Setup - Operation XM PFP 3A2776D EN For spraying two-component intumescent epoxies. For professional use only. Not for use in explosive atmospheres or hazardous locations. Important Safety Instructions Read all warnings and instructions in all supplied manuals. Save all instructions. See page 3 for model information, including maximum working pressure and approvals.
Contents Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Keep Components A and B Separate . . . . . . . . 6 Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 6 Components A and B . . . . . . . . . . . . . . . . . . . . . 6 Component Identification . . . . . . . . . . . . . . . . . . . .
Models Models Models Maximum Fluid Working Pressure A and B Materials: 6000 psi (41 MPa, 414 bar) 262869 24W626 Flushing Fluid: 4500 psi (31 MPa, 310 bar) Heating Fluid: 100 psi (0.7 MPa, 7 bar) Maximum Air Working Pressure Approvals Supply: 150 psi (1.0 MPa, 10.3 bar) Max. Setpoint: 100 psi (0.7 MPa, 7 bar) 9902471 Certified to CAN/CSA C22.2 No. 88 Conforms to UL 499 Related Manuals Manuals are available at www.graco.com.
Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
Warnings WARNING WARNING MOVING PARTS HAZARD Moving parts can pinch, cut or amputate fingers and other body parts. • Keep clear of moving parts. • Do not operate equipment with protective guards or covers removed. • Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources. EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury.
Warnings Keep Components A and B Separate Components A and B IMPORTANT! Material suppliers can vary in how they refer to plural component materials. Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination: • Never interchange component A and component B wetted parts. • Never use solvent on one side if it has been contaminated from the other side.
Component Identification Component Identification Typical Setup (Front View) V Y U J L B P C M D G K A E, F N C1 X T ti19927a WL E H S R FIG. 1 Key: A B C D E F G H J K L M N P Frame Fluid Control Assembly GCA Control Display Metering Pumps Control On and Off Buttons Main Air Supply Shutoff Valve, 1 in. npt(f) Inlet Air Filter, 1-1/4 in.
Component Identification Typical Setup (Back View) U B1 Z W X (located between metering pumps, not visible in current view) WL D D1, A1 A1 C1, A1 FIG.
Component Identification Fluid Control Assembly AA AC AL AE AG AJ ti19928a FIG.
Component Identification Main Power and Heater Controls BB BD BC BA ti20101a FIG. 4 BA Main Power ON/OFF Switch BB A Tank Water Heat ON/OFF Switch BC B Tank Water Heat ON/OFF Switch BD Optional Heated Water Flush Tank Accessory ON/OFF Switch (only used if the water heater accessory has been added to the machine) Sprayer and Flush Pump Air Controls CC CD CA CE CB CF CG r_XM1A00_312359_313289_14A FIG.
Component Identification Feed Module Air Controls CU CR CT FEED PUMP BYPASS CP CS ti20127a NOTE: Both valves shown open FIG. 6: Supply Controls CP CR CS CT CU Tank Air Pressure Regulator Tank Air Pressure Gauge Tank Air Supply Valve Agitator and Heated Water Circulation On/Off Valve Feed Pump Bypass Button Feed Pump Air Controls Feed Pump Bypass Button Use the feed pump bypass button to manually run the feed pump when the automatic tank filling function is not running the feed pump.
Component Identification User Interface NOTICE To prevent damage to soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails. DA DJ DH DG DE DF DD ti13365a DP DR DM DB DC DK DN FIG. 7: User Interface Buttons LEDs There are four types of LEDs on the display. Call out Button Function DA Use to view screens. See page 58.
Component Identification User Interface Display Main Display Screen Components NOTE: For detailed screens information, see Appendix A - User Interface Display beginning on page 58. The following figure calls out the navigational, status, and general informational components of each display screen. Current Date and Time Remaining Potlife Time Function Display Navigational Bar Go back one screen FIG.
Setup Setup Location Select a non-hazardous location with the required power and air supply to set up your sprayer. Maintain access from all sides. Unboxing The machine is shipped on two separate pallets, one with the XM PFP and one with the two feed modules. Each pallet is wrapped in heavy cardboard with a lid secured with straps. Cut the lid straps then remove the lids and cardboard.
Setup Connect Modules Choose one of the configurations shown in FIG. 9 then bolt together the three modules on a flat surface. See FIG. 10 or FIG. 11 for bolt locations. The frame bolts are included in a bag. Once connected, the assembly can be moved as one piece with a fork-truck. 5.5 in. long 1x 3.5 in. long Regardless of the chosen module configuration, the A feed module must be on the left and the B feed module must be on the right when looking at the front of the system module.
Setup Grounding 380V, 3 Phase WYE: Use a 5/32 in. (4 mm) hex key to connect the three power leads to the top terminals L1, L2, and L3. Connect neutral to N. Connect green to ground (GND). The equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode. Improper grounding can cause electric shock. Grounding provides an escape wire for the electric current.
Setup Connect Air Supply Connect air supply line to the 1 in. npt(f) air supply ball valve inlet. NOTE: Use a 3/4 in. (19.1 mm) ID minimum air hose. E ti20105a NOTE: Air supply requirement: 150 psi (1.0 MPa, 10.3 bar) maximum; 80 psi (552 kPa, 5.5 bar) minimum (while running). Flow volume required: 100 scfm (2.8 m3/min) minimum; 250 scfm (7.1 m3/min) maximum. Available fluid pressure and flow rate are directly related to available air volume.
Setup Connect Feed Module Lines to Sprayer Module 1. Connect Modules, page 15. 2. Connect the large diameter green hose from each tank bottom outlet to the respective metering pump inlet. 3. Connect the two hose bundles with a red air hose on the sprayer module to the correct connection on the respective feed module, as described below. a. Connect the red 1/2 in. air hose to the swivel union. See the ‘a’ in FIG. 14. NOTE: There is a vertical swivel union at each end of the green hose assembly.
Setup Install Level Sensor Probes Each tank uses a 37 in (94 cm) stainless steel rod, which functions as the level sensor probe, that mounts into the level sensor head and extends down into the tank. The level sensor probes are tie-wrapped to the frame of each feed module at the factory prior to shipment. The level sensor probes must be mounted into the level sensor heads before use. 1. Verify the main power switch is OFF. 2. Disconnect 3/4 in. union that holds the level sensor on top of the tank. 3.
Setup Connect the Fluid Hose Bundle to the System The system is shipped with a 50 ft (15 m) hose bundle for connecting the system to the mix manifold. 2. Connect the short purple flush hose from the solvent flush pump to the 1/4 npsm hose in the bundle. Use the 1/4 in. nipple included with the hose bundle to connect the hoses. See FIG. 17. The bundle contains one 3/4 in. ID A material hose, one 1/2 in. ID B material hose (model 262869) one 3/4 in. ID B material hose (model 24W626), one 1/4 in.
Setup 4. Locate the long temperature sensor with black heat shrink sheath and a connected cable that is tie-wrapped to the B heater power cable. a. Cut the temperature sensor loose from the tie wrap. b. Insert the sensor down inside the hose bundle so it is buried in the insulation and up against the fluid hoses. Be sure the sensor cable will not get pulled tight by the hose or catch on anything. Connect the Fluid Hose Bundle to the Mix Manifold 1. Unroll the hose bundle out to the spray area. 2.
Setup Connect the Mix Manifold to the Gun The following parts are supplied loose. Connect them to the mix manifold as follows. See FIG. 21. 1. Connect 1/2 in. ID x 2 ft hose to mix manifold (R) outlet. R S T ti20090a FIG. 21 2. Connect static mixer (S). 3. Connect 1/2 in. ID x 10 ft. hose. 4. Connect 1/2 in. x 3/8 in. nipple. 5. Connect 3/8 in. ID x 3 ft hose. 6. Connect 1/2 x 3/8 nipple. 7. Connect swivel. 8. Connect gun (T).
Setup Prime Heated Fluid Circulation System The heated fluid circulation system includes heated hoses alongside the material hoses for the length of the hose bundle, heated fluid circulation through the mix manifold, and heated fluid circulation through the tank double-wall which is insulated by a jacket. 3. Adjust the silver knob located just above the Feed Module Air Controls. When looking at the Feed Module Air Controls, the knob will be visible just above them. See FIG. 23.
Initial Startup Initial Startup Perform this procedure on new systems. Systems are tested at the factory with mineral oil and there will be residual oil in the material lines. Flush new systems if A or B material will not function properly if it contacts mineral oil. 1. Verify all procedures in the Setup section beginning on page 14 have been properly performed.
Initial Startup c. Slide main air slider valve (DA) and air motor slider valve (DF) to the OFF position. See FIG. 27. DF DE DC DD DB DA k. Ensure platen is centered on pail when it contacts it. Repeat previous steps until platen is centered on pail. l. Adjust air regulator (CB) to increase air pressure until the RAM presses into the pail. Install priming stick once fluid begins exiting the priming stick hole. NOTE: New platens components may be stiff and resist entering the pail.
Initial Startup 8. Open both ball valves on the feed module air controls. 11. Verify the sampling valves are closed. 12. Open metering pump inlet ball valves. WL D FEED PUMP BYPASS ti20127a FIG. 29 13. Turn on air supply and set metering pump air regulator to 20 psi (138 kPa 1.38 bar). To reduce the risk of explosion, never turn on heaters when solvent is in the system. 9. If not already set, adjust the feed module settings: a.
Initial Startup 20. Close the circulation valves. NOTE: To run each side independently, press repeatedly to set to or . Press and as needed to prime. Monitor containers to avoid overflow. NOTE: When priming or flushing pumps, it is normal to get cavitation or pump runaway alarms. Press to clear alarms then press again as necessary. These alarms prevent excessive pump speeds, which will damage pump packings. WL D 16. Repeat the previous step for the B side. 21.
Initial Startup 23. Prime the A material hose: a. Remove the outlet fitting from the mix manifold so materials can be dispensed without mixing. b. Place a waste pail under the mix manifold outlet. B Valve Outlet Fitting A Valve ti20088a c. Open the A side mix manifold inlet ball valve. d. Press repeatedly to set to . Press . Slowly turn metering pump air regulator (CD) clockwise to increase air pressure until metering pump A starts.
Prime Solvent Flush Pump Prime Solvent Flush Pump 7. Open the solvent flush valves. • • • • The equipment must be grounded to reduce the risk of static sparking and electric shock. Hold gun firmly to side of grounded pail when triggering into pail. Do not point gun at anyone or at any part of the body. Solvent can irritate eyes, nose, throat, and skin. Hot fluid and parts can burn skin. Wear appropriate protective wear when using flush solvents and/or if fluid temperature exceeds 110° F (43° C).
Prime Solvent Flush Pump a. After water begins dispensing from the gun, turn the water heater toggle switch located on the back of the heater ON. b. Turn the water heater power switch on the system junction box ON. ti20101a NOTE: The water heater must be filled with fluid and turned on at least 45 minutes prior to when flushing will be required. 12. Close solvent pump air valve (CB) to stop pump then trigger gun into grounded pail to relieve pressure. Engage gun trigger lock. TI19265a2 13.
Adjust Ratio and System Settings Adjust Ratio and System Settings 1. Turn key to right (setup position). Yellow LED will flash and the Setup mode Home screen will display. 2. After the red light goes out, check the temperature on the gauge and adjust as needed to get desired temperature. NOTE: Tank will not heat up faster by increasing the temperature setting. A and B Material Temperature 2. Press ting. and to change the volume ratio set- 3. When desired ratio is displayed, turn key to left.
Spray Spray 5. Open both ball valves on the feed module air controls. FEED PUMP BYPASS Do not point gun at anyone or at any part of the body. Solvent can irritate eyes, nose, throat, and skin. Hot fluid and parts can burn skin. Wear appropriate protective wear when using flush solvents and/or if fluid temperature exceeds 110° F (43° C).
Spray pressure to the metering pumps until the enabled pump(s) begin running slowly. 8. Open recirculation valves. CD CA WL D 13. Turn A and B tank fluid heaters ON. 9. Ensure metering pump air supply is OFF. 10. At the main run (fluid control) screen, press enter manual pump run mode. to ti20101a 14. To adjust tank fluid heater temperature, adjust the numbered knob on the heater. 15. Turn on the primary material heaters. a. Navigate to the Supply screen.
Spray NOTE: If you circulate the A side metering pump above 5200 psi (35.4 MPa, 354 bar), an alarm shuts down the pump to prevent accidentally spraying material while still in circulation mode. 24. Open mix manifold ball valves. 18. Once the materials reach the desired temperature as shown on the supply screen, press . ti20128a 25. Select . 26. Press to start the metering pumps. 19. Turn off the main air shutoff valve (CA). CA 20. Close recirculation valves. 27.
Spray 31. Perform the Mix and Integration Tests on page 44. When necessary, engage trigger lock then install the tip on gun. 1 2 TI19265a2 NOTE: While spraying, it is best to continuously hold the trigger. Do not release the trigger unless necessary. This maximizes the material temperature consistency and minimizes fiber buildup. 32. Adjust air regulator (CD) to the necessary spraying pressure and trigger gun to spray material on a test panel.
Flush Mixed Material Flush Mixed Material • • • • The equipment must be grounded to reduce the risk of static sparking and electric shock. Hold gun firmly to side of grounded pail when triggering into pail. Do not point gun at anyone or at any part of the body. Solvent can irritate eyes, nose, throat, and skin. Hot fluid and parts can burn skin. Wear appropriate protective wear when using flush solvents and/or if fluid temperature exceeds 110° F (43° C). Keep clear of moving parts. 7.
Park Metering Pump Rods 2. Open fluid recirculation valves. 13. Close solvent flush valves. ti20095a ti20095a WL D 3. Close mix manifold material ball valves. 14. Use a rag and solvent to clean spray tip then reinstall on gun. 15. Remove the static mixer. Clean the mix element then re-install the mixer. ti20129a Park Metering Pump Rods 4. Open the metering pump air supply ball valve. 5. Press NOTE: This procedure is only necessary when the system will not be used for more than a few hours.
Pressure Relief Procedure Pressure Relief Procedure Follow the Pressure Relief Procedure whenever you see this symbol. This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment. 1. Engage trigger lock. NOTICE The material may expand when air pressure is removed.
Pressure Relief Procedure 7. Open recirculation ball valves. 11. Close mix manifold material ball valves. ti20129a WL D 12. Perform Flush Mixed Material procedure beginning on page 36 to prevent mixed material curing in the system and to relieve pressure in the solvent lines. 8. Disengage trigger lock. 13. If the system will be shutdown for more than a few hours, fill metering pump A and B packing nuts with throat seal liquid (TSL). NOTE: Fluid pressure in the system is now relieved. TI19265a1 9.
System Verification System Verification NOTE: Each sampling valve must be primed prior to beginning this procedure to ensure best accuracy. If the clear tube connected to the sampling valve is not filled with material, prime the sampling valves. Graco recommends running the following tests daily prior to spraying on the production surface. 1. Verify the clear tube connected to each sampling valve is filled with material. If not, perform the following steps to ensure accuracy of the metering test.
System Verification 3. Set metering pump air regulator (CD) pressure to zero. Open metering pump air valve (CA). Adjust metering pump air regulator (CD) pressure to 50 psi (0.35 MPa, 3.5 bar). CA 5. Dispense fluid B as follows: a. Place a clean 1 quart (1000 cc) container under sampling valve B. CD 4. Dispense fluid A: ti20112a a. Close recirculation valves, mix manifold inlet ball valves, and sampling valves. b. Place a clean 1 quart (1000 cc) container under sampling valve A. b.
System Verification Batch Dispense or Ratio Test NOTE: This test dispenses a calculated volume of each fluid based on ratio. The two fluids combined equal the batch size selected. e. At the main run (fluid control) screen, press to enter manual pump run mode. Follow this procedure to dispense a batch (into one container) for touch-up work or to verify the dispensed ratio (use separate containers for fluids A and B).
System Verification 7. Place a clean container under sampling valve A. 12. Batch dispense: stir material until mixed. Ratio check: compare net weight of A and B materials dispensed. Confirm Batch Dispense Test The Confirm Batch Dispense Test screen displays when the batch dispense test completes without error. This screen displays the selected ratio between the metering pumps and the weight of material dispensed from each metering pump. ti20111a 8. Press . Metering pump A light comes on. 9.
System Verification 3. Enter Test mode in the run (fluid control) screen. See Test Screens on page 69. Select run down stream valve leak test. to 4. Select . Press . Ensure dosing valves (AA, AB) are open by verifying blue LEDs are illuminated for both dosing valves. 5. If test is successful, both metering pumps will stall against the downstream valves when the dosing valves (AA, AB) are open.
Empty and Flush Entire System Empty and Flush Entire System a. With director valve (DC) in the neutral position and the RAM air regulator (DB) backed out, slide main air slider valve (DA) ON. • • Running solvent through heaters can cause a fire or explosion. Turn off heaters and allow to cool before flushing. Do not turn on heaters until fluid lines are clear of solvent. Splashing fluid can land on exposed body parts and irritate the skin.
Empty and Flush Entire System f. 5. Close the circulation valves. Close the A side mix manifold inlet ball valve. g. Close the tank air supply ball valve then open the brass valve on the top of the tank to relieve tank air pressure. FEED PUMP BYPASS WL D 6. Empty the A material tank: ti20127a a. Close the A side mix manifold inlet ball valve. b. Disconnect the A material hose from the mix manifold at the fitting between the ball valve and check valve. FIG. 35 The tank lid assembly is heavy.
Empty and Flush Entire System been pumped and there is air at the metering pump inlet. Press to stop metering pump then back out the air pressure regulator. e. Continue adding solvent to tank until enough solvent is in the tank to expel the remaining material from the hose bundle material line. 8. Salvage the A material from the hose bundle material line then flush the hose bundle material line: 7. Add solvent to the A material tank: a.
Empty and Flush Entire System 9. Verify tank air pressure is still relieved, then purge the material from the tank return line. a. Open the circulation valves. WL D b. Disconnect the tank return line from side of the tank. c. Place the return line in a waste container. d. Press . Slowly turn metering pump air regulator (CD) clockwise to increase air pressure until metering pump A starts. Continue until clean solvent is dispensed, then press to stop the metering pump.
Prepare Level Sensor for Shipping Prepare Level Sensor for Shipping NOTICE To prevent damage to the level sensor probe, do not ship the feed module with the tanks empty and the level sensor probe installed. This can cause the probes to vibrate severely and damage the level sensor head. If possible, transport the tanks with at least 5 gallons (19 liters) of viscous material in the tanks, which is enough for the material level to be above the probe end and will prevent the probe from vibrating severely.
Download Data from USB Download Data from USB USB Logs Download Setup By default, the ratio spray logs record data every 60 seconds. This 60 second interval will record about 32 days of data if spraying 8 hours per day, 7 days per week. To change the default, see Download Setup, page 50. This log can hold up to 18000 lines of data. Navigate to the System Setup screen. Change the number of hours of recorded data to download (default is 768 hours), by pressing to Ratio Log 1 (Default log for download.
Download Data from USB 2. The USB download screen automatically displays, and the selected log(s) automatically downloads. The USB symbol flashes to indicate download is in process. NOTE: To cancel download, press while in process. Wait for USB icon to stop flashing, and then remove USB flash drive. 3. The USB icon stops flashing when download completes. The box below displays cates the download was successful , which indi- 4. Remove USB flash drive from USB port (DR). 5.
Maintenance Maintenance See the following table for maintenance tasks and frequency. See the following sections for details for each task. Frequency • • • • 5. After TSL is added, tighten dosing valve packing nuts 1/4 turn after nut contacts packings; about 145-155 in-lb (16-18 N•m).
Maintenance Clean the System 1. Ensure all equipment is grounded. See Grounding, page 16. 2. Ensure the area where the sprayer will be cleaned is well ventilated; and remove all ignition sources. 3. Turn off all heaters and allow equipment to cool. 4. Flush mixed material. See Flush Mixed Material, page 36. 5. Perform Pressure Relief Procedure, page 38. This includes flushing the system and parking the metering pumps. 6. Turn main power switch OFF. 7.
Troubleshooting Troubleshooting Alarms See Appendix B - Alarms, starting on page 76. General Tips The following information will help ensure the system is set up properly. Grounding • • Ensure incoming power is grounded. 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. Air Supply • Use at least a 3/4 in. (19mm) ID air hose, no longer than 50 feet (15m).
Troubleshooting Individual Control Module LED Diagnostic Information The following LED signals, diagnosis, and solutions are the same for the display module, advanced fluid control module (AFCM), fluid control cube, high power temperature control module (HPTCM), and USB module. LEDs are located next to the module power cable. Module Status LED Signal Diagnosis Solution Green on System is powered up and power supply voltage is greater than 11 Vdc.
Troubleshooting Problem Cause Solution Metering pumps do not run when Run Air pressure to metering pumps too low Increase pressure to 50 psi (0.35 MPa, Mode is selected and the blue LED is illu3.5 bar) or greater. minated. Air pressure to metering valves is too low. Check air regulator behind main air panel. Should be 80-85 psi (0.55-0.59 MPa, 5.5-5.9 bar). Circulation valves or mix manifold ball valves are not open. Open ball valves.
Troubleshooting Problem Cause Poor spray pattern. Fluid pressure too low. Also, see “System runs erratically” below. Fluid temperature too low. Spray tip dirty or worn. Solution Increase metering pump pressure. Increase fluid temperature. Relieve pressure. Clean or replace tip. Follow gun manual instructions. Mix manifold, mixer, swivel, gun, or hoses Inspect parts for cured material. Clean or partially plugged or too restrictive. replace, or use larger hoses and mixer. System runs erratically.
Appendix A - User Interface Display Appendix A - User Interface Display The user interface display is divided into three main functions: Setup, Command, and Automatic. • download USB logs.
Appendix A - User Interface Display Setup Mode Screens To enter the Setup Mode screens, turn the setup key lock (DJ) to the right. The key cannot be removed when in Setup Mode. See FIG. 7 on page 12. Some setup screens can be disabled, see Enable Setup Screens on page 63.
Appendix A - User Interface Display Home Setup Screens Software Versions Home This screen displays the versions and part number of the system components. Refer to the following table for Home is the first screen that displays in Setup mode. It shows the current metering pump ratio and enables users to change the mix ratio and access the following screens: system setup, enable/disable functions, maintenance setup, and limits. Refer to the following table for more details.
Appendix A - User Interface Display System Setup Screens Potlife/Hose Length System Setup enables users to configure system settings for fluid control and operator interaction. Refer to the following table for details. NOTE: Some system settings must be enabled from the Enable Setup screens before users can change or set configurations. See Enable Setup Screens, page 63, for instructions. Icon Function Set number of minutes before mixed material will set in hose.
Appendix A - User Interface Display Date/Time/Units Tank Fill Use this screen to set day, time, and units that will be displayed on each screen. The selected language is used in each USB log. The following USB languages are supported: English, French, German, Spanish, Russian, Italian, Chinese, Japanese, Korean, Norwegian, and Polish. Graco recommends leaving all of the settings on this screen at the factory defaults.
Appendix A - User Interface Display Enable Setup Screens Icon Use these screens to enable and disable functions, screens, and USB download log files. Checked boxes indicate the function, screen, or log file is enabled. Refer to the following table for details. To enable and disable functions, screens, and USB log files, press Enable or disable dosing valve maintenance setup screen. Enable or disable incoming air filter maintenance setup screen.
Appendix A - User Interface Display Enable Setup Screen 2 Maintenance Setup Screens (Shown with factory default settings.) Use these screens to set maintenance setpoint amounts for pumps and dosing valves. The maintenance setup 2 screen enables users to schedule the number of days between changing the main incoming air filter before a reminder advisory will sound.
Appendix A - User Interface Display User Limits Setup Screens Process Pressure Limits (for spray mode) Use these screens to set and adjust pressure and temperature limits for both metering pumps, including limits that will issue advisories and alarms. Refer to the following table for details. The allowable range for the temperature setpoint is 34° 160°F (1° - 71°C). If the temperature or pressure setpoint is zero, pressure limits and alarms are disabled.
Ratio Restrictor Spray Mode Pump Mode Park Pump (Spray Mode shown) Run (Fluid Control) Screens Pump Test Weight/Volume Batch Test Valve Test (Pump Volume Test shown) Test Screens Alarm Log Totalizer Maintenance 2 Maintenance 1 Alarm Information Information Screens in each section Go to primary screen Supply Screen Appendix A - User Interface Display Operator Command Mode Screens To enter the Operator Command Functions screens, turn the setup key lock (DJ) to the left. See FIG.
Appendix A - User Interface Display Run (Fluid Control) Screens Spray Mode Run (fluid control) is the first screen displayed at power on. It enables users to spray material, and operate and park metering pumps. Run consists of two screens: power on/enter and ratio mode. Users must be in this mode to spray or proportion material. Press the button below the spray icon to enter this mode. The power on/enter screen cycles through power on mode, spray mode, pump mode, and park mode.
Appendix A - User Interface Display Adjust Restriction Screen Park Mode Users must be in this mode to park the metering pump fluid rods to the bottom of their stroke. Press the button below the park icon to enter this mode. Ratio Mode This screen displays the current ratio or the adjust restriction screen. To access this screen, press . This screen shows the balance of the A and B fluid sides.
Appendix A - User Interface Display Test Screens Use this screen to run batch dispense tests, pump tests, and down stream valve leak tests. Icon If weight mode is used, enter the net weights of each dispensed material in the respective input boxes on this screen. If they are within the ratio tolerance set on the Setup Mode Ratio Test screen, a check will appear in the box. The results are entered into the USB logs.
Appendix A - User Interface Display Batch Dispense or Ratio Test Down Stream Valve Leak Test Use this screen to dispense a selected total volume of material on ratio. For example, 1000 ml at 4:1 = 800 ml of A + 200 ml of B. The total batch volume can be selected from the drop down menu. The dispense material can be used to check the ratio or to mix together and use in production. See Batch Dispense or Ratio Test procedure on page 42.
Appendix A - User Interface Display Information Screens Icon Use this screen to view alarm diagnostic information, alarm logs, and pump batch and grand totals. These screens also enable users to view maintenance information for pump and check valves, including the maintenance schedule. Go to maintenance screen. Allows user to view maintenance information.See Maintenance Setup 2, page 64. Flush confirm. Use when the potlife timer is enabled.
Appendix A - User Interface Display Totalizers and Job Number Use this screen view the grand and batch totals for each pump and both pumps combined. The units of measurement are displayed on the bottom of the screen and displayed in the units of measurement selected during setup. Grand total is the amount of material the system has dispensed during its lifetime. Batch total is the amount of material dispensed since the last user reset. A job number can be entered at the beginning of each spray job.
Appendix A - User Interface Display Supply Screen Use these screens to turn on and off automatic tank filling, turn on and off the fluid heaters and hose heat, and change temperature setpoints for each fluid heater and for the hose heat. When automatic tank filling is on, the feed pump will begin pumping fluid into the tank when the fluid level goes below the bottom arrow. It will continue filling until the fluid level reaches the upper arrow.
Appendix A - User Interface Display Automatically Displayed Screens Potlife Screen Icon This screen automatically displays when a potlife advisory occurs. The screen automatically closes when the advisory ends or the user presses the flush confirm button. Refer to the following table for more details. Icon Function Flashes while data download is in process. Check mark appears after download completes. Indicates download was successful. Function If download was not successful, appears.
Appendix A - User Interface Display FIG.
Appendix B - Alarms Appendix B - Alarms Alarms Overview Icon Function Moving up View Alarms Moving down 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. Top changeover Bottom changeover Both reed switches are active. Start of changeover or motor icing problem.
Appendix B - Alarms Alarm Code Key Use the following table as a quick guide to determine alarm code meaning.
Appendix B - Alarms Possible Alarms by Mode The following table outlines the alarms that you may receive while operating the system. The alarms are categorized according to each mode. Mode Spray Control Logic Dosing valves close for startup test; green light blinks. If fluid pressure is under 1000 psi (7 MPa, 70 bar), STOP. If pumps move (indicating internal leakage), STOP. P4BX Dosing valve A opens, and dosing valve B cycles to maintain ratio.
Appendix B - Alarms Alarm Code Troubleshooting NOTE: See PFP Plural-Component Sprayers Repair-Parts manuals for non-alarm based troubleshooting. * Indicates the alarm is user-defined. Alarm Code Alarm Problem When Active A4DA A4DB A/B Material Heater Over-Current Alarm Always A4DH Hose Heater Over-Current Alarm Always A8DA A8DB A/B Heater No Current Alarm Always A8DH Cause Temperature Control Module is bad. Replace module. Heater is bad.
Appendix B - Alarms Alarm Code Alarm Problem When Active Cause Solution DFAX DFBX Pump Did Not Stall Against Fluid Pressure On Up Stroke Only. Pump Test Pump piston check valve, piston packings, or dosing valve are not holding fluid pressure. Flush pump. See General Tips, page 54. Recheck. Remove, clean, and repair lower. See XM PFP repair manual. DGAX DGBX Pump Did Not Stall Against Fluid Pressure On Down Stroke Only. Pump Test Pump inlet check or dose valve is fouled, or damaged.
Appendix B - Alarms Alarm Code L3F1 L3F2 L4F1 L4F2 Alarm Problem Tank Level High Advisory Tank Level High Alarm When Active Cause Spray and Tank level greater than 10% above Tank tank full setpoint for 3 seconds. Always Tank Level Sensor Failure Alarm Always Lower the tank level. Air solenoid to feed pump is bad. Replace air solenoid. Fluid expanded when air pressure was removed. Increase air pressure to solenoid. Tank level greater than 90% of total Lower the tank level.
Appendix B - Alarms Alarm Code P9BX Alarm Problem B Pump Pressure is Abnormally Low Compared to A Pump Pressure. When Active Spray Cause B air motor is icing causing restriction and lower fluid pressure. Solution Open the air motor de-ice bleed air controls. Allow ice to melt. Dry compressed air. Heat compressed air. Use a smaller tip. QDAE Dosing Size A Alarm Spray B pump is binding. Repair lower. See XM PFP repair manual. B air motor is binding. Repair air motor. See XM PFP repair manual.
Appendix B - Alarms Alarm Code R5BE Alarm Problem Dosing Sizes Are Not Optimized. When Active Spray Cause Dosing valve is operating near high or low timing limits. Solution Balance A and B fluid hoses. See XM PFP Mix Manifold manual. Or change ‘B’ restriction. Check Restriction screen. R9BE System detected five R4BF (Ratio High B) or five R1BF (Ratio Low B) alarms within five minutes. Sprayer shuts down for five minutes for operator to resolve problem. Spray See R4BE or R1BE alarm causes.
Appendix B - Alarms Alarm Code Alarm Problem T6F1 T6F2 Tank RTD Failure Advisory T8DA T8DB A/B Material Temperature Not Rising Alarm T8DH Hose Temperature Not Rising Alarm V1MA V1MB V1MH When Active Always Cause Temperature sensor is bad Replace temperature sensor Cable is disconnected or bad Connect temperature sensor cable to system. Heater A/B Heater bad. Repair heater. Heater voltage too low. Increase heater voltage to 200 - 240 VAC. Hose Heater Heater bad. Repair heater.
Technical Data Technical Data XM PFP Mix Ratio Range Ratio Tolerance Range (before alarm) Maximum Flow Rate (measured with oil) Fluid Viscosity Range US 1:1-10:1 (in 0.01 increments) +/- 5% 3 gallons per minute Metric 13.6 liters per minute Handles mastic materials which are loaded into heated tanks with ram-fed priming piston pumps Air Inlet 1 in.
Technical Data XM PFP US Wetted Parts Suction Tube (Flush) Tanks Flush Pump Hoses A and B Metering and Feed Pumps Dosing Valves Manifold Metric Aluminum Stainless Steel Carbide, PTFE, stainless steel, UHMWPE Nylon Carbon steel, alloy steel, stainless steel, zinc and nickel plating, ductile iron, tungsten carbide, PTFE Carbon Steel, nickel plating, carbide, polyethylene, leather Carbon steel, nickel plating, carbide, stainless steel, PTFE, UHMWPE Stainless steel housing with stainless elements Mixer Appr
Technical Data Dimensions Min: 70 in. (1780 mm) Max: 84 in. (2130 mm) ti20268a 76 in. (1930 mm) 52 in. (1320 mm) Min: 70 in. (1780 mm) Max: 84 in. (2130 mm) ti20267a 104 in. (2640 mm) 38 in.
Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.
