Graco XM PFP Setup & Operation Download Page 64

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Troubleshooting Information

3A2776K

Metering pumps do not run when Run
Mode is selected and the blue LED is illu-
minated.

Air pressure to metering pumps too low

Increase pressure to 50 psi (0.35 MPa,
3.5 bar) or greater.

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.

Air pilot lines are obstructed

Check pilot lines for kinks or pinches.

Solenoid valve stuck.

Actuate solenoid manually, if it does not
operate, replace solenoid. See the XM
PFP repair manual.

Air pilot valve(s) to motor stuck.

Replace valve(s). See XM PFP repair
manual.

Metering valve(s) not opening.

Service or replace valve(s). See XM PFP
repair manual.

Air motor stalled.

See manual 3A5423.

Pump Test completes without error, but A
or B component has more than 750cc of
fluid in beaker.

Incorrect metering pumps were selected
in System Setup screens.

See

Appendix A - User Interface Dis-

play

beginning on page 67.

Air is trapped in fluid due to excessive
agitation, circulation, and heat. Fluid is
measured by volume when it is com-
pressed under pressure.

Repeat Pump Test with fresh fluid.

If the specific gravity of each fluid is
known, check samples by weight (750cc
x specific gravity equals weight in grams).
If weight is correct, extra volume in bea-
ker is air.

Batch Test completes without error, but A
or B component has more fluid in beaker
than displayed on screen.

See causes for previous pump test prob-
lem.

See solutions for previous pump test
problem.

Sprayer does not start when start button
is pressed.

Faulty start switch or wire harness.

Check start switch and wiring harness
continuity; switch is normally open circuit.
See Electrical Schematics in the XM PFP
repair manual.

Faulty stop switch or wiring harness.

Check stop switch and wiring harness
continuity; stop switch is normally closed
circuit. See Electrical Schematics in the
XM PFP repair manual.

Fluid valves leaking at rod.

Loose or worn packings.

Tighten packing nut. If leak continues,
replace packings.

Fluid valve leaking between main and
outlet housings.

O-ring on seat has failed.

Replace both o-rings on that seat.

Material does not cure consistently.

Ratio not set correctly.

Check that correct ratio is set and set by
volume.

Material not mixing correctly.

Test metering pump. Make sure mixer is
clean; flush as needed.

Position mixer after integrator hose.

Material not properly conditioned before it
was added to sprayer.

Mix material thoroughly.

Not using enough integration hose.

Add more integration hose.

Select “fast dosing” in setup.

Problem

Cause

Solution

Summary of Contents for XM PFP

Page 1: ...ction PFP intumescent epoxies For professional use only See page 3 for model information including maximum working pressure and approvals Important Safety Instructions Read all warnings and instructions in this manual and in all related manuals before using this equipment Save all instructions WL E EN ...

Page 2: ... 30 Prime Flush Pump 36 Adjust Ratio and System Settings 38 Verify Desired Ratio Mode 38 Adjust Ratio Set Point 38 Temperature Settings 38 Spray 40 Flush Mixed Material 44 Park Metering Pump Rods 45 Pressure Relief Procedure 46 System Verification 48 Pump and Metering Test and Calibration for Ratio by Weight Mode 48 Batch Dispense or Ratio Test 50 Down Stream Valve Leak Test 52 Mix and Integration...

Page 3: ...ditional information 262943 A 1 5 1 to 4 1 9902471 Certified to CAN CSA C22 2 No 88 Conforms to UL 499 Not for use in explosive atmospheres or hazardous locations 9902471 Certified to CAN CSA C22 2 No 88 Conforms to UL 499 II 2 G Ex db ia pxb IIA T3 Gb Maximum Fluid Working Pressure Maximum Air Working Pressure A and B Materials 6000 psi 41 MPa 414 bar Flushing Fluid 4500 psi 31 MPa 310 bar Heatin...

Page 4: ... Parts 312376 Check Mate Pump Packages Instructions Parts 312792 Merkur Pump Repair Parts 312794 Merkur Pump Assembly Instructions Parts 313526 Supply Systems Operation 313527 Supply Systems Repair Parts 312374 Air Control Instructions Parts Accessories 332073 Hot Water Flush Kit Instructions 3A2987 Air Dryer Kit Instructions 406691 Hose Rack Parts 334931 Caster Kit Instructions Other 306861 Ball ...

Page 5: ...t be connected to ground at one point For information on the required dimensions of the flameproof joints contact the holder of this certifi cate Graco Inc Flame path joints are not intended to be repaired Special fasteners for securing equipments covers on the flameproof heaters shall have a minimum yield strength of 1 100 MPa and be corrosion resistant and sized M8 x 1 25 x 30 FIRE AND EXPLOSION...

Page 6: ...Procedure when you stop spraying and before cleaning checking or servicing equipment Tighten all fluid connections before operating the equipment Check hoses and couplings daily Replace worn or damaged parts immediately BURN HAZARD Equipment surfaces and fluid that s heated can become very hot during operation To avoid severe burns Do not touch hot fluid or equipment MOVING PARTS HAZARD Moving par...

Page 7: ... in which you are using it Use equipment only for its intended purpose Call your distributor for information Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not kink or over bend hoses or use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations TOXIC FLUID OR FUMES HAZARD Toxic fluids or fume...

Page 8: ... 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 NOTICE Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime When changing materials flush the equipment multiple times to ensure it is thoro...

Page 9: ...lter 1 1 4 in G Air Controls for Sprayer and Flush Pump see page 13 H Viscon HP Heater for hose bundle J Main Power and Heater Controls see page 12 K Viscon HF Material Heater L Air Powered Agitator with Lubricator M Feed Pump N Recirculation Control Valve P Pressure Tank Double Wall Temperature Conditioned R Remote Mix Manifold S Static Mixer Assembly T Spray Gun U Air Motor V Feed Module Air Con...

Page 10: ...r W High Pressure Fluid Metering Pump X Flush Pump Merkur Pump Z Air Regulator for Feed Tanks and Pumps A1 Heated Tank Circulation Components uses a Viscon B1 TSL Supply Bottle and Bracket C1 Heated Fluid Circulation Pump for Hose Bundle D1 Insulation Jacket E1 Explosion Proof Box Hazardous Location System only F1 Junction Box Non Hazardous Location System only or Purge Box Hazardous Location Syst...

Page 11: ... AA Dosing Valve AC Recirculation Valve AE Sampling Valve AG Outlet Check Valve AJ Hose Connection Model 262869 A side 3 4 npt m B side 1 2 npt m Hose Connection Model 24W626 A side 3 4 npt m B side 3 4 npt m AL Pressure Sensor FIG 3 AA AC AG AL AE AJ ti19928a ...

Page 12: ...h BD Optional Heated Water Flush Tank Accessory ON OFF Switch only used if the water heater accessory has been added to the machine standard on hazardous location models CA Main Power ON OFF Switch hazardous location FIG 4 ti26689a BB BD Hazardous Location System Non Hazardous Location System CA r_XM1A00_312359_313289_14A Hazardous Location System BB BD BA ...

Page 13: ... tion Main Power On Off Switch hazardous location see Main Power and Heater Controls page 12 CB Flush Pump Air On Off Control CC Inlet Air Pressure Gauge CD Metering Pump Air Regulator CE Metering Pump Air Regulator Gauge CF Flush Pump Air Gauge CG Flush Pump Air Regulator FIG 5 CA CB CC CD CE CG CF r_XM1A00_312359_313289_14A ...

Page 14: ...3 Feed Pump Air Controls DA RAM Air ON Exhaust Slider Valve DB RAM Air Regulator DC RAM Up Down Director Valve DD RAM Blowoff Valve DE Air Motor Regulator DF Air Motor ON Exhaust Slider Valve RAM Blowoff Valve DD To easily remove the RAM from the pail press and hold the RAM Blowoff Valve button while lifting the RAM platen A small amount of air pressure will be supplied to the pail to push the pai...

Page 15: ...s DE Alarm Reset Resets alarms and advisories DF Left Right Move between screens in run or setup 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 drop down fields option boxes and selectable values within Setup screens DJ Setup Key Lock Change ratio or enter Setup mode DR USB Port Connection for data download Ref L...

Page 16: ... components of each display screen The system ratio mode shows if the mix ratio target is by volume or weight If the weight is crossed out the system must be calibrated before running See Pump and Metering Test and Calibration for Ratio by Weight Mode on page 48 FIG 8 Main Display Screen Components shown with all display features enabled Current Date and Time Go back one screen Navigational Bar Fu...

Page 17: ... which are higher volume and or viscosity on the A side and lower volume and or viscosity on the B side 1 1 mix ratio machines will normally change the B side circulation return hose from 3 8 in to 1 2 in ID to balance the recirculation speeds 1 1 mis ratio machines also use outlet hose bundles which are 3 4 in on both sides The outlet fittings on the machine and the inlet fittings on the mix mani...

Page 18: ...ithin 12 in of each other and in one of the two configurations in FIG 9 to ensure hoses and cables can reach their connections If the front to back module configuration is used install the two supplied straight steel horizontal braces between each feed module and the sprayer module see FIG 11 These are not used in the side by side module configuration Part Description Qty 115211 SCREW cap hex head...

Page 19: ...on Hazardous Location Use a 5 32 in 4 mm hex key to connect the three power leads to the top terminals T4 L1 and L2 Connect neutral to L3 Connect green to ground GND Hazardous Location Models 200 240 VAC 3 Phase Delta Hazardous Location Use a screwdriver to connect the three power leads to the left side of terminals TB3 TB4 and TB5 Connect green to ground TB1 350 415 VAC 3 Phase WYE Hazardous Loca...

Page 20: ...supply line to the 1 in npt f air supply ball valve inlet Use a 3 4 in 19 1 mm ID minimum air hose 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 A typical single gun XM PFP application...

Page 21: ... vertical unions are tightened check that the hose clamps on the green hose are tightened to approximately 90 100 in lb 10 11 N m 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 15 b Connect the 1 4 in OD air signal tube to the t...

Page 22: ...hose from the dosing valve connects to the side of the A tank The 3 8 in circulation hose from the dosing valve connects to the side of the B tank Systems that will be used for 1 1 mix ratio materials need to change some fittings and circulation hoses Use parts from kit 24X461 supplied with your machine See manual 334939 for instructions FIG 16 3UHVVXUH 7DQN 6 VWHP OXVK HDWHU HDWHU PS1 TB8 TB9 TB1...

Page 23: ... sensor heads before use 1 Verify the main power switch is OFF 2 Disconnect 3 4 in union that holds the level sensor on top of the tank 3 Apply blue thread lock to the threads in the top of the rod 4 Feed the rod into the tank and screw the threaded end up into the sensor head 5 Use a pliers to grab the flat on the rod and tighten the rod up into the sensor head Do not over tighten Level Sensor Ca...

Page 24: ...ion the hose bundle end with the four loose red and blue tubes at the machine outlet Systems 262869 and 262943 Connect the 3 4 in A and 1 2 in B hoses to the respective material outlet check valves on the front of the system See FIG 19 Systems 24W626 and 262945 Connect the 3 4 in A and 3 4 in B hoses to the respective material outlet check valves on the front of the system See FIG 19 2 Connect the...

Page 25: ...t nipple and connect the 3 4 in A and 3 4 in B hoses to the material inlet ball valves on the mix manifold Color code material hoses green and blue with respective color identification on mix manifold See FIG 23 3 Remove the U shaped tube connectors only from the end of the longer set of red and blue tubes Trim the excess tubing to fit the one set of the red and blue tubes fully into the two brass...

Page 26: ...ket heat circulation system was pre filled at the factory The tank to tank circulation hoses use quick disconnect fittings that were connected back to their own tank for shipping Disconnect these fittings and connect them back to the opposite tank as shown in FIG 25 or FIG 26 Prime Heated Hose Bundle Fluid Circulation System The heated fluid circulation system includes heated hoses alongside the m...

Page 27: ...Setup 3A2776K 27 FIG 25 Heated Fluid Diagram For Tank Heat WL E Side By Side Configuration See Front to Back Configuration FIG 4 page 12 ...

Page 28: ...Setup 28 3A2776K FIG 26 Heated Fluid Diagram For Tank Heat Hazardous Location Shown Front to Back Configuration ...

Page 29: ...g System NOTE The double walled tanks are pre filled with a water glycol mix at the factory If your tanks are already filled skip this section On all models there is only one pump and one heater which is located on the A side feed module 1 Add a 50 water 50 glycol anti freeze mix to the small translucent tank located between the tank and feed pump on the feed module 2 Turn the agitator and tank he...

Page 30: ... c While the system is in the purge sequence wait approximately 3 minutes until the right indicator light turns green The system display will turn on when the purge complete indicator turns green after a 3 minute purge sequence For hazardous location models the system will turn off if the air is locked turned off or depressurized Open the main power switch CA to turn on system and allow the purge ...

Page 31: ...h material NOTE If adding flush solvent remove the platen from the feed pump by loosening the two setscrews and the air tube Drop the feed pump directly into the pail a Navigate to the Supply screen then press to activate automatic tank filling See page 83 b Remove the priming stick from the platen c Slide main air slider valve DA and air motor slider valve DF to the OFF position See FIG 32 d Back...

Page 32: ...de the air motor slider valve DF to the OFF position to stop the feed pump n To lift the platen out of the pail press the blow off valve DD then lift the director valve The feed pump will push pressurized air into the pail to remove it from the platen Do not let the pail lift off of the frame If it does lower the platen then retry o Repeat the previous steps as necessary until both tanks are fille...

Page 33: ...ing pump A starts Continue to run pump slowly and dispense into pail until clean material comes out of the return line Press to stop pump Back out the metering pump air regulator 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...

Page 34: ...eatedly to set to Press Slowly turn metering pump air regulator CD clockwise to increase air pressure until metering pump A starts b With a waste container beneath the valve open the A sampling valve slowly until clean material dispenses then close the sampling valve 23 Repeat the previous step to prime the B sampling valve 24 Prime the A material hose a Remove the outlet fitting from the mix mani...

Page 35: ... dispenses from the A material line then press to stop pump e Close the A side mix manifold inlet ball valve then reconnect to the mix manifold Back out the metering pump air regulator f Repeat for the B material line NOTE Now all of the material lines are primed except for the section from the mix manifold to the gun 25 Perform the Prime Flush Pump procedure on page 36 to flush out the oil from t...

Page 36: ...e hot water flush kit is not used place flush pump siphon tube in the pail of solvent 6 If the optional hot water flush kit is used turn on the water hose connected to the water inlet Do not turn on the water heater yet a Fill the tank b Be sure that the flush pump siphon hose pick up tube is latched in the water tank c Turn on the heated water circulation pump 1 2 cycle second 7 If the hot water ...

Page 37: ... with a rag to prevent splash back 10 Open flush pump air valve CB Pull out and slowly turn flush pump air regulator CG clockwise until flush pump begins to slowly cycle 11 Continue to dispense until all air is purged 12 Close flush pump air valve CB to stop pump then trigger gun into grounded pail to relieve pressure Engage gun trigger lock 13 Close the flush ball valves on the mix manifold ti201...

Page 38: ...cks to be done by weight See Appendix A Ratio Test page 71 Adjust Ratio Set Point 1 Turn key to right setup position Yellow LED will flash and the Setup mode Home screen will display 2 Press and to change the volume or weight ratio setting Current setting of volume or weight is shown in the upper right corner 3 When desired ratio is displayed turn key to left Yellow LED will turn off 4 Change all ...

Page 39: ... B primary heaters See Spray procedure for pre heating procedure to use prior to spraying Hose Bundle Temperature Set the desired hose bundle temperature on the supply screen Be sure the knob on the Viscon HP hose heater the middle of the three heaters on the front of the system is turned fully clockwise full ON position Always leave in the full ON position Heater has a separate digital control mo...

Page 40: ...ering pump regulator CD is turned counterclockwise to 0 psi 3 For non hazardous location models Turn the main power switch BA ON and verify the XM PFP air supply ball valve E is open Open the pump air valve CA For hazardous location models Turn the main power valve CA ON and verify the XM PFP air supply ball valve E is open 4 Perform Prime Flush Pump page 36 to ensure the flush pump is prepared to...

Page 41: ...or CD to slowly increase the air pressure to the metering pumps until the enabled pump s begin running slowly For Hazardous Location Models the system on off valve is already open 14 Turn A and B tank fluid heater BB ON if it isn t already ON 15 To adjust tank fluid heater temperature adjust the numbered knob on the heater 16 Turn on the primary material heaters a Navigate to the Supply screen See...

Page 42: ...he pump to prevent accidentally spraying material while still in circulation mode NOTE If the circulation valves are closed while circulating but the control is left in Circulation Mode the machine will alarm after 5 seconds and exit Circulation Mode This is done to prevent spraying in Circulation Mode 19 Once the materials reach the desired temperature as shown on the supply screen press 20 Turn ...

Page 43: ...rial temperature consistency and minimizes fiber buildup 33 Adjust metering pump air regulator CD to the necessary spraying pressure and trigger gun to spray material on a test panel Look at ratio screen to ensure it is reading the correct ratio Continue spraying on the test panel until the desired pattern results then begin spraying the production surface 34 Follow Flush Mixed Material on page 44...

Page 44: ...l valves on the mix manifold 7 Disengage trigger lock and trigger gun into a grounded pail Use a pail lid with a hole to dispense through Seal around hole and gun with a rag to prevent splash back 8 Open flush pump air supply valve CB Pull out and slowly turn flush pump air regulator CG clockwise to increase air pressure Use lowest pressure needed to flush material out of hose 9 Continue dispensin...

Page 45: ... pump shaft by extending the pump so the portion of the shaft that is exposed to material is not exposed to the air 1 Turn the metering pump air regulator CD counterclockwise to 0 psi 2 Open fluid recirculation valves 3 Close mix manifold material ball valves 4 Open the metering pump air supply ball valve 5 Press then press to start metering pumps Slowly adjust air pressure regulator until pumps b...

Page 46: ...structions Read all warnings and instructions in this manual before using the equipment Save these instructions 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 equ...

Page 47: ...d hole and gun with a rag to prevent splash back 10 Engage trigger lock 11 Close mix manifold material ball valves 12 Perform Flush Mixed Material procedure beginning on page 44 to prevent mixed material curing in the system and to relieve pressure in the flush lines 13 If the system will be shutdown for more than a few hours fill metering pump A and B packing nuts with throat seal liquid TSL NOTE...

Page 48: ... the fluid can be returned to the supply tanks NOTE During each dispense the flow will stop once to stall the upstroke once to stall the downstroke and then it will finish the dispense Do not close the sampling valve until the fluid flow stops and the blue metering pump light DK goes out NOTE Material hoses from the system to the mix manifold must be filled with material and pressurized for testin...

Page 49: ...lly twice during test and again when dispense completes Metering pump A light DK turns off metering pump B light DK turns on e Close sampling valve A AE 6 Dispense fluid B as follows a Tare and place a clean 1 quart 1000 cc container under sampling valve B b Slowly open and adjust sampling valve B to achieve desired flow Metering pump stops automatically twice during test and again when dispense c...

Page 50: ...r to verify the dispensed ratio use separate containers for fluids A and B When checking the ratio use a gram scale to tare the two containers then weigh the dispensed materials 1 Close mix manifold material ball valves 2 Close recirculation ball valves 3 Pressurize the material lines d Set metering pump air regulator CD pressure to 0 psi Verify metering pump air valve CA is open e At the main run...

Page 51: ...under sampling valve B AF b Slowly open and adjust sampling valve B AF to achieve desired flow The metering pump stops automatically when dispense completes Metering pump B light DK turns off c Close sampling valve B AF 13 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 display...

Page 52: ...mote mix manifold 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 78 Select to run down stream valve leak test 4 Select Press Ensure dosing valves AA AB are open by verifying blue LEDs are illuminated for both dosing valves 5 If test is successful both metering pumps will ...

Page 53: ...us pattern on foil at typical pressure setting flow rate and tip size until multiple changeovers of each metering pump have occurred Trigger and de trigger at typical intervals for the application Do not overlap or cross over your spray pattern 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...

Page 54: ... air slider valve DA ON b Lift the director valve to the UP position then press and hold the blowoff button DD while increasing the air pressure using the RAM air regulator When the feed pump exits the pail move the director valve to the neutral position and release the blowoff button 3 Empty the feed pump outlet material lines to the tank a Slide the air motor slider valve DF ON b Rotate air moto...

Page 55: ...emaining material from the walls of the tank into the tank outlet j Re install the tank lid assembly k Close the brass valve on the top of the tank then open the tank air supply ball valves to pressurize the tank l With selected press Slowly turn metering pump air regulator CD clockwise to increase air pressure until metering pump A starts Wait until the metering pump speed decreases meaning that ...

Page 56: ...ering pump air regulator CD clockwise to increase air pressure until metering pump A starts Continue until clean solvent is dispensed then press to stop the metering pump Back out the air pressure regulator e Reconnect hose bundle material line to the mix manifold f Disengage trigger lock then trigger gun into the waste container and press Slowly turn metering pump air regulator CD clockwise to in...

Page 57: ...oose but will not be removed It is not necessary to remove the level sensor cable 2 Use a pliers to grasp the flat on the rod and unscrew it out of the sensor head 3 Pull the probe up out of the tank and tape it to the square tube frame securely to prevent vibration 4 Replace the 3 4 in union and level sensor head on the tank lid Tighten securely for shipping 5 After shipment see Install Level Sen...

Page 58: ... to 39000 lines of data Data Log 4 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 43000 lines of data The 120 second recording period cannot be adjusted Download Setup Navigate to the System Setup screen Change the number of hours of recorded data...

Page 59: ...aco 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 c...

Page 60: ...filter see XM PFP Repair Parts manual 3A2989 Replace Air Filter Element section for instructions Air regulator filter 5 micron on air control assembly see XM PFP Repair Parts manual 3A2989 Replace Air Filter Element section for instructions Seals Once a week check and tighten throat seals on metering pumps and dosing valves Be sure to follow the Flush Mixed Material page 44 prior to tightening sea...

Page 61: ...to cool 4 Flush mixed material See Flush Mixed Material page 44 5 Perform Pressure Relief Procedure page 46 This includes flushing the system and parking the metering pumps 6 Turn main power switch OFF 7 Clean external surfaces only using a rag soaked in solvent that is compatible with the spray material and the surfaces being cleaned 8 Allow enough time for solvent to dry before using sprayer CA ...

Page 62: ...or stalling The B fluid pressure should always be 15 to 30 higher than A pressure A larger pressure difference indicates A motor icing A smaller or negative pressure difference indicates B motor icing If icing occurs use the de ice bleed air valve to run warm air through the valve to run warm air through the valve and exhaust for de icing Ensure that the motor is left active when not spraying to k...

Page 63: ...emove token and upload software token again All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations Problem Cause Solution Display not lit No green light present on back of display module No electric power Disconnect off or breaker open Reset main disconnect and breaker Voltage jumpers not installed or config ured in power junction box Install ...

Page 64: ...ic gravity of each fluid is known check samples by weight 750cc x specific gravity equals weight in grams If weight is correct extra volume in bea ker is air Batch Test completes without error but A or B component has more fluid in beaker than displayed on screen See causes for previous pump test prob lem See solutions for previous pump test problem Sprayer does not start when start button is pres...

Page 65: ...ll or too long Use 3 4 in minimum ID air supply hose See Technical Specifications page 98 Inadequate air supply Use larger CFM compressor Air pressure to metering pumps too low Increase metering pump air pressure Spray tip too small Relieve pressure Install larger tip Follow gun manual instructions Mix manifold mixer swivel gun or hoses partially plugged or too restrictive Inspect parts for cured ...

Page 66: ... closest to purge controller output is open See Expo manual for additional troubleshooting Purge Controller left indicator does not turn green Hazardous Location Models Leak in purge box or obstructed purge exhaust Check purge box for leaks See above for possible leak locations Verify pinch valves in purge controller are all closed except for the 2 min pinch valve Verify no obstruction on purge en...

Page 67: ...creens to run pumps including flush circulate and prime procedures park metering pumps so pump rods are down when not in use mix and spray view mix ratio run pump tests calibrate weight mode run batch dispense ratio tests run valve leak checks view dispense totals view alarms diagnose alarms clear alarms set and view A heater B heater and hose bundle temperatures view tank temperatures and levels ...

Page 68: ...in Setup Mode See FIG 7 on page 15 Some setup screens can be disabled see Enable Setup Screens on page 72 Setup Mode Screens Navigation Diagram Software Versions Home Volume Mix Ratio Maintenance 2 Maintenance 1 Enable Options 2 Enable Options 1 Potlife Hose Length Date Time Units System USB Tank Fill Ratio Test Temperature Pressure From All Screens Enable Options 3 ...

Page 69: ...em components Refer to the following table for details To access this screen press from the Home Setup screen Icon Function Increase or decrease mix ratio Press and to change the mix ratio Navigate to jump to system setup screens Navigate to enable disable options screens Navigate to maintenance setup screens Navigate to pressure and temperature limits setup screens Icon Function Display module ve...

Page 70: ...id flow stops the displayed potlife time counts down in one minute intervals The timer automatically resets when the calculated mixed fluid volume is dispensed Icon Function Set number of minutes before mixed material will set in hose Resets after material volume set by user is passed through hose Indicates total hose volume Always displayed in cc units Set length of hose after mix manifold Used t...

Page 71: ...achine and should not be changed If the tank level goes beyond one of these settings an alarm will result See Alarm Code Troubleshooting on page 89 The middle two settings are for maintaining the tank level when automatic tank filling is on Automatic tank filling will maintain the fluid level in the tank to between these two levels Changing these levels will move the arrows shown next to the tanks...

Page 72: ... and B heater outlet temperatures on run screens Enable or disable ability to change metering pump size in system setup screens Enable or disable ratio screen If enabled ratio screen will automatically display after sprayer runs for 10 seconds Enable or disable pump maintenance setup screens Icon Function Enable or disable dosing valve maintenance setup screen Enable or disable incoming air filter...

Page 73: ... number of days between changing the main incoming air filter before a reminder advisory will sound The number displayed below each selectable field indicates the amount of material dispensed counting up to the setpoint requiring maintenance Maintenance Setup 1 Maintenance Setup 2 Icon Function Set amount of material moved through pump that will result in a maintenance warning Set amount of materi...

Page 74: ...ering pump pressure always runs 10 20 higher than the A metering pump pressure Process Pressure Limits for spray mode Process Temperature Limits for spray mode Icon Function Set and adjust pressure limits for both metering pumps during spray mode Set and adjust high and low temperature limits for both fluid heaters during spray mode Set target pressure or temperature Set and adjust limits above or...

Page 75: ...7 on page 15 Operator Command Mode Screens Navigation Diagram Run Fluid Control Screens Park Pump Pump Mode Spray Mode Spray Mode shown Restrictor Ratio Test Screens Valve Test Batch Test Pump Test Information Screens Pump Volume Test shown Weight Volume Alarm Information Maintenance 1 Totalizer Alarm Log Maintenance 2 Supply Screen Go to primary screen in each section ...

Page 76: ...creen remains blank until a mode is selected Spray Mode Users must be in this mode to spray or proportion material Press the button below the spray icon to enter this mode Pump Mode Users must be in this mode to operate metering pumps for priming or flushing Press the button below the metering pump icon to enter this mode Continue pressing the metering pump icon button to cycle through metering pu...

Page 77: ...alance of the A and B fluid sides If the bar graph remains all the way to the right there is not enough restriction on the B side and adding more restriction smaller hose diameter will lower the dosing size If the bar graph remains all the way to the left there is too much restriction on the B side Reducing restriction larger hose diameter will reduce dosing size The first number below the date an...

Page 78: ...rial in the respective input boxes on this screen If the calculated ratio is within the ratio tolerance set on the Setup Ratio Test screen a check will appear in the box The results are entered into the USB logs The target ratio by volume for this test is set on the Setup Home screen on page 69 The tolerance is set on the Setup Ratio Test screen on page 71 Ratio by Volume Mode Test by Weight Enter...

Page 79: ...t be measured by weight Confirm Batch Dispense Test This screen displays when the batch dispense test completes without error This screen displays the selected ratio between the metering pumps and the desired weight of material dispensed from each metering pump The gray at the bottom of the beaker represents the material dispensed by metering pump A The black at the top of the beaker represents th...

Page 80: ...e Setup Home screen on page 69 The tolerance is set on the Setup Ratio Test screen on page 71 Down Stream Valve Leak Test Use this screen to test for closed or worn valves down stream of the A and B dosing control valves It can be used to test the mix manifold shutoff check valves or any remote circulation valves While running the test if there is continuous metering pump movement on the A or B si...

Page 81: ...s This voltage should read between 4 9 5 1 VDC The third number below the alarm code is the A side pump dosing size This value is displayed in volumes of cubic centimeters cc and is the volume pumped on the A side when the B side dosing valve is off Optimizing the restriction of the system will keep this value small and ensure material is mixed well Alarm Log Use this screen view details regarding...

Page 82: ...e number or to cancel Maintenance 1 Screen Use this screen view setpoints for the amount of material that needs to move through both pumps and dosing valves that will result in a maintenance warning Maintenance 2 Screen Use this screen view number of days between changing the main incoming air filter before a reminder advisory is issued Reset Maintenance Counter 1 Press and to scroll through and s...

Page 83: ...order for automatic tank filling to run the director valve 3DC must be in the DOWN position and the RAM slider valve DA and air motor slider valve DF must both be in the ON position with proper air pressure air supplied to the RAM and air motor See Feed Pump Air Controls on page 14 This screen also displays the current volume of each tank and the current temperature measured at each fluid heater a...

Page 84: ...er available logs are displayed in the boxes on the right side of the screen Refer to the following table for more details Recommended USB Flash Drives It is recommended that users use the USB flash drive 17L724 included with the PFP sprayer for data download Icon Function Advisory has been issued Potlife timer is enabled Time after potlife expires Starts at 0 00 and counts down in negative one mi...

Page 85: ... This should be between 4 9 5 1 Volts The third line shows the A side pump dosing size This value is displayed in volumes of cubic centimeters cc and is the volume pumped on the A side when the B side dosing valve is off Optimizing the restriction of the system will keep this value small and ensure the material is mixed well The center of the screen shows linear sensor vertical bar graphs and reed...

Page 86: ... Alarm D Output Discharge B Heater B R Ratio 5 Calibration F Input Feed C Level Sensor A T Temperature 6 Sensor Failure I Internal D Level Sensor B V Voltage 7 Unexpected Non Zero Value M Power Supply E Hose 8 Unexpected Zero Value P Pneumatic Supply H Heater Hose R Recirculation J Linear Sensor 9 Unstable K Reed Switch C Communication A Loss P Display D Pump A Runaway T Temperature Control Module...

Page 87: ...weight mode and uncalibrated R5DX Park Both dosing valves open A and B blue lights turn on User opens circulation valves or sprays gun When pump reaches bottom stroke the blue light turns off If park does not complete in 10 minutes turn off air to both motors DEAX DEBX Circulation A and or B dosing valves close and motor air turns on If fluid pressure exceeds 3000 psi 21 0 MPa 210 bar on the A pum...

Page 88: ...lue 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 P1AX P1BX Check for no movement of pumps stall within 10 seconds F7AX F7BX Mode Control Logic Alarms ...

Page 89: ...rial Heater Unexpected Current Alarm Always Temperature Control Module is bad Replace module Heater is bad Repair heater A9DH Hose Heater Unexpected Current Alarm Always Temperature Control Module is bad Replace module Heater is bad Repair heater CACA CACB Temperature Control Module Heater Loss Of Communication Alarm with A B Material Heater Always Network communication cable is bad Replace commun...

Page 90: ...k 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 Remove inlet housing clean and inspect See XM PFP repair manual DJAX DJBX Pump Motor Linear Sensor Has No Signal Always No linear sensor signal from motor Swap A and B sensors Replace sensor if problem follows...

Page 91: ...o by Weight Mode page 48 F8RX No movement occurred in circulation mode Circulation Pump did not move for 5 seconds while in circulation User may have attempted to spray in circulation mode Use spray mode for spraying L2F1 L2F2 Tank Level Low Advisory Spray and Tank Tank level less than 10 below tank empty setpoint for 3 seconds Add material to tank Air solenoid is bad Replace air solenoid Increase...

Page 92: ... bar on A side Decrease pump air regulator pressure P5AX P5BX Pressure Exceeded Alarm Limits Spray Pressure exceeded high or low alarm limits for more than 15 seconds Adjust pump pressure regulator change tips or adjust target set point P6AX P6BX Pressure Sensor Failure No Signal Always Pressure sensor or cable is bad on the side indicated Replace sensor and cable assembly See XM PFP repair manual...

Page 93: ...estriction R1BE Ratio Low B Under Dose B System Delivering Not Enough B Component Spray B dosing valve will not open Check for air signal to valve B mix manifold valve closed Open green mix manifold valve Pump filter plugged on B side Use alternate 30 mesh screen See manual 311762 for part number Clean B pump outlet filter See manual 311762 R4BE Ratio High B Overdose B System Delivering Too Much B...

Page 94: ... Same as T5DA or T5DB T3CA T3CB A B Material Heater Temperature Control Module Over Temperature Advisory Always Module is bad Replace module Cool system down T3CH Hose Heater Temperature Control Module Over Temperature Advisory Always Module is bad Replace module Cool system down T4CA T4CB A B Material Heater Temperature Control Module Over Temperature Alarm Always Module is bad Replace module Coo...

Page 95: ... or bad Connect temperature sensor cable to system T8DA T8DB A B Material Temperature Not Rising Alarm Heater A B Heater bad Repair heater Heater voltage too low Increase heater voltage to 200 240 VAC T8DH Hose Temperature Not Rising Alarm Hose Heater Heater bad Repair heater Heater voltage too low Increase heater voltage to 200 240 VAC V1IT Low Voltage CAN Always 24 VDC power supply Check voltage...

Page 96: ...rance adjust or replace power supply V4MA V4MB A B Material Heater High Line Voltage Alarm Always Temperature Control Module is bad Replace module Heater is bad Repair heater V4MH Hose Heater High Line Voltage Alarm Always Temperature Control Module is bad Replace module Heater is bad Repair heater Alarm Code Alarm Problem When Active Cause Solution ...

Page 97: ...Appendix B Alarms 3A2776K 97 Dimensions WL E Min 70 5 in 179 cm Max 84 in 213 cm 76 in 193 cm 52 in 132 cm WL E Min 70 5 in 179 cm Max 84 in 213 cm 38 in 96 5 cm 104 in 264 cm ...

Page 98: ...ter 3 micron purge controller filter Hazardous Location only Ambient Operating Temperature Range 32 to 130 F 0 to 54 C Ambient Storage Temperature Range 30 to 160 F 1 to 71 C Environmental Conditions Rating Altitude up to 13 123 ft Altitude up to 4000 m System Weight empty no fluid 2175 lb 987 kg Air Filtration 40 micron main filter 5 micron control air filter 3 micron purge controller filter Haza...

Page 99: ...arbide stainless steel PTFE UHMWPE Mixer Stainless steel housing with stainless elements Purge Requirements For hazardous models only Purge air is filtered to instrumentation quality by filters listed above Minimum Purge Time 3 minutes Minimum Purge Flow 4 8 scfm Maximum Air Temperature 104 F 40 C Noise dBa Sound Pressure 92 2 dBA at 100 psi 92 2 dBA at 0 7 MPa 7 bar 85 8 dBA at 70 psi 85 8 dBA at...

Page 100: ...n material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warr...

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