom of the screen and displ
21. transducers read pump output and cavitation and not just dampened hose pressure Note Additional guns may only be added after the integration hose and mixer I Vem Spray Gun 2 312359J Appendix C Appendix C Power Cord Guidelines Use the guidelines listed in the following table to determine the power cord needed for your specific system Table 3 Power Cord Guidelines XM A 00 11 13 XM A 14 19 XM D 00 11 13 XM D 17 19 27 21 23 30 32 24 29 XM B all XM C all 21 23 30 32 29 XM E all Power Supply Power Supply won NE NN wall wall junction box box Low alternator altemstor alternator Viscon HP Fluid 2 a 2 EN 2 Wood Heaters Configuration Options 32 A at 240 V 1 PH wired by user with explosion proof Viscon HP 2 methods Hopper 13 A at 240 V 13 A at 240 V 13 A at 240 V Immersion 1 PH 1 PH 1 PH Heaters 2 16 A at 240 V 16 A at 240 V 1 PH wired b 1 PH wired b Viscon HP 16 A at 240 V 16 A at 240 V 16 A at 240 V y y 1PHe 1 PH 1PHe user with user with with Heat explosion proof explosion proof Circulation 1 or or or p p p p 15 A at 240 V 15 A at 240 V 15 A at 240 V methods methods Electric Hose 1 PHe 1 PH 1PHe Control 1 Full Load Peak 0 A Amperes at 240 V air only 1 Phase Cord Specification AWG mm at 4 21 2 240 V 1 PH 2 wire Te mnm wm 3 240 240 v3 PHI 3 PH 3 wire mnm wm pm 3 300 v
22. with Recirculation Back View 0 0c eee 14 Fluid Control Assembly 15 Junction Box Heater Controls 16 AI GOMWONS 2 neeg xi eel P dba e itt d 16 User Interface llle 17 SETUD m 19 Connect Power Cord 0000000 19 Configure to Supply Power 20 Wire Sprayers with Explosion Proof Heaters 21 Connect Air Supply llus 21 Connect Fluid Hose Assembly 22 Adjust Packing Nuts 22 Basic Operation 23 Power On Alternator Power Supplied Systems 23 Power On Wall Power Supplied Systems 23 Adjust Ratio and Setup 23 Final Setup i cdam bein eer xd uan 23 View Alarms leeren 23 Set System Settings Optional 24 Set Maintenance Parameters Optional 25 Set Sprayer Limits Optional 26 PIME iver va ex ode Node x E Us du PX vcrc ca 27 Prime A and B Fluids 27 Prime Solvent Flush Pump 29 Hecirculate iue i a Sed Bid e ee eee ee Fe ee oc 30 Without Heat 4 uada oa Ar Sete eet 30 With Heat 2 0 0 cee eee 31 ICAU HINO 4 5 EM say a ee ee cet eS 31 SPAY iata aid tines bide deeb ede 32 Adjust B Machine Outlet Restriction 33 Pressure Relief Procedure 34 Flush Mixed Material 36 Park Fluid Pump Rods
23. without heaters for non hazardous locations include a U S style NEMA 5 15 power cord and an IEC 320 power cord European and Australian adapters are also included These power cords are rated for 90 240 Vac 47 63 Hz See the XM Plural Component Sprayers Repair Parts manual or the XM Plural Compo nent OEM Sprayers Instructions Parts manual for part numbers NOTE Disregard terminal numbers on disconnect switch blocks Wire to positions shown 1 Open junction box cover 2 Connect electrical cord as follows 312359J Setup 230V 1 Phase Use a screwdriver to connect two power leads to the top terminals N and L2 positions Connect green to ground GND tia611a 230V 3 Phase Delta Use a screwdriver to connect three power leads to top terminals L1 L2 and L3 Con nect green to ground GND ti8612a 380V 3 Phase WYE Use a screwdriver to connect three power leads to the top terminals L1 L2 and L3 Connect neutral to N Connect green to ground GND ti8613a HOW e 19 Setup Configure to Supply Power Non hazardous location sprayers only aA NOTE Disregard terminal numbers on disconnect switch blocks Wire to positions shown 1 Locate power jumpers Power Jumpers ti18664a TB2 Terminal Blocks Position red jumpers as shown 380V 30 WYE as shipped 20 2 Us
24. 1M pajqgu3 AeidS 9 8S LfL sn uoe sn wd isd d OF LL 9S ERTZA 92 47 0 L9 8896 OL 0 a aa e en 698 9 paiqeug eydS 9 SPELL Sn uoles sn udb isd j 8cL tL 9S BETZA 97 7 0 0 0 bh 0L 0 qe pP 9 re See iN pajqgu3 AeidS 9 L rveEeLTE sn uojeb6 sn wd6 isd d 9237 9S 9ic 977 0 0 0 t2 0 1 0 gt datar e i tasca es 9 paigesiq eyds 9 ftLtL s 3 9 zrg amp E zal eee 2 z Er Bri E z d 2 33 68 g g s i ls s is g 3 2 2 F e ER a E c lc S 3 gt m s 2 2 g 8s 3 82 o gt o m o ES ja E x 9 lt lt S amp S eo g E i232 g d 5s 6 z s o o n S E eZ E o N D o I 3 3 S o o 3 F 3 a 2 200601 LOCMSL I 3123595 Appendix A Example Spray Log Fic 8 76 Appendix B Appendix B Metering Diagrams Metering Diagram without Remote Mix Manifold XM Metering Diagram Linear Reg Transducers Double a Motor Pilots wn I im f i a f f Switc S gt E d Controls j Recirculation Back Pressure Control b E am Ht l T ij I H j j i i i O E i j P H H li l l E lI l l E 2 EET R T 7 l l l l i l l l E i if l l l Le IR Control i li i i l Gravity Feed oui EV l i i Or li i i Pump Feed i oe 4 j l Circulation ii IF i l Shut Check co aL fe I ee N d N MC foo N I I NH qe jp Sample y amp Tes
25. 2 Temperature Limits System USB Pump Config 09716711 14 58 fal 0 3 i n Vei OT Det sec i E RE oo TEB Rr E e 312359J Home Setup Screens Home Home is the first screen that displays in Setup mode It shows the current pump ratio and enables users to change the mix ratio and access the following screens system setup enable disable functions maintenance setup and limits Refer to the following table for more details Increase or decrease mix ratio Press 4 and v to change the mix ratio ra Press to jump to system setup screens Press to jump to functional enable disable fF setup screens Press to jump to maintenance setup Ta screens Press to jump to pressure and temperature limits setup screens A B 10 0 13 312359J Appendix A Version Control This screen displays the versions and or status of the system components Refer to the following table for details To access this screen press gt from the Home Setup screen LI Display module version Vs E Fluid control module version Vs USB version Vs m d USB Configuration Vc A Total amount dispensed by pump A B Total amount dispensed by pump B A B Total amount dispensed by pumps A and B e Number of hours system has been running Bl 5101001 T Vs 1 014 001 us 1 06001 vc 101 001 galills A 000000 La B UDOCDLEH EE A 6 DEIDIDIICIE EST C 0000161 Hours 63 Appendix A System Setup Screens S
26. 8PH V 3 PH 4 wire pm Wired by user if ordered Cord size determined by user amp Full load amperes with all components operating at maximum capabilities Fuse requirements for various flow rates and heater temperature settings may be less 312359J 79 Dimensions Dimensions System Dimensions without Hoppers 39 5 in 1003 3 mm p ol el ol el 70 0 in 1788 0 mm Oo 0 0 4 38 0 in 36 0 in 914 4 mm 965 2 mm ti21282a 80 312359J Dimensions System Dimensions with Hoppers Two 20 Gallon Hoppers Side Mounted N l l 72 5 in Jon oO 1841 5 mm Co oO jf i Cd ates i i i i A B A 7 M go N 9 ED 43 1 in fcm 9 9 frm 1094 7 mm o Oo o o ibe p Le 98 6 in 2504 4 mm 54 0 in 1371 6 mm 49 7 in Two 20 Gallon Hoppers 1262 4 mm Rear Mounted Top View f a p A
27. 9 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 312359J Alarms 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 4 a Je by 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 This screen also shows diagnostic information There are three lines of data on the left side The top line shows the power supply or alternator power supply This should be between 23 25 Volts for power supply sys tems and 10 14 Volts for alternator systems The middle line shows the sensor voltage This should be between 4 9 5 1 Volts The center of the screen shows linear sensor vertical bar graphs and reed switch information The A side information is on the left and the B side information is on the right Linear sensor position is displayed on the bar graph that g
28. ARRANTY 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 enter
29. C 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 e Read MSDSSs to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines e Always wear impervious gloves when spraying or cleaning equipment 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 Wait until equipment fluid has cooled completely PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you from serious injury including eye injury inhalation of toxic fumes burns and hearing loss This equipment includes but is not limited to e Protective eyewear e Clothing and respirator as recommended by the fluid and solvent manufacturer e Gloves e Hearing protection 6 312359J Models Models Zw A XM sprayers are not approved for use in hazardous locations unless the base model all accessories all kits and all wiring meet local state and national codes Check the identification plate ID for the 6 digit part number of the sprayer Use the following matrix to define the construction of the sprayer based on the six digits For example Part XM1A00
30. CC CD CA CE CB CF CG r XM1AO00 312359 313289 14A FiG 5 Air Controls CA Main Pump and Air On Off Control CE Main Pump Air Regulator Gauge CB Solvent Pump Air On Off Control CF Solvent Pump Air Gauge CC Inlet Air Pressure Gauge CG Solvent Pump Air Regulator CD Main Pump Air Regulator 16 312359J User Interface DA DG DF a c DD DM DB DK Fic 6 User Interface Buttons LEDs Component Identification DE XC GAR B v DP ti13365a DC DN There are four types of LEDs on the display Use to view Ratio Mode Selection Error Call Conditions Totalizers System Informa out LED tion DK Start Initiates Active Run Mode function cur reniy soad infu Sereen o currently selected E Jmtosadsmovue o options and save values ML e Reset Move between screens in run or setup Yellow modes DG Function Activates mode or action represented by the icon above each of the four buttons in the LCD DH Up Down Move between selection boxes drop down fields and selectable values within Setup screens DJ Setup Key Change ratio or enter Setup mode MP adb NN USB Port Connection for data download Use only PL inorrazarousteatons o DA Display Screen 312359J Dosing valve active e on dosing valve is active e Off dosing valve is not active Spray mode active e spray mode is on active e spray mode is off inactive Alarm e on alarm is present off
31. ENSIONS iex daev ACE ea de doe dcs 80 System Dimensions without Hoppers 80 System Dimensions with Hoppers 81 System Dimensions with Hoppers 82 Pump Performance Charts 83 Technical Data 2 ur Ema eee 84 Graco Standard Warranty 86 Graco Information 86 312359J Helated Manuals Related Manuals Manuals are available at www graco com Component Manuals in U S English Manual Description 0 XM Plural Component Sprayers 313289 Repair Parts XM Plural Component OEM Sprayers 313292 Instructions Parts 311762 Xtreme Displacement Pumps Instructions Parts 311238 NXT Air Motor Instructions Parts Double Wall Hopper Kit 312747 Instructions Parts 309524 Viscon9 HP Heater Instructions Parts 312145 XTR 5 and XTR 7 Spray Guns Instructions Parts Feed Pump and Agitator Kits 312769 Instructions Parts 312794 Merkur Pump Assembly Instructions Parts Caster Kit Instructions Parts Electric Heated Hose Power Supply Kit 313258 Instructions Parts Hopper or Hose Heat Circulation Kit 313299 Instructions Parts Lower Strainer and Valve Kit Instructions Parts XM Mix Manifold Kit Instructions Parts Alternator Conversion Kits 313293 Instructions Parts Dosing Valve Repair Kit 313342 Instructions Parts 313343 High Flow Severe Duty Shutoff Check Valve Repair Kit Instructions Parts 312770 312749 312359J 3 Warnings
32. L 99S 9vcc bL8e GO LSSE 96 ci EL v pn 065 9 pajqgu3 eydS 9 8 ZL L Sn uojeb sn wd6 isd d 8c sos ae 608 cost cese CAL ci VL ee ee x I1 9 8085 is pajqeu3 Keds 9 82Zb rL sn uoe sn wd6 isd d Be LL g85 EFEZ 8087 L plte 2087 LL EL 8 i ma 12665 19 pajqgu3 eds 9 L SL ZL PL sn uoe sn wd6 isd d troll 6099S CPEE 9087 20 OrSt OPEC ZL EL cC r e aa aa 8 pajqgu43 AesdS 9 L 80 ZEvk sn uoe sn wd6 isd d rrollL PoS L 2e S082 80 rv6sSt 0c6c ZL Z VL Lm emend 1665 9 pajqgu3 eydS 9 8S amp 9Lt L sn uoe sn wd6 isd d QL LL ros roc t09c 60 Otrt ct8c L2 EL 6 ee J EDOS8 19 pajqeu3 Keds 9 8f9LfL Sn uoe sn wd6 isd d Str lL pos 8 eee cose 10 L6St S960 21 Z 6 Mea 90098 19 pajqgu3 AesdS 9 L SE OL FL sn uoe sn wd6 isd d 80cLiL 99 LECC LOSZ L SRE 1286 V2 EL LL 9 008 19 pajqgu3 eydS 9 8Z9Lt L Sn uoje5 sn wd6 isd d tril w 98 GETZ 86 7 80 L6ft LLG CL ZL C a a 8008 i pajqgeu3 AeidS 9 8L9L L sn uoles sn wdb isd d Stril 98 PEZ 264 GO lst Ltoc cL EL 0 a Fee 8 pajqgu3 eyds 9 80 9LfL Sn uoe sn wd6 isd d 9trLL 9S etc 96 7 L LEE 87280 L4 4 OF Se Si ue 1 oes M pajqgu3 AesdS 9 L 8 amp SLEvk sn uoe sn wd isd d tril 8 9S LECZ v6 2 L0 ZL9E Z66Z ZL Z V o
33. Operation G g GRACO XM Plural Component Sprayers TM For spraying two component epoxy and urethane protective coatings in hazardous and non hazardous locations For professional use only Important Safety Instructions See page 7 for model information and agency approvals e Read all warnings and instructions in this See page 84 for maximum working pressure manual Save these instructions m E i u s I i S S B 2 Fe Jt J INN S e Sm E P i B X v 2 e ti21272a CE PROVEN QUALITY LEADING TECHNOLOGY Contents Related Manuals 3 Warnings 3552 99 E Eod ERE RN EUR 4 MOGeIS 053 79193 cones RE HE SCR ELA d CEP e aet 7 OVOerVIGW cioe ie Ge aka a ax aca uates 9 Usage ids bd os apa oe ROLE we aia acs whos car ad 9 Isocyanate Hazard lus 9 Material Self Ignition Ls 9 Moisture Sensitivity of Isocyanates 9 Components Aand B 10 Changing Materials 00005 10 LOCAU p PET 11 CROUCHING aca od dud UE Re E eR UR OR a 11 Proper Lifting of Sprayer 11 Initial System Setup 12 Component Identification 13 Typical Setup 20 Gallon Hoppers with Recirculation Front View leeren 13 Typical Setup 20 Gallon Hoppers
34. See manual 313343 for more information Alternator Conversion Kit 256991 For converting an XM sprayer from wall power supply to intrinsically safe alternator power supply See manual 313293 for more information Mix Manifold Kit 255684 See manual 312749 for more information Remote Mix Manifold and Carriage Kit 256980 For converting to a remote mix manifold kit with a pro tective guard See manual 312749 for more information Restrictor Valve Kit 24F284 For B dosing outlet on remote mix manifold machines Use to convert early XM machines without the valve on the B outlet Restrictor Valve Wrench 126786 For adjusting restrictor valve See page 33 312359J Appendix A User Interface Display The user interface display is divided into three main functions Setup Command and Automatic Setup Functions key ON The setup functions enable users to e set desired mix ratio e configure system settings e set potlife parameters e enable disable functions displays and display components e set which USB logs to download e schedule maintenance parameters for alarms and advisories e and set pressure and temperature limits NOTE All setup functions except for mix ratio must be enabled from the Enable Setup screens before users can change or set configurations See Enable Setup Screens page 66 for instructions 312359J Appendix A Command Functions key OFF or removed The co
35. XM sprayer See manual 312769 for more information Hopper Hose Heat Circulation Kit 256273 For circulating heated water through 20 gallon hoppers heated hose and Viscon HP heater See manual 313259 for more information 59 Accessories and Kits Desiccant Dryer Kit 256512 For use with 20 gallon hoppers See manual 406739 for more information Caster Kit 256262 For mounting casters on XM sprayer frame See manual 406690 for more information Hose Rack Kit 256263 For mounting to side front or back of XM sprayer frame See manual 406691 for more information Lower Strainer and Valve Kit 256653 For straining material from a feed pump to an XM sprayer fluid inlet See manual 312770 for more informa tion Electric Heated Hose Power Supply Kit 256876 For monitoring and controlling fluid temperature in low voltage heated hoses See manual 313258 for more information 5000 psi Two Component Main Heated Hose Set Kit Electric heated hose set for adding additional sections Part Description 248907 Heated hose set 1 4 in ID x 3 8 in ID 50 ft 248908 Heated hose set 3 8 in ID x 3 8 in ID 50 ft Xtreme Pump Wetcup Wrench 15T258 Xtreme Pump Filter Wrench 16G819 60 10 1 Drum Feed Kit 256433 For supplying highly viscous material from a 55 gallon drum to an XM sprayer See manual 312769 for more information Shutoff Check Valve Kit 255278 For replacing shutoff valve or check valve
36. a 312359J 29 Recirculate Recirculate Without Heat If using a system that does not require heat recircula tion is still required prior to spraying Recirculation ensures that any settled fillers are mixed in the pump lines are fully primed and the pump check valves are operating smoothly 1 Follow Prime page 27 2 Close mix manifold valves AH AJ AH 3 Ensure recirculation hoses are in the correct hop 0 MA d Z ZE 30 4 Open recirculation valves AC AD AC AD 5 Select pumps to recirculate by pressing ATB to scroll through Ta p or AFB 6 Turn on the main air shutoff valve CA Use system air regulator CD to slowly increase the air pressure to the pumps until they start running slowly 7 Ifthe pumps are running too quickly close the restrictor on each fluid line 312359J 8 Run the pumps until the material has reached the desired temperature See Heat Fluid page 31 9 Once desired temperature is reached press V 10 Turn off the main air shutoff valve CA AD 12 See Spray page 32 NOTE If you circulate the A side 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 exc
37. alue NOTE The allowable range for the temperature setpoint is 34 160 F 1 71 C 312359J Prime Prime A and B Fluids Wear gloves when using flush solvents and or if fluid temperature exceeds 110 F 43 C NOTE Do not install gun spray tip yet To avoid splashing use the lowest pressure possible to prime 1 Condition materials prior to adding to hoppers Ensure resin materials are thoroughly agitated homogenous and pourable prior to adding to hop per Stir hardeners back into suspension prior to adding material to hopper 2 Fil A and B reservoirs with proper materials Fill A side with major volume of material fill B side with minor volume of material 20 Gallon Hopper Shown 3 Move recirculation lines to empty containers 7 Use manual pump run mode 312359J Prime Open ball valves into pumps Turn mix manifold valves AH AJ clockwise to close them Turn on air supply Set main pump air regulator CD to 20 psi 138 kPa 1 38 bar Y Y Ss 27 Prime NOTE When run independently set to p Or T Press T and V as needed to prime Monitor containers to avoid overflow 8 Select Pump A Ta Press gt Slowly turn main pump air regulator CD clockwise to increase air pressure until pump A starts Dispense into pail until clean fluid comes out of A Close recirculation valve NOTE Wh
38. ar maximum 50 psi 0 35 MPa 3 5 bar minimum while running Flow volume required 70 scfm 1 96 m3 min minimum 250 scfm 7 0 m min maximum Available fluid pres sure and flow rate are directly related to available air vol ume See Pump Performance Charts page 83 General flow volume guidelines e 70 scfm 1 96 m min per gpm lpm while spraying e 10 scfm 0 28 m min added per agitator e 10 scfm 0 28 m min added per drum feed pump NOTE If your sprayer is for use in hazardous areas the control box is powered by an air driven alternator NOTE Dosing valves are operated by air The sprayer will not operate correctly if the inlet air gauge drops below 50 psi 0 35 MPa 3 5 bar while spraying 21 Setup Connect Fluid Hose Assembly 1 Connect fluid hose to fluid manifold outlet Do not install gun spray tip yet r XM1A00 312359 313289 20A Fluid Integrator Hose NOTICE Do not assemble static mixer directly to the fluid man ifold Install static mixer after first 25 ft 7 5 m of inte grator hose to ensure material doses are completely integrated Spraying poorly integrated material could require rework of parts sprayed 2 Tighten all fittings 22 Adjust Packing Nuts 1 Fill A and B pump packing nuts with throat seal liq uid TSL and torque to 50 ft Ibs 67 5 Nem Fol low instructions in Xtreme Lowers manual 311762 NOTE After the first day of use re torque packi
39. ayed 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 to identify the batch total Clear Batch Totalizer To clear the batch totalizer values for A B and A B 18245 press 62209 to set all values to zero Og 26 11 09 33 A oon Les py ooo zs B DOO OU Too E Ea nalillsj 12245 Bana 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 p oe OO O00 TUE B nny DOD OW 196 A B mmr Change Job Number 1 Press to highlight the first digit Press A and v to change the number and ian gt to move to the next digit Press to save the number or e9 to cancel 74 Maintenance 1 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 0 005 000 0 O00 DILIL 0 005 000 0 000 OO t i 8 EAD T
40. balanced hose sizes can cause off ratio slugs at the mix manifold during pressure and or flow transitions See XM Mix Manifold Kits manual e Ifa minimum of integration and mix hose is used ensure that Fast Dosing is selected in the setup Screens Software Version e Ensure all modules in the system use software from same token Different software versions may not be compatible e The latest software version for each system can be found at Tech Support at www graco com 45 Empty and Flush Entire System new sprayer or end of job Empty and Flush Entire System new sprayer or end of job i Procedure NA s A AN wW d NV Om 1 Follow Prime page 27 and Flush Mixed Material page 36 as required Engage trigger lock Turn main pump air regulator CD fully counter clock NOTE wise to shut off e Ifthe system includes heaters and heated hose turn them off and allow to cool before flushing Do not turn on heaters until fluid lines are clear of sol vent e Cover fluid container and use the lowest possible pressure when flushing to avoid splashing e Before color change or shutdown for storage flush at a higher flow rate and for a longer time e To flush only the fluid manifold see Flush Mixed Material page 36 Guidelines 2 Move circulation return lines to separate fluid con tainers to pump remaining fluid out of system Flush new systems if coating materials will be contami nate
41. bs NESS j GA BINA NT SA kS af PL MICE A ERE AO SANS F TT te Sy 04d NM L VP pg E ip G d ay R mw D LA Pal ge u NW A c 3 53 ti21272a FiG 1 Typical Setup 20 Gallon Hoppers with Recirculation Front View A Frame G Pump Control On and Off Buttons B Fluid Control Assembly see Fluid Control Assembly H Air Filter page 15 J Air Controls C 20 Gallon Hopper Assembly see manual 312747 K Viscon HP Fluid Heater D 20 Gallon Hopper Bracket see manual 312747 L Junction Box Heater Controls see Junction Box Heater E Main Air Valve Controls page 16 F GCA Control Display see User Interface Display page M Inline Fluid Heater Control 18 N Air Powered Agitator P Pressure Feed Pump R Recirculation Control Valve 312359J 13 Component Identification Typical Setup 20 Gallon Hoppers with Recirculation Back View A S Dp o NA Tn g d i Bi A O aS o o o o SY o o ZN oOo E Oo do 6 u o eo Oo o U C O O C T Co C Co V FiG 2 Typical Setup 20 Gallon Hoppers with Recirculation Back View Air Motor High Pressure Fluid Pump Solvent Flush Pump Merkur Pump Fluid Inlet
42. 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 49 Maintenance Maintenance Filters Once a week check clean and replace if needed the following filters Be sure to follow the Flush Mixed Mate rial page 36 prior to performing filter maintenance e Both pump filters see manual 311762 for instruc tions e Main air inlet manifold filter see manual 313289 Replace Air Filter Element section for instructions e Air regulator filter 5 micron on air control assem bly see manual 313289 Replace Air Filter Element section for instructions e B side mix manifold strainer as required see man ual 312749 Seals Once a week check and tighten throat seals on both pumps and dosing valves Be sure to follow the Flush Mixed Material page 36 prior to tightening seals 50 Cleaning Procedure io m i fj y W 1 Ensure all equipment is grounded See Grounding page 11 2 Ensure the area where the sprayer will be cleaned is well ventilated and remove all ignition sources 3 Turn off all heaters and allow equipment to cool 4 Flush mixed material See Flush Mixed Material page 36 5 Relieve pressure See Pressure Relief Procedure page 34 6 Shutdown sprayer and turn off all power See Shut down Entire System page 3
43. cessary These g pung alarms prevent excessive pump speeds that can dam WV age pump packings Press 12 Follow Park Fluid Pump Rods page 38 6 Wipe reservoirs clean then add solvent to each 13 Remove pump fluid filters if installed and soak in Move circulation lines to waste containers solvent Clean and replace filter cap Clean filter o rings and leave out to dry Do not leave o rings in 7 Repeat Step 4 to flush through each side until clean solvent solvent exits recirculation hose 14 Close main air valve E 8 Press v Move recirculation hoses back to reser NOTE voirs Continue recirculating until system is thor Fill A and B pump packing nuts with TSL Also always oughly flushed leave some type of fluid such as solvent or oil in the system to prevent scale build up This build up can flake off later Do not use water 312359J 47 Download Data from USB Download Data from USB wW Do not connect USB device in explosive atmospheres USB Logs Spray Log 1 Default log for download 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 By default the spray log records 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
44. d by 10W oil 3 Increase main pump air regulator CD pressure to 20 psi 138 kPa 1 38 bar Flush system when any of the following situations occur Flushing will help prevent materials from clogging the lt gt line between hoppers and pump inlets 4 Select T Press e anytime sprayer will not be used for more than NOTE one week e if materials used will settle e if using thixotropic resins that require agitation When running pumps independently set to or T Press T and V as needed to clean NOTE If sprayer does not start with static pressure increase air pressure by 10 psi 69 kPa 0 7 bar increments To avoid splashing do not exceed 35 psi 241 kPa 2 4 bar 46 312359J Empty and Flush Entire System new sprayer or end of job 5 Openrecirculation valves AC AD for respective 9 Close recirculation valves AC AD and open mix pump dispense side Run pumps until the A and B manifold valves AH AJ Dispense fresh solvent reservoirs are empty Salvage the material in sepa through mix manifold valves and out gun rate clean containers anal nt L MEN Vu e o ar umen AF U9 DEM AC W ID W rn AJ NOTE When priming or flushing the pumps it is normal to get 10 Close mix manifold valves AH AJ cavitation or pump runaway alarms Clear the alarms 11 Slowly open sampling valves AE AF to flush sol lt gt vent through until clean Close sampling valves s and press again as ne
45. d ia px IIA T2 Tamb 0 C to 54 C See Special Conditions for Safe Use in Warnings page 4 Table 1 Lower Models and Corresponding Identification Codes System Pressure A Lower B Lower ETE BM NEM bar see manual 311762 see manual 311762 5200 5200 psi 35 350 35 350 L250C4 L220C4 ers 5200 psi 35 350 L250C3 L220C3 6300 psi 49 490 v L180C4 L145C4 6300 psi 49 490 EE L180C3 L145C3 Table 2 Additional Kits Identification Code Part No Index Heated Hopper Hose Circulation NO N N 32 NOTE See Accessories and Kits page 59 for more information See Related Manuals page 3 for kit manual numbers 8 312359J Overview Usage XM plural component sprayers can mix and spray most two component epoxy and urethane protective coatings When using quick setting materials less than 10 minute pot life a remote mix manifold must be used XM plural component sprayers are operated via the user interface air controls and fluid controls Zw A XM sprayers are not approved for use in hazardous locations unless the base model all accessories all kits and all wiring meet local state and national codes See Models page 7 to determine the appro priate location for your particular sprayer model Isocyanate Hazard 2 ttt A W AN 3 Spraying materials containing isocyanates creates potentially harmful mist
46. e Place in hopper or drum See manual 312747 for instruc tions Heplace USB label front of control panel with cor rect language version if needed Replace Alarms Codes label under fluid control valves with correct language version if needed Install hopper hose heated circulation kit if ordered See manual 313259 for instructions For non hazardous location sprayers connect power cord not supplied See Connect Power Cord page 19 for instructions For non hazardous location sprayers connect junc tion box wiring for immersion or recirculation heat ers See manual 312747 for immersion heater instructions See manual 309524 for recirculation heater instructions 15 16 17 For hazardous location sprayers connect explo sion proof heaters See Wire Sprayers with Explo sion Proof Heaters page 21 and manual 309524 for instructions and recommendations Connect air supply line See Connect Air Supply page 21 for instructions and recommendations Connect fluid hose assembly including whip hose and gun See Connect Fluid Hose Assembly page 22 for instructions Also connect remote mix manifold if ordered See manual 312749 for instruc tions 312359J Component Identification Component Identification Typical Setup 20 Gallon Hoppers with Recirculation Front View r eO A C QU L ERN scri TE fe s c OP us GS NS Hf r
47. e a flat blade screwdriver to move red jumpers from storage positions to positions for your power as shown below Push jumpers firmly into new position NOTE For 230V 1 Phase and 230V 3 Phase Installations change jumper positions as shown below Machine is shipped with jumpers in the fail safe 380 30 position 3 Close junction box cover N PLT Cy E 230V 10 230V 39 Delta 312359J Wire Sprayers with Explosion Proof Heaters Hazardous location sprayers only Zw If your sprayer is rated for hazardous areas and you have explosion proof heaters you must have a quali fied electrician connect heater wiring Ensure wiring and installation comply with local electrical codes for hazardous areas Improperly installed or connected equipment will create a hazardous condition and cause fire explosion or elec tric shock Follow local regulations When explosion proof heaters are used ensure wiring wiring connections switches and electrical distribution panel all meet flame proof explosion proof require ments Refer to Viscon HP heater manual 309524 for electrical connection instructions and guidelines in hazardous locations 312359J Setup Connect Air Supply Connect air supply line to 3 4 npt f air filter inlet NOTE Use a 3 4 in 19 1 mm ID minimum air hose X E B Te NOTE Air supply requirement 150 psi 1 0 MPa 10 3 b
48. e trigger lock TI1953a i 8 Engage trigger lock N ad gt TI949a t 711949a 2 Press V 3 If fluid heaters are used shut them off using the Relieve Pump Fluid Pressure and Flush Mix controls on the heater control box or the heater Hose power junction box 9 Close mix manifold valves AH AJ then open sol vent flush valve AK on mix manifold ITIL NS if AH EX de d Fluid Heater B Fluid Heater A ti21275a 4 Shutoff feed pumps if used 5 Remove spray tip and clean 6 Disengage trigger lock T11950a 34 312359J Pressure Relief Procedure 10 Open solvent pump air control valve CB Use low 13 Shut off solvent pump air control valve CB est pressure needed to flush material out of hose 14 Disengage trigger lock 15 Close solvent flush valve AK on mix manifold mca zn Ed rd acus ON d ee les AK 11 Disengage trigger lock 16 Release any residual gun pressure and engage trig x 4 ger lock Ds 12 Hold a metal part of the gun firmly to a grounded metal pail with a splash guard in place Trigger gun to flush mixed material out of line with clean solvent TI1950a T11949a 312359J 35 Flush Mixed Material Flush Mixed Material ZO we Flush Mix Manifold Use Solvent Pump 1 Press V to turn off system Engage trigger lock Hemo
49. e under 250 psi 1 75 MPa 17 5 bar High pressure pumps receive a pressure boost that is twice the pressure feed on the upstroke only High feed pressures can cause pressure swings between A and B The system will compensate but the bar graph will the show the swing Resin AU T 711 13 38 dosing U cc size 1 0 gpmiUs Combined flow rate The restrictor adjust bar graph is shown when K is pressed This screen is used to adjust the restrictor e At maximum fluid flow the bar should be in the cen ter e At flows less than maximum the bar should be on the right side e The bar should never be on the left e Configure the system at maximum fluid flow Then turn the restrictor clockwise if the bar graph is on the right and counter clockwise if the bar graph is on the left NOTE A pump dosing size shown on the upper left cor ner will be minimum when the restrictor is adjusted cor rectly Once the restrictor is set for a given ratio and material it should be locked in place and left alone 33 Pressure Helief Procedure Pressure Relief Procedure 7 Hold a metal part of the gun firmly to a grounded AN metal pail with a splash guard in place Trigger gun to relieve pressure in material hoses Follow Flush Mixed Material when you stop spraying or dispensing and before cleaning checking servic ing or transporting equipment Relieve A and B Fluid Pressure 1 Engag
50. ed 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 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 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 312359 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2009 Graco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com Revised March 2013
51. ed switch Replace cable if problem per sists Otherwise replace reed sensor assembly See manual 313289 Reed switch cable is plugged in Power sprayer off and back on while power is on Do not plug in reed switch cable while power is on Bad connection inside fluid con Replace fluid control module trol module See manual 313289 P6A Pressure sensor failure no Always Pressure sensor or cable is bad Replace sensor and cable P6B signal on the side indicated assembly See manual 313289 54 312359J Alarms Alarm Code Alarm Problem When Active Cause Voltage low control Always Voltage dropping below 9 Vdc Change air filter in control filter from power supply regulator See manual 313289 Check the pressure setting is 18 psi 0 13 MPa 1 3 bar on turbine air regulator Check voltage on information Screen Turbine not spinning with air on Replace air turbine cartridge See manual 313289 Display has no signal Always No display communication sig Check cable connections nal Replace display See manual 313289 Machine powered down in Press stop button before turning spray mode off power DLA A air motor reed switch signal Always Reed switch does not see the Replace air motor reed switch missing advisory air motor magnet magnet Reed switches are bad Replace air motor reed switch Prevent air motor icing See advisory P9A and P9B DLB B air motor reed switch signal Always Reed
52. eded high or low alarm limits for more than four minutes Pressure exceeded high or low advisory limits for more than 15 seconds Fluid temperature exceeded high or low limits for more than four minutes Have not sprayed enough vol ume to keep fresh mixed fluid in the integration hose mixer whip hose and spray gun If fluid temperature is too low return to circulation mode to increase fluid temperature Adjust heater set point if needed See Heat Fluid page 31 If fluid temperature is too high lower heater set point and return circulation mode to cool See Heat Fluid page 31 Adjust temperature target set point See Heat Fluid page 31 Same as P5A or P5B above Same as T5A or T5B above Spray fluid or flush Resets when you leave spray mode See Spray page 32 or Flush Mixed Material page 36 312359J 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 Spray Dosing valves close for startup test green light blinks boom If fluid pressure is under 1000 psi 7 MPa 70 bar STOP If pumps move indicating internal leakage STOP FHA FHB If fluid pressure is more than 103 of allowed maximum air motor shuts None off until fluid pressure drops If is pressure more than 11096 of allowed maximum STOP Dosing valve A opens and dosing valve B cycles to maintain ratio
53. en priming or flushing pumps it is normal to get cav itation or pump runaway alarms Clear alarms e9 and press 9 again as necessary These alarms prevent excessive pump speeds which will damage pump pack ings 9 Move recirculation line back to reservoir 10 Repeat for B side 28 11 Dispense a small amount of each material through both sampling valves AE AF NOTE Open sampling valves slowly to avoid splashing AF 12 Close both sampling valves AE AF NOTE If a remote mix manifold is used disconnect hoses at mix manifold and prime with material Reconnect hoses 312359J Prime Prime Solvent Flush Pump 5 Disengage trigger lock and trigger gun into a grounded pail Use a pail lid with a hole to dispense 2 through Seal around hole and gun with a rag to pre N ae vent splash back Be careful to keep fingers away aie MEM from front of gun 5 TI1950a M ve 6 Open solvent pump air valve CB Pull out and slowly turn solvent pump air regulator CG clock wise to prime solvent pump and push air out of mix hose and gun Trigger gun until all air is purged 1 Connect flush pail ground wire to a metal pail of sol vent 2 Place siphon tube in the pail of solvent 7 Close solvent pump air valve CB and trigger gun to relieve pressure Engage gun trigger lock dl S Sf N T11949a ll S NN t11949
54. essive pump wear If you circulate the A side pump above 5200 psi 35 4 MPa 354 bar an alarm shuts the pump down to pre vent accidentally spraying material while still in circula tion mode 312359J Hecirculate With Heat Using recirculation mode when heating the material is required Note the temperature at the top of the heater outgoing or back to hopper When the thermometer and display reach operating temperature the material is ready to spray Heat Fluid To heat fluid evenly throughout the system 1 Circulate fluid at approximately 1 gpm 10 20 cycles min to raise temperature of hoppers to 80 90 F 27 32 C 2 Decrease circulation rate to approximately 0 25 gom 5 cycles min to increase the heater outlet temper ature to match the spray temperature NOTE Circulating fluid too quickly without decreasing the circu lation rate will increase only the hopper temperature Similarly circulating fluid too slowly will increase only the heater outlet temperature NOTE Agitate recirculate and heat material only as necessary to avoid mixing air into the fluid 31 Spray Spray Fy RD 2 Wear gloves when using flush solvents and or if fluid temperature exceeds 110 F 43 C NOTE After the first day of spraying follow Pressure Relief Procedure page 34 and then tighten throat seals on both pumps and dosing valves 1 If heaters are used use heater junction
55. g below 80 psi Check air filters See manual 0 55 MPa 5 5 bar while spray 313289 ing B dosing valve not closing Use larger air hose correctly Use larger compressor Use smaller gun tips or less guns to reduce flow rate Solenoid air regulator set below Adjust air regulator 80 psi 0 55 MPa 5 5 bar R1B Ratio Low B under dose B Spray B dosing valve will not open Check for air signal to valve system delivering not enough B mix manifold valve closed Open green mix manifold valve B t COMPONEN Pump filter plugged on B side Use alternate 30 mesh screen See manual 311762 for part number Clean B pump outlet filter See manual 311762 REC System detected five R4B Spray See R4B or R1B alarm causes See R4B or R1B alarm solu ratio high B or five R1B tions Flush mixed material if ratio low B alarms within five necessary and purge off ratio minutes Sprayer shuts down mixed material in hose for five minutes to resolve problem System detects pump move Spray Recirculation valve or dosing Close or repair recirculation ment fluid flow when there valve open or leaking for more valve and run Pump Test See should not be than five seconds Pump and Metering Test page 40 See manual 313289 if needed 52 312359J Alarms Alarm Code Alarm Problem When Active Cause R2D Dosing sizes are not opti Spray Dosing valve is operating near Adjust mix manifold B
56. hanging the main incoming air filter before a reminder advisory is issued Maintenance Setup 1 0 004 000 A 2 0 005 000 LI 000 00a 1 0 Ob DIETS y UOS UDO O O04 Dan t a ans nan js 1 1 O00 uu 0 O00 OU Maintenance Setup 2 67 Appendix A User Limits Setup Screens Process Pressure Limits for spray mode User Limits Setup enables users to set and adjust pres sure and temperature limits for both pumps including 03 25 09 12 07 al limits that will issue advisories and alarms Refer to the C B following table for details NOTE The allowable range for the temperature setpoint is 34 160 F 1 71 C If the temperature or pressure set point is zero pressure limits and alarms are disabled Set and adjust pressure limits for both E LL Set and adjust high and low temperature l limits for both pumps Set target pressure or temperature ce Set and adjust limits that if exceeded will issue an advisory Used with pressure and temperature limits Set and adjust limits that if exceeded will issue a alarm Used with pressure and temperature limits 68 312359J Appendix A and alarm control The follow ing figure demonstrates the flow of the Command mode screens beginning with the run fluid control screens Command mode screens are divided into three major sections run fluid control test Operator Command Functions Screens 69 EUF EEEE Le Geel rr QOL
57. ient conditions It can cause pressure loss or motor stalling e The B fluid pressure should always be 15 to 30 higher than A pressure e A larger pressure difference indicates A motor icing e Asmaller or negative pressure difference indicates B motor icing 312359J e Ensure that the NXT motor De Ice bleed valves are open to bleed warm air across the ice e 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 e Always use filter screens in the XM pump lowers Filter style pumps come with 60 mesh screens Optional 30 mesh elements are also supplied e Always use a gun filter 60 mesh is provided in the gun Check that the static mixer is clean e Early mix manifolds 2009 had a 40 mesh screen on the B side The screen could plug with materials that have filled B side fluids Remote Mix Manifold Applications Ensure remote mix manifold outlet kit is installed See XM Repair parts manual The kit includes outlet check valves which isolate the pump pressure sensors from the outlet hoses and includes a B side restrictor valve for the machine outlet NOTE Early remote manifold machines didn t include the B restrictor valve from the factory e Ensure that the A and B outlet hose sizes volume balanced close to the mix ratio Un
58. llowing table for more details 312359J Appendix A Flashes while data download is in process v Check mark appears after download com pletes Indicates download was successful If download was not successful Y appears Displays total memory to download and remaining memory left to download Displays time remaining for log download to D complete Press to cancel download If download is Me cancelled remove USB flash drive Indicates which log s is being down 1 loaded Recommended USB Flash Drives It is recommended that users use the USB flash drive 16A004 included with the XM sprayer for data down load However the following USB flash drives can also be used but are not available through Graco e Crucial Gizmo 4GB USB flash drive model JDO4GB 730 or 8GB USB flash drive model 7DOD8GB 730 e Transcend JetFlash V30 4GB USB flash drive model TS4GJFV30 e Transcend JetFlash 300 4GB USB flash drive model TS4GJF300 e Corsair Flash Voyager 8GB USB flash drive model CMFUSB2 0 8GB 75 Sn uoe sn wd6 isd d PLL 99S Sec 9 8c SO 4cS tO0C LZ EL 8 L Mm cmt u J 9 8085 if pajqgu3 eydS 9 808Lt L Sn uoles sn wd isd d 8990 99G 6 vec Slee L cere tc8C0 CL CL Ck uci ie a 18 pajqeu3 fesdS 9 BS ZL FL Sn uoe sn wd6 isd j 8c LL cogs LEZ clez L 86re SESZ ci z OL n aa inkaa 2008 i9 pajqgu3 AesdS 9 L 8tZkEvk sn uoles sn wd6 isd d c
59. maged parts immediately MOVING PARTS HAZARD Moving parts can pinch 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 in this manual Disconnect power or air supply Warnings EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury e Do not operate the unit when fatigued or under the influence of drugs or alcohol e Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings For complete information about your material request MSDS forms from distributor or retailer Check equipment daily Repair or replace worn or damaged parts immediately with genuine manu facturer s replacement parts only Do not alter or modify equipment Use equipment only for its intended purpose Call your distributor for information Houte 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 TOXI
60. mmand functions enable users to e run pumps including flush circulate and prime procedures e park pumps so pump rods are down when not in use e mix and spray e view mix ratio e run pump tests e run batch dispense ratio tests e run valve leak checks e view dispense totals e view alarms e diagnose alarms e and clear alarms Automatic Display Functions The automatic display functions enable users to e issue potlife timer alarms e and download USB logs 61 Appendix A Setup Mode Screens Setup mode screens are divided into five major sections home limits maintenance enable and system The follow ing figure demonstrates the flow of the Setup mode screens beginning with the Home screen Home Version Control Ball 1 01001 gaus A 00000018 DDDDD 12 A B 10 0 1 H T Vs 1 01 001 A B 000000036 Vs 106 001 p uc 1nlDgj 0000161 Hours Od gu i B Q U o bad E l Pressure Limits 03 25 09 12 07 E 1 A B Tmt S amp LO S300 psi amp 0500 psi z t Maintenance Setup 1 1 0 004 000 H 2 i 0o00 003 0o00 003 0000003 i 0000003 aal ls Q od o S c c bud E shown with factory default settings Enable Setup 1 Enable Setup Potlife Hose Length fal 1 5 MM 2 0008 18 System Setup 037 16 09 i 13 30 am a oc 3r 39 62 Enable Setup
61. n during setup 1 Relieve system pressure See Pressure Relief Pro cedure page 34 2 Flush and prime system See Prime page 27 Flush Mixed Material page 36 and Park Fluid Pump Rods page 38 3 Check ratio accuracy Run Pump and Metering Test page 40 and Batch Ratio Dispense Test page 43 to check ratio accuracy 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 error codes alarms and adviso ries A bell icon indicates an alarm 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 Diagnose Alarms See Alarm Codes and Troubleshooting page 52 for causes and solutions to each alarm code Clear Alarms Press e9 to clear alarms and advisories Press gt to return the run fluid control screen For more information on alarms and alarm codes see Alarms page 51 23 Basic Operation Set System Settings Optional NOTE For details regarding the user interface display screens see User Interface Display page 61 To set user interface parameters and USB parameters A press Us from the Home Setup screen Set User Interface Parameters Press gt from the potlife hose length screen to move to
62. nded DFA Pump did not stall against Pump Test Pump piston check valve pis Flush pump See XM Setup DFB fluid pressure on up stroke ton packings or dosing valve and Troubleshooting Guide only are not holding fluid pressure page 45 Recheck Remove clean and repair lower See manual 313289 DGA Pump did not stall against Pump Test Pump inlet check or dose valve Remove inlet housing amp clean DGB fluid pressure on down stroke is fouled or damaged and inspect See manual only 313289 DEA Pump does not move in 10 Park or Pump Recirculation valves were not Open recirculation valves DEB minutes Test opened to allow flow General System Component Alarms DJA Pump motor linear sensor Always No linear sensor signal from Swap A and B sensors DJB has no signal motor Replace sensor if problem fol lows sensor See manual 313289 Linear sensor plugged in while Power sprayer off and back on power is on Do not plug in linear sensor while power is on Bad connection inside fluid con Replace fluid control module trol module See manual 313289 Sprayer is not properly See Grounding page 11 grounded Pump motor linear sensor is Always Linear sensor is beyond range Replace sensor or sensor mag out of range net See manual 313289 DKA DKB Pump motor reed switch fail Always Bad motor cable connections Swap A and B motor cables ure missing signals from one or both switches or bad re
63. ner with a desiccant dryer in the vent or a nitrogen atmosphere Never store ISO in an open container e Use moisture proof hoses specifically designed for ISO such as those supplied with your system e Never use reclaimed solvents which may contain moisture Always keep solvent containers closed when not in use e Never use solvent on one side if it has been contam inated from the other side e Always park pumps when you shutdown e Always lubricate threaded parts with Part 217374 ISO pump oil or grease when reassembling Overview Components A and B Changing Materials e When changing materials flush the equipment mul roan tiple times to ensure it is thoroughly clean Material suppliers can vary in how they refer to plural component materials e Always clean the fluid inlet strainers and outlet filter after flushing Flush Mixed Material page 36 Be aware that in this manual Component A refers to resin or major volume e Check with your material manufacturer for chemical Component B refers to the hardener or minor volume compatibility NOTE e Epoxies often have amines on the B hardener This equipment doses the B component into the A com side Polyureas often have amines on the A resin ponent flow An integration hose must always be used side after the mix manifold and before the static mixer NOTE If the amine will switch between the two sides see NOTE Flush Mixed Material page 36 Follow these
64. ng nuts 2 Fill metering valves A and B packing nuts with throat seal liquid TSL and tighten 1 4 turn after nut con tacts packings about 145 155 in Ibs 16 18 Nem NOTE For pump and meter valves check packing nut tightness after first hour of operation and again after 24 hours Then check as needed or when TSL discolors or seeps over packing nut Also check tightness whenever sprayer is transported Tighten packing nuts only when all fluid pressure is relieved 312359J Basic Operation Power On Alternator Power Supplied Systems 1 Set main pump air regulator CD to minimum set ting 2 Open main air valve E and main pump and air valve CA to start air powered alternator Main air pressure is displayed on gauge CC Fluid Control screen will display after five seconds TN a Nt I e q l Power On Wall Power Supplied Systems Turn on main power disconnect Fluid Control screen will display after five seconds Adjust Ratio and Setup 1 Turn key to right setup position Yellow LED will flash and the Home Setup screen will display 2 Press 4 and v to change ratio 3 When desired ratio is displayed turn key to left Yel low LED will turn off 4 Change optional setup selections to desired param eters as described in Set System Settings Optional page 24 312359J Basic Operation Final Setup Perform the following steps if shutting dow
65. ng the limits setup screens see User Limits Setup Screens page 68 To set and adjust pump pressure limits and temperature limits i 1 Select iz in the Enable Setup 2 screen See Enable Setup Screens page 66 for instructions 2 From the Home Setup screen press to jump to the limits screens 3 Follow the instructions in Set Pressure Limits and Set Temperature Limits Set Pressure Limits Use the following instructions to set pressure limits for each pump that if met will issue an advisory and or warning To set pressure limits press A and v to move through each field and press i to make a field selectable Press i to scroll through each pres sure digit and press 4 and v to scroll through the optional values Continue this process until you reach the desired pressure limit Press d to save NOTE The B pump pressure always runs 10 20 higher than the A pump pressure 03 25 09 12 07 A 4 000 psi 26 Set Temperature Limits Use the following instructions to set temperature limits that if met will issue an advisory and or warning Press gt to move to the temperature limits screen To set temperature limits press 4 and Y to move through each field and press to make a field selectable Press gt to scroll through each tempera ture digit and press rN and v to scroll through the optional values Continue this process until you reach your desired temperature limit Press to save the v
66. nly Lift Using a Hoist Sprayer can also be lifted and moved using a hoist Con nect a bridle swing hooking an end to each of the air motor lift rings Hook the center ring to a hoist See the following figure Carefully lift the sprayer make sure it balances evenly 2 0 ft 0 61 m ee a o 7 o N el ti21274a 11 Initial System Setup Initial System Setup Complete the following steps in the order they are listed as they apply to your specific system for initial system setup 1 10 11 12 13 14 12 Check your shipment for accuracy Ensure you have received everything you ordered See Component Identification page 13 to familiarize yourself with typical system components Mount caster kit if ordered See manual 406690 for instructions Mount hopper brackets if ordered See manual 312747 for instructions Loosely mount hoppers if ordered on brackets See manual 312747 for instructions Connect bottom hopper outlet if using a gravity feed pump See manual 312747 for instructions Tighten hopper mounting bolts See manual 312747 for instructions Mount and connect agitator s and feed pump s if ordered See manual 312769 for instructions Mount and connect hopper immersion heater kit if ordered See manual 312747 for instructions Connect recirculation hose restrictor valve includ ing knob and nipple and recirculation tub
67. no alarm Warning on is active off no warning indicated Ratio and setup fields are not change able flashing key is present and turned Ratio and setup fields are changeable 17 Component Identification User Interface Display NOTE For details regarding the user interface display see User Interface Display page 61 Main Display Screen Components The following figure calls out the navigational status and general informational components of each display screen Current Date and Time Remaining Potlife Time 03 16 09 10 14 10 14 Current Status Bar p Function Display ME ear psi Bi TF Navigate to screens within same group Navigational Bar T Go back one screen Fic 7 Main Display Screen Components shown with all display features enabled NOTICE To prevent damage to soft key buttons do not press the buttons with sharp objects such as pens plastic cards or fingernails 18 312359J Setup Connect Power Cord For sprayers with heater junction boxes Non hazardous location sprayers only aA Graco does not supply heater junction box power cords Use the following chart to determine which power cord your specific model requires Power Cord Requirements Voltage Cord Specification AWG mm 240V 1 PH 4 21 2 2 wire ground 240V 3 PH 6 13 3 3 wire ground 380V 3 PH 6 13 3 4 wire ground NOTE Sprayers
68. oes up and down when the pump moves This bar graph should move from top to bottom to match each pump stroke The state of the two reed switches in each air motor are shown with the arrow above each vertical bar graph 312359J Alarms Moving up Moving down Top changeover Bottom changeover 2 One reed switch signal is missing Blank No reed switch signal Diagnose Alarms See Alarm Codes and Troubleshooting for causes and solutions to each alarm code Clear Alarms Press R to clear alarms and advisories From the alarm information screen press s to return to the run fluid control screen 51 Alarms Alarm Codes and Troubleshooting NOTE See XM Plural Component Sprayers Repair Parts manuals for non alarm based troubleshooting Alarm Code Alarm Problem When Active Cause General Performance Alarms R4B Ratio High B Overdose B Spray B Dosing valve not closing Perform Pump Test to test for system delivering too much B leakage See Pump and Meter component ing Test page 40 Loosen valve packing nut See manual 313289 Check air signal at valve top Repair valve or air solenoid See manual 313289 No B restriction at mix manifold Increase B Restriction by turn ing B restrictor stem clockwise See Adjust B Machine Outlet Restriction page 33 Pump filter plugged on A side Clean filter See manual 311762 Use alternate 30 mesh screen See manual 311762 for part number Inlet air droppin
69. pump and metering valve e Verifies that the recirculation valves AC AD are closed and do not leak This test will dispense 750 ml of component A and then 750 ml of component B Dispense into separate cups so the fluid can be returned to the supply tanks 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 third flow stops and the blue pump light DK goes out 1 Enter Test mode in the run fluid control screen See Test Screens on page 71 Select auum to run pump test Us 16 09 10 33 312359J 2 Setmain pump air regulator CD pressure to zero Open main pump and air valve CA Adjust main pump air regulator CD pressure to 50 psi 0 35 MPa 3 5 bar 3 Dispense fluid A a Close recirculation valves AC AD mix man fold valves AH AJ and both sampling valves AE AF 312359J AD AF AJ System Verification b Place aclean 1 quart 1000 cc container under sampling valve A AE E oes did UT pd V E lf Hi IL J o m d q a Xm 1 c Press Q Pump A light DK comes on d Slowly open and adjust sampling valve A AE to achieve desired flow Pump stops automati cally twice during test and again when dis pense completes Pump A light DK turns off P
70. r Heater Kit 240V 256257 For heating fluid in a 20 gallon hopper See manual 312747 for more information Universal Hopper Fluid Inlet Kit 256170 For connecting any of the four lower models included with XM sprayer to a 20 gallon hopper See manual 312747 for more information Universal Hopper Mounting Kit 256259 For mounting a 20 gallon hopper to the side or back of an XM sprayer See manual 312747 for more informa tion Twistork Agitator Kit 256274 For mixing viscous materials held within a 20 gallon hopper See manual 312769 for more information T2 Feed Pump Kit 256275 For supplying viscous material from a 20 gallon hopper to an XM sprayer See manual 312769 for more informa tion 312359J Accessories and Kits 5 1 Feed Pump Kit 256276 For supplying viscous materials from a 20 gallon hopper to an XM sprayer See manual 312769 for more informa tion 7 Gallon Hopper and Bracket Kit 256260 Green 24N011 Blue One 7 gallon hopper and mounting brackets Mounts to the side or back of an XM sprayer See manual 406699 for more information 2 1 Drum Feed Kit 256232 One T2 pump feed kit and one Twistork agitator kit for mixing and supplying viscous materials from a with 55 gallon drum to an XM sprayer See manual 312769 for more information 5 1 Drum Feed Kit 256255 One 5 1 pump feed kit and one Twistork agitator kit for mixing and supplying viscous materials from a with 55 gallon drum to an
71. reen remains blank until a mode is selected 70 Spray Mode Users must be in this mode to spray or proportion mate rial Press the button below the spray icon to enter this mode Pump Mode Users must be in this mode to operate pumps for prim ing or flushing Press the button below the pump icon to enter this mode Continue pressing the pump icon but ton to cycle through pump A pump B and both pumps 312359J Park Mode Users must be in this mode to park fluid rod pumps at the bottom of the stroke Press the button below the park icon to enter this mode Ratio Mode Displays the current ratio or the restrictor screen To access this screen press 14 The bar graph indi cates whether the B restriction adjustment should be turned clockwise or counter clockwise See Adjust B Machine Outlet Restriction page 33 NOTE If the A B 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 Lire il 42 Restrictor Screen Function Display Ratio show the accuracy of the fluid mix ratio Display Restrictor Adjust Adjust the restric X tor to optimize the mix ratio icon 104 e Atthe maximum fluid flow the bar should be in the center e Atless than maximum flow the bar should be on the right side 312359J Appendix A Test Screens Test screens enable
72. reens on page 71 Select to run batch dispense test Us 16 09 10 54 2 Adjust dispense amounts from 500 ml to 2000 ml in 250 ml increments by pressing to open the drop down box Then press A and v to select the desired value Press to select that value 3 Set main pump air regulator CD pressure to zero Open main pump and air valve CA Adjust main pump air regulator CD pressure to 50 psi 0 35 MPa 3 5 bar 312359J System Verification 4 Close recirculation valves AC AD mix manifold AC AH valves AH AJ and sampling valves AE AF AD AF AJ A m 5 Place a clean container under sampling valve A N IN INS cR CG CO d T_T i j HI a o J TX H Li o un i q i K 6 Press 9 Pump A light comes on 43 System Verification 7 Dispense fluid A Slowly open and adjust sampling valve A AE to achieve desired flow The pump stops automatically when dispense completes Pump A light DK turns off Pump B light DK turns on 8 Close sampling valve A AE 9 Dispense fluid B as follows a Batch dispense move container under sam pling valve B AF 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 pump stops auto matically when dispense complete
73. represents an XM Plural Component sprayer XM 5200 psi pump set with pump filters 1 wall power supply no heaters no junction box and is not approved for hazardous areas A with no additional kits 00 NOTE Some configurations in the following matrix cannot be built Consult with distributor or Graco representative To order replacement parts see Parts section the XM Plural Component Sprayer Repair Parts manual 313289 The digits in the matrix do not correspond to the Ref Nos in the Parts drawings and lists Fifth and First and Sixth Second o _ hain Digits Third Digit Fourth Digit Digits System Choice Additional See Table 1 for lower models Kit Choice Kit page See Table Pump Set Remote Control Fluid Junction Location see page 8 2 for ee mE Box Heaters EN E for approvals E XM Wall Power CE FM plural TR 5200 pum Supply FMc ponent sprayer Wall Power owl CE FM mounted 5200 psi Supply FMc on a frame Wall Power CE FM 6300 psi Supply FMc IS CE FM 6300 psi Alternator FMc Ex IS 5200 psi EHE EH 6 950p 7 6300 psi TE nm MEN Location Category Key NE Not for use in explosive atmospheres EH For use in explosive atmospheres and hazardous locations 312359J 7 Models Approvals See appropriate column on page 7 C US C US APPROVED APPROVED FMO9ATEX0015X Intrinsically safe for Class I Div 1 Group D T2 q p5 G Class I Division 1 G D T2 go o ac pps roup Ex
74. restrictor mized high or low timing limits stem clockwise or counter clockwise as indicated by bar graph on restrictor screen See Adjust B Machine Outlet Restriction page 33 P4A Pressure high Always Fluid pressure is above maxi Decrease main air regulator P4B mum DAA Pump runaway above 80 Always No material in pump or lines no Refill material in tank or hoses DAB cpm for 10 sec fluid restriction install fluid tip DDA Pump cavitation dives more Spray No fluid or valve closed Refill supply and open inlet than 1 2 of stroke valve Material is too cold or thick Increase material temperature to reduce viscosity See Heat Fluid page 31 Shear material with agitation to reduce viscos ity Pump inlet check valve not Clear debris from check valve closing Or replace ball seat and seal DDB Feed pump not providing mate Check feed pump if used rial Inlet strainer plugged if used Check and clean strainer See manual 313289 P1A Pressure low Spray Pump Fluid pressure is below 1000 Increase main air regulator P1B Test Leak Test psi 7 MPa 70 bar P4R Pressure high Recirculation Pressure is above maximum Decrease pump air regulator advisory limit of 3000 psi 21 pressure MPa 210 bar on A side P5R Pressure high Recirculation Pressure is above maximum Decrease pump air regulator warning limit of 5200 psi 35 9 pressure P9A A pump pressure is abnor Spray A air motor is icing up ca
75. rformance Charts page 83 32 130 F 0 54 C 30 160 F 1 71 C Indoor outdoor use Altitude up to 4000 m Maximum relative humidity to 99 up to 130 F 54 C Pollution degree 11 Installation category 2 86 dBA at 100 psi 0 7 MPa 7 bar 98 dBA at 100 psi 0 7 MPa 7 bar aluminum carbide PTFE stainless steel UHMWPE nylon carbon steel alloy steel 303 440 17 ph grades stainless steel zinc and nickel plating ductile iron tungsten carbide PTFE carbon steel nickel plating carbide polyethylene leather carbon steel nickel plating carbide 302 stainless steel PTFE UHMWPE stainless steel housing with acetal elements Refer to soray gun manual See Dimensions page 80 Base sprayer XM1A00 and XM5A00 models 742 lbs 336 87 kg Add component weights to base sprayer weight for your specific model weight Minimum flow rate is dependent on material being sprayed and mixing capability Test your material specific to flow rate 312359J 312359J Technical Data 85 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 dete
76. rk Fluid Pump Hods Park Fluid Pump Rods 1 Relieve pressure See Pressure Relief Procedure 5 Shut off main pump air valve CA and air supply to page 34 entire system 2 Press Pj 3 Turn recirculation valves AC AD counter clockwise to open them Each pump will run through recircula tion until they reach the bottom stroke and then stop AD 4 When each blue pump LED turns off close the cor responding circulation valve AC AD 38 312359J Shutdown Entire System Shutdown Entire System Follow this procedure prior to servicing equipment or 2 Engage trigger lock turn off air regulator and close shutdown main air shutoff valve Remove spray tip 1 Follow Flush Mixed Material page 36 Use a metal pail lid with a splash guard to avoid splashing e po T11949a T11948a 3 For overnight shutdown Ww FF T11953a e Follow Park Fluid Pump Rods on page 38 e Cap fluid outlets to keep solvent in the lines e Fil pump A and B packing nuts with throat seal liquid TSL 312359J 39 System Verification System Verification Graco recommends running the following tests daily Mix and Integration Tests Use the following tests to check for proper mix and inte gration Butterfly Test A 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 p
77. rmined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO W
78. rsection with selected air con outlet pressure curve Follow left to scale to read fluid out sumption curve Follow right to scale to read air consump let pressure tion NOTE Ratio setpoint has no significant effect on curves in either performance chart Air consumption includes turbine alternator it does not include feed pumps or agitators XM50 Fluid Performance and Air Consumption 7000 49 0 490 eaan 3 S o 5000 E 35 0 350 8 5 m 3000 5 21 0 210 o o O o Ti Oo 1000 3 5 7 0 70 LL 0 0 1 0 2 0 3 0 KEY 3 8 7 6 11 4 A 100 psi 0 7 MPa 7 bar B 70 psi 0 48 MPa 4 8 bar Fluid Flow in gpm Ipm XM70 Fluid Performance and Air Consumption _ 7000 180 gt E 49 0 490 5 0 o O S 140 7 5000 39 350 350 9 5 100 S 28 S 3000 zj 5 21 0 210 Bo T o 1 7 a 1000 3 2 7 0 70 20 w m 069 3 0 0 KEY 7 6 A 90 psi 0 62 MPa 6 2 bar ee i9 ele B 70 psi 0 48 MPa 4 8 bar Fluid Flow in gpm Ipm 312359J 83 Technical Data Technical Data Mixed ratio FAN OC ser Cu dico V Bes Deoa e ROO ie edic e e ee Ratio tolerance range before alarm Flow rates DVI eene tee eae he Un dtr bo ino det o d VEXIMUMN ou PH pa E War YHP ADEST Fluid viscosity range FUA Tl ALIOD su uenit Vorrei nV rtu eic oe Deu ee eme 8 Air inlet Fluid inlets without feed kits llllllsnn Maximum fluid working pre
79. s Pump B light DK turns off c Close sampling valve B AF 10 Batch dispense stir material until mixed Ratio check compare A and B fluid 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 pumps and the volume of material dispensed from each pump 44 The gray at the bottom of the beaker represents the vol ume of material dispensed by pump A and the black at the top of the beaker represents the volume of material dispensed by pump B 09719711 10 4 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 037 16 09 10 55 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 71 Select o run down stream valve leak test 4 Select cL Press T Ensure dosing valves AA AB are open by verifying blue LEDs are illumi nated for both dosing valves 5 Iftest is successful both pumps will stall against the down stream valves when the dosing valves AA AB are open If any movement is detected in the pumps after stalling an alarm is issued
80. s vapors and atomized partic ulates Read material manufacturer s warnings and material MSDS to know specific hazards and precautions related to isocyanates Prevent inhalation of isocyanate mists vapors and atomized particulates by providing sufficient ventila tion in the work area If sufficient ventilation is not available a supplied air respirator is required for everyone in the work area To prevent contact with isocyanates appropriate per sonal protective equipment including chemically impermeable gloves boots aprons and goggles is also required for everyone in the work area 312359J Overview Material Self Ignition 2 uu uu Some materials may become self igniting if applied too thick Read material manufacturer s warnings and material MSDS Moisture Sensitivity of Isocyanates Isocyanates ISO are catalysts used in two component urethane coatings ISO will react with moisture such as humidity to form small hard abrasive crystals which become suspended in the fluid Eventually a film will form on the surface and the ISO will begin to gel increasing in viscosity If used this partially cured ISO will reduce performance and the life of all wetted parts NOTE The amount of film formation and rate of crystallization varies depending on the blend of ISO the humidity and the temperature To prevent exposing ISO to moisture e Always use a sealed contai
81. s the volume of material dispensed by pump A The black at the top of the beaker represents the volume of material dispensed by pump B 3 18 11 10 47 lal D Pal mL B 150 0 mL A 600 0 mL e 72 Down Stream Valve Leak Test This screen enables users 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 shut off check valves or any remote circulation valves While running the test if there is continuous pump movement on the A or B side an error will be issued The error indicates a leak in the valve There is no confirmation screen for this test However if the down stream valve leak test fails an warning is issued to indicate the cause of the failure 312359J Alarm Control Screens The Alarm control screens enable users 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 A displays Alarm The Alarm screen displays the specific alarm code There are two levels of error codes alarms and adviso ries 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
82. sable pump maintenance setup ti screens 66 j Enable or disable dosing valve mainte TY nance setup screen Enable or disable incoming air filter mainte nance setup screen Enable or disable limits pressure and tem perature screens p 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 USB log files 1 3 to of download Fast Dosing Function Fast Dosing Advisory B3A Alarm B4A Enable Setup 1 Shown with factory default settings 312359J Enable Setup 2 Shown with factory default settings 312359J Appendix A Maintenance Setup Screens The maintenance setup 1 screen enables users 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 indi cates the amount of material dispensed counting up to the setpoint requiring maintenance Set amount of material moved through pump that will result in a maintenance warning Set amount of material moved through dos ing valve that will result in a maintenance warning Set number of days between c
83. ssure of mixed material SO Ve nes ca ota E ala xen tart tod eve neyo ovde eM OT ae r o rnm Maximum fluid temperature Air supply pressure range Maximum pump air set pressure 203 eae ie te e EAEE ee AE E EE eE re E r a TO NE e E E mira NE A ap dee E A Maximum pump inlet fluid feed pressure Maximum air consumption at 100 psi 0 7 MPa 7 0 bar ib SEE TI DRM DI Yael EUR a d Araton a ete son Erie eerie oret Send re aoc es Ambient temperature range Operating ence IC DTP Environmental conditions rating Sound pressure fii ie bbe ee wee ks SOMA POWE I xv 3i ei er ed sed es eed ed Wetted parts Suction tubes FUSA pump cani aud Dese ce iO Pore bee ee re E Hoses Pumps A and B Metering valveS 0 0 ees Manifold Spray gun Dimensions 84 1 1 10 1 in 0 1 increments 5 1 qt min 0 95 liter min 3 gal min 11 4 liter min 200 20 000 cps heavier viscosities can be mixed using heat circulation and or pressure feeding 60 mesh 238 micron standard on pump outlets filter assembly not included on some models alternative 30 mesh screens included 3 4 npt f 1 1 4 npt m 5200 psi 35 8 MPa 358 bar 6300 psi 43 5 MPa 435 bar 160 F 71 C 50 150 psi 0 35 1 0 MPa 3 5 10 3 bar 100 psi 0 70 MPa 7 0 bar 90 psi 0 62 MPa 6 2 bar 250 psi 1 7 MPa 17 bar 70 scfm per gpm 1 96 m min per Ipm 40 micron main filter 5 micron control air filter see Pump Pe
84. switch does not see the Replace air motor reed switch missing advisory air motor magnet magnet Reed switches are bad Replace air motor reed switch Air motor is icing up Prevent air motor icing See advisory P9A and P9B DMA A air motor linear sensor Always M ime ct m UE a B air motor linear sensor Always BIN Air motor is icing up Optional User Settable Maintenance Warnings MAA Maintain pump Always if enabled Pump usage exceeds user set Service pump See manual MAB limit Maintenance due 313289 MEA Maintain dosing valve Always if enabled Dosing valve usage exceeds Service dosing valve See man MEB user set limit Maintenance ual 313289 due MGO Maintain air filter Always if enabled Air filter exceeds user set limit Service main air filter and con Maintenance due trol filter regulator See manual 313289 P5A Pressure exceeded alarm Pressure exceeded high or low Adjust pump pressure regulator P5B limits alarm limits for more than 15 change tips or adjust target set seconds point 312359J 55 Alarms Alarm Code Alarm Problem When Active Cause Optional User Settable Spray Limits Temperature exceeded alarm limits TSA T5B i uw ali un Pressure exceeded advisory limits P2A P2B T2A T2B ul Temperature exceeded advi sory limits Pot life timer expired Mixed fluid will cure in hoses mixer and gun 56 Fluid temperature exce
85. t life in hose is much shorter than dry time of coating 312359J Adjust B Machine Outlet Restriction Adjust the restriction stem on mix manifold or on restric tor valve if mix manifold is remote to optimize the B side dosing control window The goal is to create a near con stant flow on the A side and frequent dosing or a near constant flow on the B side Restriction Stem 1 With material at normal spray temperature and tip installed on spray gun trigger gun for at least 10 seconds 2 Navigate to Ratio Mode screen See Ratio Mode page 71 Check bar graph 1011 lade The ratio bar graph is shown when 14 is pressed This screen is used to show the accuracy of the spray ratio The bar should be in the center three segments when the restrictor is adjusted 3 Press M to go to the restrictor adjustment screen 312359J Adjust B Machine Outlet Restriction NOTE e For remote mix manifolds set the machine restrictor first Then close the remote mix manifold restrictor to approximately the same setting or until the restrictor screen starts to move to the left e tis normal for the bar to move on the graph while spraying If the adjustment is too far off you will receive an alarm If the ratio will not hold you will receive alarm R4B or R1B See Alarm Codes and Troubleshooting page 52 e Ifthe bar swings back and fourth and you are using feed pumps the feed pressure may be too high Keep feed pressur
86. t xX upd nee Mix Manifold Shut off amp gt Check Valves Valves Settable B J ed Balancing Mandel Restriction Integration Hose 3 8 x 25 ft Note Additional guns may only be added minimum after the integration hose and mixer CREER Cr L ISpray Gun 3 Po 777777777 Fluid Line I Ao TAURUAUA M Control cable a hie Whip Hose 7577577757575 312359J 77 Appendix B Metering Diagram with Remote Mix Manifold XM Metering Diagram with Remote Mix Manifold Linear Transducers Double Motor Pilot No r lt lt E g f RM Recirculation Controls Back Pressure Control I TE I I I IEEE i 2 dod l l H l IO 1 TE a l I P H Control H E I l I P E valves dg l i I E A ZEE IA I Io T ZEE IT R 1 EE al It E EEL ELS l um m l A Gravity Feed I R l PL 4 R or Pump Feed lt 7 L Lol 1 I2 l l l NZ Circulation On Off aa X Sample amp Test Valves Shut off amp Hose Isolation Check Valves r7 IF I Ib Il l I H l l l Remote Y Shut off amp Check Valves d 3X PX NT l Mix Manifiold A f Settable B Balancing Restriction Fluid Line Control cablesss e m Air Signal Integration Hose 3 8 x 25 ft minimum 78 I I L These hose isolation check valves must be added when mix manifold is remote This insures that pressure
87. the user interface parameters screen The following user interface parameters are configu rable date format date factory set time factory set units of measurement for e fluid flow rate e pressure e temperature e hose length To change the date format press Y to select the field Press to open the drop down field Press 2 and v to select the preferred format Press his again to save that date format Follow this procedure to change the units of measurement formats as well 24 To change the date and time press Y to select the field Press to make the field selectable Press 2 and v to scroll through each digit Press lt and sj to move to the next digit in the field Press lt to save the change Set USB Parameters Press sie from the user interface parameters screen to move to the USB parameters screen To set the sprayer number configure the number of hours downloaded to external USB flash drive and how often the data will record press and Y to move through each field Press to make a field select able Press 2 and v to scroll through each digit Press lt and nip to move to the next digit in each field Press to save the change 09716711 14 59 i A ef 00 060 sec lt mM COO veo hr t E 312359J Set Maintenance Parameters Optional NOTE Prior to configuring system settings see Enable Setup Screens page 66 to ensure screens shown in this
88. ump B light DK turns on Close sampling valve A AE Dispense fluid B as follows Place a clean 1 quart 1000 cc container under sampling valve B AF 41 System Verification b Slowly open and adjust sampling valve B to achieve desired flow Pump stops automatically twice during test and again when dispense completes Pump B light DK turns off c Close sampling valve B AF 6 Compare fluid amounts in containers they should be equal at 750 ml 25 3 fl oz each Repeat test if fluids are not equal If problem persists see Alarm Codes and Troubleshooting page 52 7 Return fluid used in test to corresponding fluid sup ply container Confirm Pump Test The Confirm Pump Test screen displays when the pump test completes without error This screen displays the target volume of material dispensed into each beaker from each pump 3718 11 11 08 42 312359J Batch Ratio Dispense Test NOTE This test dispenses a calculated volume of each fluid based on ratio The two fluids combined equal the batch size selected Follow this procedure to dispense a batch into one con tainer for touch up work or to verify a ratio setting use separate containers for fluids A and B Dispense into a container with graduations no greater than 5 of each component If the ratio is known by weight use a scale for greatest accuracy 1 Enter Test mode in the run fluid control screen See Test Sc
89. ump have occurred Fold the sheet of foil over the fluid then peel it back and look for unmixed material appears mar ble like Curing Test Spray a single continuous pattern on foil at typical pres sure setting flow rate and tip size until multiple change overs of each pump have occurred Trigger and de trigger at typical intervals for the application Do not overlap or cross over your spray pattern Check curing at various time intervals listed on the material data sheet For example check for dry to touch by running your finger along the test pattern s entire length at the time listed on the data sheet NOTE Spots that take longer to cure indicate insufficient inte gration Appearance Test Spray material onto metal substrate Look for variations in color gloss or texture that may indicate improperly catalyzed material 40 Pump and Metering Test This test checks the following four items and should be run every time a new job is started or if there is a sus pected problem e Verifies that the pumps installed match the pumps selected on the Setup screen by dispensing exactly 750 ml of each material e Verifies that each pump holds fluid against the pump inlet valve by stalling on the down stroke e Verifies that each pump holds fluid against the pump piston valve and packings by stalling on the upstroke e Verifies that each metering valve holds fluid and that there are no external leaks between the
90. users to run batch dispense tests pump tests and down stream valve leak tests Pump Test dispenses 750cc of each A and B verifies pump selection operation and metering Batch Dispense dispenses proportioned p amounts of A and B with a selectable total lt lt Pump Test Down Stream Valve Leak Test test if valves after the dosing valves hold pressure This screen enables users to dispense a fixed 750 ml volume of material from each pump When the pump is active it flashes in black on the screen When the pump completes dispensing it displays gray on the screen Confirm Pump Test This screen displays when the pump test completes without error This screen displays the target volume of material dispensed into each beaker from each pump 71 Appendix A Batch Dispense Test This screen enables users 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 When the pump is active it flashes in black on the screen When the pump completes dispensing it dis plays in gray on the screen 1500 mL 4065 psi Z030 psi Confirm Batch Dispense Test This screen displays when the batch dispense test com pletes without error This screen displays the selected ratio between the pumps and the volume of material dis pensed from each pump The gray at the bottom of the beaker represent
91. using Open the air motor de ice bleed mally low compared to B restriction and lower fluid pres air controls Allow ice to melt pump pressure sure Dry compressed air Heat com pressed air Use a smaller tip A pump is binding Repair lower See manual 313289 MPa 359 bar on A side A motor is hanging up Repair air motor See manual 313289 P9B B pump pressure is abnor Spray B air motor is icing up causing Open the air motor de ice bleed mally low compared to A restriction and lower fluid pres air controls Allow ice to melt pump pressure sure Dry compressed air Heat com pressed air Use a smaller tip B pump is binding Repair lower See manual 313289 312359J 53 Alarms Alarm Code Alarm Problem When Active Cause B3A Dosing size A advisory Spray The fluid dosing size is greater Adjust the B side fluid restric than 35 cc when fast dosing is tion See Adjust B Machine turned off Outlet Restriction page 33 The fluid dosing size is greater Decrease the air motor velocity than 20 cc when fast dosing is with a smaller tip turned on B4A Dosing size A alarm Spray The fluid dosing size is greater Adjust the B side fluid restric than 45 cc when fast dosing is tion See Adjust B Machine turned off Outlet Restriction page 33 The fluid dosing size is greater Decrease the air motor velocity than 30 cc when fast dosing is with a smaller tip turned on Pump Test Daily Check Recomme
92. ve spray tip 4 DWYS lt NS 3 P LPS LA p TI1949a TI1948a 2 Ensure sampling valves AE AF and mix manifold valves AH AJ are closed N oO AF yore oorh FH i j 3 Open solvent shutoff valve AK at mix manifold 36 4 Open solvent pump air valve CB Pull out and slowly turn solvent pump air regulator CG clock wise to increase air pressure Use lowest possible pressure 5 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 pre vent splash back Be careful to keep fingers away from front of gun Flush out mixed material until clean solvent dispenses A T11950a T11953a 6 Engage trigger lock gt TI1949a 312359J Flush Mixed Material 7 Close solvent pump air valve CB and solvent shut 9 Engage trigger lock off valve AK at mix manifold Trigger spray gun to relieve pressure E Be Es zn E gt TI1949a AK 10 Disassemble and clean spray tip with solvent by hand Reinstall on gun 8 Follow Pressure Relief Procedure page 34 312359J 37 Pa
93. ystem Setup enables users to configure system set tings for fluid control and operator interaction Refer to the following table for details NOTE System settings must be enabled from the Enable Setup screens before users can change or set configurations See Enable Setup Screens page 66 for instructions Set number of minutes before mixed mate rial will set in hose Resets after material volume set by user is passed through hose Indicates total hose volume Always dis 2 played in cc units Set length of hose after mix manifold Used C to indicated total hose volume ke Set calendar date and format 7 Set time E Set units of measurement desired for dis play such as fluid and temperature Set sprayer number if using more than one kr sprayer Set number of hours of recorded data to EH record to USB data logs Set how often data will record to USB spray em logs i Select resin pump size for A side n t Select hardener pump size for B side E Potlife Hose Length This screen enables users to set the potlife timer and enter the hose inside diameter and length of each mixed material hose specific to the system The potlife time displays in the upper right corner ali 1 c NE G DOO Tz G 0008 38 2 Uce 64 Set Potlife Hose Length To set the potlife timer and enter the mixed material hose dimensions press 4 and v to move through each field and press i to make a field selectable

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