312359P, Manual, XM Plural-Component Sprayers, Operation, English

312359, 312359P, MM 312359

Graco Inc.

312359P, Manual, XM Plural-Component ... - Graco Inc.

XM Plural-Component OEM Sprayers Instructions-Parts. 311762 ... Electric Heated Hose Power Supply Kit Instructions-Parts ... Revision P, February 2021.

312359P, Manual, XM Plural-Component Sprayers ... - Graco Inc.

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation ... When using quick-setting materials (less than 10 minute pot life) a remote ... www.graco.com. Revision P, February 2021.

312359P, Manual, XM Plural-Component Sprayers, Operation ...

Manifold Kits manual for operation instructions. (Related Manuals, page 3). Adjust Packing Nuts. 1. Fill A and B pump packing nuts with throat seal.

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312359EN-P

Operation

XMTM Plural-Component Sprayers

312359P
EN

For spraying two-component epoxy and urethane protective coatings in hazardous and non-hazardous locations. For professional use only.

Important Safety Instructions
Read all warnings and instructions in this manual and in all related manuals before using the equipment. Save all instructions.

See page 7 for model information and agency approvals. See page 103 for maximum working pressure.

WLD

Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Important Isocyanate (ISO) Information . . . . . . . . . . . . . . 7
Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . . . . . 7 Keep Components A and B Separate . . . . . . . . . . . . . . 7 Moisture Sensitivity of Isocyanates . . . . . . . . . . . . . . . . 8 Changing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Proper Lifting of Sprayer . . . . . . . . . . . . . . . . . . . . . . . . . 16 Initial System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Component Identification . . . . . . . . . . . . . . . . . . . . . . . . 18
Typical Setup: 25 Gallon Double Wall Hopper with Recirculation . . . . . . . . . . . . . . . . . . . . . . . . 18
Typical Setup: 25 Gallon Double Wall Hopper with Recirculation (Back and Side Views) . . . . . . 19
Fluid Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . 21 Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Air Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Hopper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Connect Power Source . . . . . . . . . . . . . . . . . . . . . . . . 27 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Connect Explosion-Proof Heaters . . . . . . . . . . . . . . . . 30 Connect Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Connect Fluid Hose Assembly . . . . . . . . . . . . . . . . . . 31 Adjust Packing Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Adjust Ratio and Setup . . . . . . . . . . . . . . . . . . . . . . . . 32 View Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Set System Settings (Optional) . . . . . . . . . . . . . . . . . . 33 Set Maintenance Parameters (Optional) . . . . . . . . . . . 34 Set Sprayer Limits (Optional) . . . . . . . . . . . . . . . . . . . 35 Prime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Prime A and B Fluids . . . . . . . . . . . . . . . . . . . . . . . . . 36 Prime Solvent Flush Pump . . . . . . . . . . . . . . . . . . . . . 38 Recirculate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 With Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Without Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Heat Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Adjust B Machine Outlet Restriction . . . . . . . . . . . . . . . 42

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . . . 43 Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Flush Mixed Manifold, Hose, and Spray Gun . . . . . . . 44 Flush Hoppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Empty and Flush Entire System (new sprayer or
end of job) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Park Fluid Pump Rods . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Shutdown Entire System . . . . . . . . . . . . . . . . . . . . . . . . 50 System Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Mix and Integration Tests . . . . . . . . . . . . . . . . . . . . . . 51 Pump and Metering Test . . . . . . . . . . . . . . . . . . . . . . 51 Batch Dispense or Ratio Test . . . . . . . . . . . . . . . . . . . 54 Download Data from USB . . . . . . . . . . . . . . . . . . . . . . . . 56 USB Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Download Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Download Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 56 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Feed Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Agitators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 XM Setup and Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 LED Diagnostic Information . . . . . . . . . . . . . . . . . . . . 62 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Accessories and Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 User Interface Display . . . . . . . . . . . . . . . . . . . . . . . . 75 Change a Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Setup Mode Screens . . . . . . . . . . . . . . . . . . . . . . . . . 76 Operator Command Mode Screens . . . . . . . . . . . . . . 84 Automatically Displayed Screens . . . . . . . . . . . . . . . . 92 Appendix B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Metering Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Appendix C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Power Cord Guidelines . . . . . . . . . . . . . . . . . . . . . . . . 95 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 XM System Dimensions without Hoppers
(Non-Hazardous Locations) . . . . . . . . . . . . . . . . 96 XM System Dimensions without Hoppers (Hazardous
Locations) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 10-Gallon Rear Mount Steel Tank . . . . . . . . . . . . . . . 98 25-Gallon Rear Mount Steel Tank . . . . . . . . . . . . . . . 99 System Dimensions with Hoppers . . . . . . . . . . . . . . 100 System Dimensions with Hoppers . . . . . . . . . . . . . . 101 Pump Performance Charts . . . . . . . . . . . . . . . . . . . . . . 102 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . 103 California Proposition 65 . . . . . . . . . . . . . . . . . . . . . . . 105 Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . 106

312359P

Related Manuals

Manuals are available at www.graco.com.

Manual in English 313289 313292 311762 3A5423 3A6110 3A2954 312145 3A4032 312794 406699 406739 406690 406691 313258 313259 312770 312749 313293 313342 313343 307044 3A7670 3A7523 3A7524 3A5313

Description
XM Plural-Component Sprayers Repair-Parts XM Plural-Component OEM Sprayers Instructions-Parts Xtreme® Displacement Pumps Instructions-Parts XL6500 and XL3400 Air Motor Instructions-Parts Double Wall Stainless Steel Lined Hopper Kit Instructions-Parts Viscon® HF Heater Instructions-Parts XTRTM 5 and XTRTM 7 Spray Guns Instructions-Parts Xtreme DutyTM and Agitator Instructions-Parts Merkur® Pump Assembly Instructions-Parts 7-Gallon Plastic, 10-Gallon Stainless Steel Hopper Installation Kit Instructions-Parts Desiccant Kit Instructions-Parts Caster Kit Instructions-Parts Hose Rack Kit Instructions-Parts Electric Heated Hose Power Supply Kit Instructions-Parts Hopper or Hose Heat Circulation Kit Instructions-Parts Lower Strainer and Valve Kit Instructions-Parts XM Mix Manifold Kit Instructions-Parts Alternator Conversion Kits Instructions-Parts Dosing Valve Repair Kit Instructions-Parts High Flow Severe Duty Shutoff Check Valve Repair Kit Instructions-Parts Feed Pump Instructions-Parts Remote Recirculation Manifold Instructions-Parts Junction Box for XP and XM Proportioners Instructions-Parts Xtreme-Wrap Electric Heated Hose Instructions-Parts Xtreme-Wrap Water Heated Hose Parts

312359P

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.
DANGER
SEVERE ELECTRIC SHOCK HAZARD This equipment can be powered by more than 240 V. Contact with this voltage will cause death or serious injury. · Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment. · This equipment must be grounded. Connect only to grounded power source. · All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
WARNING
FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent flowing through the equipment can cause static sparking. To help prevent fire and explosion:
· Use equipment only in well-ventilated area. · Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static sparking). · Ground all equipment in the work area. See Grounding instructions. · Never spray or flush solvent at high pressure. · Keep work area free of debris, including solvent, rags and gasoline. · Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present. · Use only grounded hoses. · Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are anti-static or conductive. · Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment
until you identify and correct the problem. · Keep a working fire extinguisher in the work area. · Do not connect USB device in explosive atmospheres.
SPECIAL CONDITIONS FOR SAFE USE · To prevent the risk of electrostatic sparking, the equipment's non-metallic parts must be cleaned only
with a damp cloth. · Flamepath joints are not for repair. Contact the manufacturer. · Special fasteners for securing equipment covers shall have a minimum yield strength of 1000 MPa,
and be corrosion resistant and sized M8x1.5x30.

312359P

Warnings
WARNING
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 regulations and the following safety requirements.
· Only models with model number XM_D00, XM_N_ _, or XM_E_ _, utilizing the air-driven alternator are approved for installation in a Hazardous (explosive atmosphere) Location - see Approvals, 11. 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: - 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. - 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 Safety. 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 (explosive atmosphere) location.
· If explosion-proof heaters are used, ensure wiring, wiring connections, switches, and electrical distribution 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.
· Engage trigger lock when not dispensing. · Do not spray without tip guard and trigger guard installed. · Engage trigger lock when not spraying. · Do not point gun at anyone or at any part of the body. · Do not put your hand over the spray tip. · Do not stop or deflect leaks with your hand, body, glove, or rag. · Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or
servicing equipment. · Tighten all fluid connections before operating the equipment. · Check hoses and couplings daily. Replace worn or damaged parts immediately.

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. · Equipment can start without warning. Before checking, moving, or servicing equipment, follow the
Pressure Relief Procedure and disconnect all power sources.

312359P

Warnings
WARNING
EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury.
· Do not operate the unit when fatigued or under the influence of drugs or alcohol. · Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Specifications in all equipment manuals. · Use fluids and solvents that are compatible with equipment wetted parts. See Technical
Specifications in all equipment manuals. Read fluid and solvent manufacturer's warnings. For complete information about your material, request Safety Data Sheets (SDSs) from distributor or retailer. · Do not leave the work area while equipment is energized or under pressure. · Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use. · Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer's replacement parts only. · Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards. · Make sure all equipment is rated and approved for the environment in which you are using it. · Use equipment only for its intended purpose. Call your distributor for information. · Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces. · Do not kink or over bend hoses or use hoses to pull equipment. · Keep children and animals away from work area. · Comply with all applicable safety regulations.
TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled or swallowed.
· Read Safety Data Sheets (SDSs) for handling instructions and to know the specific hazards of the fluids you are using, including the effects of long-term exposure.
· When spraying, servicing equipment, or when in the work area, always keep work area well-ventilated and always wear appropriate personal protective equipment. See Personal Protective Equipment warnings in this manual.
· Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
BURN HAZARD Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe burns:
· Do not touch hot fluid or equipment.
PERSONAL PROTECTIVE EQUIPMENT Always wear appropriate personal protective equipment and cover all skin when spraying, servicing equipment, or when in the work area. Protective equipment helps prevent serious injury, including long-term exposure; inhalation of toxic fumes, mists or vapors; allergic reaction; burns; eye injury and hearing loss. This protective equipment includes but is not limited to:
· A properly fitting respirator, which may include a supplied-air respirator, chemically impermeable gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory authority.
· Protective eyewear and hearing protection.

312359P

Important Isocyanate (ISO) Information

Isocyanates (ISO) are catalysts used in two component materials.

Isocyanate Conditions

Keep Components A and B Separate

Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and atomized particulates.
· Read and understand the fluid manufacturer's warnings and Safety Data Sheets (SDSs) to know specific hazards and precautions related to isocyanates.
· Use of isocyanates involves potentially hazardous procedures. Do not spray with this equipment unless you are trained, qualified, and have read and understood the information in this manual and in the fluid manufacturer's application instructions and SDSs.
· Use of incorrectly maintained or mis-adjusted equipment may result in improperly cured material. Equipment must be carefully maintained and adjusted according to instructions in the manual.
· To prevent inhalation of isocyanate mists, vapors, and atomized particulates, everyone in the work area must wear appropriate respiratory protection. Always wear a properly fitting respirator, which may include a supplied-air respirator. Ventilate the work area according to instructions in the fluid manufacturer's SDSs.
· Avoid all skin contact with isocyanates. Everyone in the work area must wear chemically impermeable gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory authority. Follow all fluid manufacturer recommendations, including those regarding handling of contaminated clothing. After spraying, wash hands and face before eating or drinking.

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.

312359P

Important Isocyanate (ISO) Information

Moisture Sensitivity of Isocyanates
Exposure to moisture (such as humidity) will cause ISO to partially cure, forming small, hard, abrasive crystal that become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity.
NOTICE
Partially cured ISO will reduce performance and the life of all wetted parts.
· Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container.
· Keep the ISO pump wet cup or reservoir (if installed) filled with appropriate lubricant. The lubricant creates a barrier between the ISO and the atmosphere.
· Use only moisture-proof hoses compatible with ISO.
· Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.
· Always lubricate threaded parts with an appropriate lubricant when reassembling.

Changing Materials
NOTICE Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime.
· When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.
· Always clean the fluid inlet strainers after flushing.
· Check with your material manufacturer for chemical compatibility.
· When changing between epoxies and urethanes or polyureas, disassemble and clean all fluid components and change hoses. Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the B (resin) side.

NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature.

312359P

Models

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 XM1L00 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 (L). 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. numbers in the Parts drawings and lists.
Table 1: Hazardous Locations
(See Top Level Sprayer Approvals on page 11)

First Two Digits

Third Digit

Fourth Digit

Fifth Digit

Sixth Digit

Model

Pump Set (psi)

Remote Manifold

Control Power Wall Power Intrinsically Safe
XM_A00 Alternator XM_D00

Viscon HP Fluid Heaters Explosion Proof
240V

Feed System Heated Hose
Feed

1 XM50 (5200)

3 XM70 (6300)

5 XM50 (5200)

N E*

0 None 0 None

10-Gallon

1 Stainless

Steel

7 XM70 (6300)

* Uses Explosion-Proof Viscon High Pressure (HP) Fluid Heaters.

Table 2: Designed with Hazardous Location Approved Components
(No Top Level Sprayer approval - individual component approvals listed in Approvals, page 11)

First Two Digits Model

Third Digit

Pump Set (psi)

Remote Manifold

Fourth Digit

Control Power

Wall Power XM_A00

Intrinsically Safe
Alternator XM_D00

Viscon HF Fluid Heaters
Explosion Proof
240V 480V

XM50 (5200)

XM70 (6300)

XM50 (5200)

XM70 (6300)

* Uses Explosion-Proof Viscon High Flow (HF) Fluid Heaters.

Junction Box Explosion Proof

240V

480V

Fifth Digit

Sixth Digit

Feed System Feed

Heated Hose

None 0 None

10-Gallon 1 Stainless W Water
Steel

25-Gallon

2 Heated E Electric

Skid

312359P

Models

Table 3: Non-Hazardous Locations
(No Top Level Sprayer approval - individual component approvals listed in Component Level Approvals, page 12)

First Two Digits Model
XM

Third Digit

Fourth Digit

Control Power

Pump Set (psi)

Remote Manifold

Wall Power XM_A00

Intrinsically Safe
Alternator XM_D00

XM50 (5200)

Viscon HF Fluid Heaters

240V

480V

XM70 (6300)

XM50 (5200)

XM70 (6300)

* Uses Viscon High Flow (HF) Fluid Heaters.

Junction Box

240V

480V

Fifth Digit Feed System

Sixth Digit

Feed

Heated Hose

None

0 None

10-Gallon 1 Stainless W Water
Steel 25-Gallon 2 Heated E Electric
Skid

312359P

Approvals

Table 4: Top Level Sprayer Approvals

Sprayer Model

Top Level Approvals

II 2 G Ex ib pxb IIA T3 Gb Tamb = 0°C to 54°C FM09ATEX0015X

XM_N_ _

Ex i, Class I, Div 1, Group D, T3. Ta = 0°C to 54°C

II 2 G Ex db ib pxb IIA T3 Tamb = 0°C to 54°C FM09ATEX0015X

XM_E_ _

Ex i, Class I, Div 1, Group D, T3. Ta = 0°C to 54°C

XM_P_ _ XM_F_ _
XM_J_ _ XM_K_ _ XM_L_ _ XM_M_ _ XM_H_ _

System is intended for hazardous locations with the classification of Class 1, Division 1, Group D T3 0°C to 54°C System is intended for hazardous locations with the classification of Class 1, Division 1, Group D T3 0°C to 54°C

Approvals

312359P

Approvals

Table 5: Component Level Approvals

Control Power

North American Location

European Atmosphere

Component

Description

NonHazardous

Hazardous

Non-

Class 1 Division 1 Hazardous

Hazardous

Approvals

II 2 G

FM09ATEX0015X Ex db ib pxb IIA T3 Tamb = 0°C to 54°C

Intrinsically

XM_D00

Safe

Alternator

Intrinsically safe/ Sécurité intrinseque, Ex i, Class I, Div 1, Group D, T3. Ta = 0°C to 54°C

XM_A00

Wall Power

Viscon Fluid Heater

North American Location

European Atmosphere

Component

Description

Non-

Hazardous

Non-

Hazardous Class 1 Division 1 Hazardous

Hazardous

Approvals

26C476

480V HF Ex

9902471

Class 1, Division 1, Groups C, D (T3)

Ta = -20°C to 60°C

Certificate No: 18-KA4B0-0072X

ATEX Ratings:

II 2 G Ex db IIB T4 Gb

ATEX Certificate No.

24W248

240V HF Ex

ITS14ATEX18155X

IECEx Ratings EX db IIB T4 Gb IECEx Certificate No. IECEx ETL 14.0046X Ta = -20°C to 60°C

24P016

240V HF Ordinary

26C475

480V HF Ordinary

9902471

Certified to CAN/USA C22.2 No. 88

Conforms to UL499

312359P

Approvals

Junction Box

Component

Description

North American Location

Ordinary

Hazardous Class 1 Division 1

European Atmosphere
Ordinary Hazardous

Approvals

Explosion Proof

Electrical

Enclosure

26C583

480V Explosion Proof Junction Box

26C906

480V Explosion

Proof Junction Box,

Electric Hose Heat

26C581

240V Explosion Proof Junction Box

26C905

240V Explosion

Proof Junction Box,

Electric Hose Heat

Ordinary Location Electrical Enclosure

26C582

480V Junction Box

26C904

480V Junction Box, Electric Hose Heat

26C580

240V Junction Box

26C899

240V Junction Box, Electric Hose Heat

Class 1, Division 1, Groups B, C, & D UL 1203/CSA C22.2 No. 25 & 30 Designed to Standards: UL 60079-0 UL 60079-25
9902471 Conforms to UL STD 508A Certified to CAN/CSA C22.2 No. 14

312359P

Approvals

Component Description

273117

25 Gallon Stainless Steel Lined Heated
Hopper

Ordinary

Hazardous Class 1 Division 1

Ordinary Hazardous

25P239*

Immersion Heaters, 480V

C US Class 1, Division 1, Groups B, C, & D (T4)

25N577

Immersion Heaters, 240V

C US Class 1, Division 1, Groups B, C, & D (T4)

25N584 25N588

5:1 Monark Pump
Xtreme Duty Hopper Agitator

*Selected if XM_H_ _, XM_F_ _ are ordered. Will default to 240V immersion heater if XM_M_ _, XM_P_ _ or XM_J_ _ are ordered.

Heated Hose

Component

Description

North American Location Category

Ordinary

Hazardous Class 1 Division 1

European Atmosphere Category
Ordinary Hazardous

See your water heated hose manual for complete list of part numbers

Water Jacketed

See your electric heated

hose manual for complete list of part

Electric

numbers and approvals

Approvals II 2 G Ex h T5 Gb

312359P

Overview

Location

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.
The XM sprayer operates using compressed air pressure. XM plural-component sprayers are operated via the user interface, air controls, and fluid controls.
The hazardous location XM model variants feature an intrinsically safe alternator powered by a compressed air-fed turbine as a power supply. The alternator module working pressure must be set to 18 +/- 1 psi (12.6 +/- 10 kPa, 1.26 +/- 0.07 bar).

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 9, to determine the appropriate location for your particular sprayer model.

312359P

Proper Lifting of Sprayer

Follow instructions to avoid serious injury or damage to equipment. Never lift with the hopper(s) filled.
NOTICE To prevent spilling and to ensure even weight distribution, drain all fluid prior to lifting th proportioner.
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 evenly.
NOTE: If 25-gallon hoppers are installed, make sure the forklift arms extend across the entire unit. The forklift must approach from the front of the unit.

Lift Using a Hoist
Sprayer can also be lifted and moved using a hoist. Connect 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. Do not lift with 25 gallon hoppers attached to the unit.
2.0 ft (0.61 m) minimum

WLE

WLD
16

312359P

Initial System Setup

Complete the following steps in order, as they apply to your specific system, for initial system setup.
1. Check your shipment for accuracy. Ensure you have received everything you ordered. See Component Identification, page 18, to familiarize yourself with typical system components.
2. Mount caster kit, if ordered. See your kit manual.
3. Replace USB label (front of control panel) with correct language version, if needed.
4. Replace Alarms Codes label (under fluid control valves) with correct language version, if needed.
5. Ground all equipment in the work area. See Grounding on page 27.
6. For non-hazardous location sprayers without primary fluid heaters and junction box, connect the supplied power cord. See Connect Power Source, page 27, for instructions.
7. For hazardous location sprayers, connect explosion-proof heaters. See Connect Explosion-Proof Heaters, page 30, and your heater manual.

8. Connect air supply line. See Connect Air Supply, page 30, for instructions and recommendations.
9. Connect fluid hose assembly, including whip hose and gun. See Connect Fluid Hose Assembly, page 31, for instructions. Also connect remote mix manifold, if ordered. See your Mix Manifold manual for installation and parts information (Related Manuals, page 3).
10. Add heating fluid to 25 gallon heated hoppers and service agitator and feed pumps for service, if applicable.
NOTE: A minimum of 12 gallons (45 liters) of ethylene glycol and 12 gallons of water is needed, plus additional water is needed if a water heated hose is used.
NOTE: A minimum of 10 gallons (39 liters) of "A" and "B" materials are needed to load the hoppers and prime the system.
NOTE: A minimum of 25 gallons (95 liters) of solvent is required for flushing.
NOTE: Empty metal pails for both "A" and "B" materials are required for flushing.

312359P

Component Identification

Typical Setup: 25 Gallon Double Wall Hopper with Recirculation

)

% =

7 &

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88 -
; 77
66

:: 99 //

FIG. 1: Typical Setup: 25 Gallon Double Wall Hopper with Recirculation (Front View)

Key: A Frame B Fluid Control Assembly (see Fluid Control Assembly
page 21). C 25 Gallon Double Wall Hopper E Main Air Valve F GCA Control Display (see User Interface, page 24) G Pump Control On and Off Buttons H Air Filter J Air Controls K Viscon HF Fluid Heater L Junction Box/Heater Controls (see Junction Box, page
22) M Viscon HF Fluid Heater Control N Air Powered Agitator P Pressure Feed Pump

R Fluid Inlet Assembly S Tank Pallet T Fill Port Cap U Immersion Heater V Air Motor W Diaphragm Pump Assembly (Water Heated Hose only) X Overflow Tank (Water Heated Hose only) Y Viscon HP Fluid Heater (Water Heated Hose only) LL Integrator Hose SS Static Mixer Housing TT Fluid Whip Hose UU Airless Spray Gun VV Static Mixer Adapter WW Static Mixing Element

312359P

Component Identification
Typical Setup: 25 Gallon Double Wall Hopper with Recirculation (Back and Side Views)
69

FIG. 2: Typical Setup: 25 Gallon Double Wall Hopper with Recirculation (Back and Side Views)

Key: R Fluid Inlet Assembly V Air Motor Z High Pressure Fluid Pump
JJ Solvent Flush Pump (Merkur® Pump)

WLD

312359P

Component Identification

Heater Information
Viscon HF Fluid Heaters (K): Primary heaters that heat the resin and hardener before mixing. Improves the chemical reaction and lowers viscosity to improve the spray pattern. There are two Viscon HF heater variants (hazardous location heaters and non-hazardous location heaters). For approval rating, see Models on page 9 and Approvals on page 11 regarding your primary fluid heaters.
Viscon HP Fluid Heaters (Y): These are used for heating water or oil through heated hose to prevent material from losing heat when spraying remote. They are used with a diaphragm pump to circulate the heated fluid throughout the hose. There are two Viscon HP heater variants (hazardous location heaters and non-hazardous location heaters). For approval ratings, see Models on page 9 and Approvals on page 11 regarding your water heated hose fluid heaters.
Hopper Heaters (U): Immersion heaters are used to heat the outer jacketed area of the double walled hoppers. The outer jacket is filled with oil or a 50% water and 50% ethylene glycol mixture to heat the spray material. The double wall hopper design prevents the spray material from losing heat.

Pump Information
High Pressure Fluid Pumps (Z): These pumps feed the A and B fluid.
Solvent Flush Pump (JJ): This pump flushes the mix manifold, hose, and gun.
Pressure Feed Pump (P): This pump transfers material from the 25 gallon heated hoppers to the main high pressure pumps. This is the preferred method of transferring viscous material compared to gravity feed.
Diaphragm Pump (W): This pump is used to circulate the heated water through water heated hose.

312359P

Fluid Control Assembly
AA
AC AL AE
AH
FIG. 3: Fluid Control Assembly AA Dosing Valve A AB Dosing Valve B AC Recirculation Valve A AD Recirculation Valve B AE Sampling Valve A

Component Identification
AB
AD
AF
AG AM AJ
AK
AF Sampling Valve B AG Restriction Valve AH Mix Manifold Shutoff / Check Valve A AJ Mix Manifold Shutoff / Check Valve B AK Solvent Shutoff Valve AL Pressure Sensor AM Solvent Check Valve

312359P

Component Identification

Junction Box

Non-Hazardous Location

&%&

%''

%&&

%''

Hazardous Location
%$ %) %(
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%00
%. %/

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Key: BA Electrical Enclosure BB Main Power Switch BC Primary Heater Switches BD Hopper Heater Switches BE Hose Heater Switch BF Power Indicator Light BG Main Power Entry Point BH Strain Relief (Non-hazardous locations only)

%00

BJ Electric Heated Hose Temperature Controller / Display (Non-hazardous locations only)
BK Hose Heater Harness Entry Point BL Thermocouple Sensor Entry Point BM Fluid Heater and Hopper Heater Harness Entry Point BN Electric Heated Hose Temperature Controller (Hazardous
locations only) BP Temperature Display (Hazardous locations only)

312359P

Air Controls
CA
CB
FIG. 4: Air Controls CA Main Pump and Air On/Off Control CB Solvent Pump Air On/Off Control CC Inlet Air Pressure Gauge CD Main Pump Air Regulator

Component Identification
CC CD CE
CF CG CE Main Pump Air Regulator Pressure Gauge CF Solvent Pump Air Pressure Gauge CG Solvent Pump Air Regulator

312359P

Component Identification
User Interface

FIG. 5: User Interface

Buttons

Ref. Button Function

DA Display Screen

Use to view Ratio, Mode Selection, Error Conditions, Totalizers, System Information.

DB Start

Initiates Active Run Mode function currently selected in Run Screen.

DC Stop

Terminates Active Run Mode function currently selected.

DD Enter

Press to open drop-down fields, selection options, and save values.

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 selection boxes, drop-down fields, and selectable values within Setup screens.

DJ Setup Key Change ratio or enter Setup mode. Lock

DR USB Port Connection for data download. Use only in non-hazardous locations.

ti13365a

LEDs There are four types of LEDs on the display.

Ref. LED DK Blue DM Green DN Red DP Yellow

Function
Dosing valve active - on - dosing valve is active - off - dosing valve is not active
Spray mode active - spray mode is on (active) - spray mode is off (inactive)
Alarm - on - alarm is present - off - no alarm
Warning - on - is active. - off - no warning indicated. Ratio and setup fields are not changeable. - flashing - key is present and turned. Ratio and setup fields are changeable.

312359P

Hopper Assembly

(. (' ($ (-

Key: EA Double-Wall Hopper EB Hopper Lid EC Immersion Heater ED Agitator EE Feed Pump EF Y-Strainer EG Recirculation Tube EH Material Drain EJ Heating Fluid Drain Valve

Component Identification

(( (3

()

WLE

(+
EK Heating Fluid Fill Port EL Heating Fluid Vent EM Air Valve (Feed Pump) EN Air Regulator (Feed Pump) EP Air Valve (Agitator) ER Air Regulator (Agitator) ES Y-Strainer Valve ET Fill Port Cap

312359P

Component Identification

User Interface Display

For details regarding the user interface display see User Interface Display, page 75. Main Display Screen Components

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. Follow Pump and Metering Test, page 51.

Current Date and Time

Remaining Potlife Time

System Ratio Mode (Volume/Weight)

Function Display

Navigational Bar

FIG. 6: 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.

Go back one screen

312359P

Setup

Grounding
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 for the electric current.
System: Connect the power source ground wire in the electrical compartment as show in Connect Power Source on page 27. Connect the XM sprayer ground wire clamp (FG) to a true earth ground.

To maintain grounding continuity when flushing or relieving pressure: hold the metal part of the spray gun firmly to the side of a grounded metal pail, then trigger the gun.
Object being sprayed: Follow your local code.
Fluid supply container: Follow your local code.
Air compressor: Follow manufacturer's recommendations.
Connect Power Source

FG
Air and fluid hoses: Use only electrically conductive hoses with a maximum of 500 ft (152 m) combined hose length to ensure grounding continuity. Check electrical resistance of hose regularly. If total resistance to ground exceeds 29 megaohms, replace hose immediately.
Spray gun: Ground through connection to a properly grounded fluid hose and pump.
Solvent pails: Follow your local code. Use only conductive metal pails, placed on a grounded surface. Do not place the pail on a non-conductive surface, such as paper or cardboard, which interrupts grounding continuity.

To help prevent injury from electric shock, turn off and disconnect power at the main switch before connecting any cables and before servicing equipment. All electrical work must be done by a qualified electrician and comply with local codes and regulations.
See Power Cord Guidelines on page 95 for information specific to XM models.
XM _ L _ _ Models
For sprayers that are wall powered and less than 240 V in non-hazardous locations only.
Sprayers must be used in non-hazardous locations and with a U.S. style NEMA 5-15 plug. Power cord adapters are supplied with European and Australian cord sets.

312359P

Setup

XM _ M _ _ , XM _ H _ _ , XM _ J _ _ , and XM _ K _ _ Models
For sprayers with junction boxes to include 230V-480V.
All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.
Use the intended entry locations shown in Junction Box, page 22.
1. Turn the main power switch (BB) Off.
2. Open the junction box door.
3. Non-Hazardous Locations only: Route the power cord through the strain relief (BH) into the electrical enclosure (BA).
Hazardous Locations only: Follow local codes and regulations for routing the power cord through the main power entry point (BG) electrical enclosure (BA).

4. Connect the ground wire to ground terminal (GT). See FIG. 7, page 29.
5. Connect the power cord to the disconnect as shown in the FIG. 7, page 29. Tighten conductors to 55 in-lb (6.2 N·m). Gently pull on all connections to verify that they are properly secured.
6. Non-Hazardous Locations only: Tighten strain relief (BH).
Hazardous Locations only: Follow local codes and regulations for sealing the power cable entering into the enclosure.
7. Install the supplied terminal jumpers in the positions shown in the FIG. 7, page 29.
8. Verify that all items are connected properly as shown in the FIG. 7, page 29, then close the junction box door.
NOTE: The machine is provided with jumpers in the 380 Vac 3-Phase Wye position.
NOTE: Jumpers are only applicable with 230V-380V.

312359P

Wiring Diagram

NON-HAZARDOUS LOCATION

Disconnect

Terminal Jumpers

Setup
HAZARDOUS LOCATION Disconnect

Terminal Jumpers

230 Vac 1-Phase

8T4 1L1 3L2 5L3
Disconnect

7L4 2T1 4T2 6T3

PJ
Grounding Terminal (GT)

230 Vac 3-Phase Delta
L1 L2 L3
8T4 1L1 3L2 5L3

380 Vac 3-Phase Wye
N L1 L2 L3
8T4 1L1 3L2 5L3

7L4 2T1 4T2 6T3

ti37278a
WLD
480 Vac 3-Phase Delta
L1 L2 L3 1L1 3L2 5L3
2T1 4T2 6T3

Terminal TB TB TB TB TB Jumpers 11 12 13 14 15

TB TB TB TB TB 11 12 13 14 15

FIG. 7: XM Wiring Diagram

312359P

Setup
Connect Explosion-Proof Heaters
Hazardous location sprayers only (XM_J_ _ and XM_K_ _)

Connect Air Supply
Connect air supply line (SL) to 1.0 in. (10.1 mm) npt(f) air filter inlet.
Use a 1.0 in. (25.4 mm) ID minimum air hose.

If your sprayer is intended for hazardous locations, a qualified electrician must connect the explosion-proof heater wiring. Ensure wiring and installation comply with local electrical codes and regulations for hazardous locations.
Improperly installed or connected equipment may result in fire, explosion, or electric shock. Follow local codes and regulations.
Ensure wiring, wiring connections, switches, and electrical distribution panel all meet flame-proof (explosion-proof) installation requirements.
Refer to your Junction Box manual for the wiring diagram for hazardous locations.
Refer to your Viscon HP heater manual for electrical connection instructions and guidelines in hazardous locations.
Refer to your Viscon HF heater manual for electrical connection instructions and guidelines in hazardous locations.

SL
WLD
Air supply requirement: 150 psi (1.0 MPa, 10.3 bar) maximum; 50 psi (0.35 MPa, 3.5 bar) minimum while running System Verification (page 51), and 80 psi (0.55 MPa, 5.5 bar) while spraying.
Flow volume required: 70 scfm (1.96 m3/min) minimum; 250 scfm (7.0 m3/min) maximum. Available fluid pressure and flow rate are directly related to available air volume. See Pump Performance Charts, page 102.
General flow volume guidelines: - 70 scfm (1.96 m3/min) per gpm (lpm) while spraying - 10 scfm (0.28 m3/min) added per agitator - 10 scfm (0.28 m3/min) added per drum feed pump
If your sprayer is for use in hazardous locations, the control display (F) is powered by an air-driven alternator.
Dosing valves are operated by air. The dosing valves on the sprayer will not operate correctly if the inlet air gauge drops below 80 psi (0.55 MPa, 5.5 bar) while spraying. The B side dosing valves may not be able to close, which will result in B overdosing and going off ratio.

312359P

Setup

Connect Fluid Hose Assembly
1. Connect fluid hose to fluid manifold outlet. Do not install gun spray tip yet.

Adjust Packing Nuts
1. Fill A and B pump packing nuts with throat seal liquid (TSLTM) and torque to 50 ft-lb (67.5 N·m). For more detail regarding your Xtreme Lower pump, see your Xtreme Lowers manual.
NOTE: Re-torque the packing nuts after the first day of use.
2. Fill dosing valves A and B packing nuts with throat seal liquid (TSL) and tighten 1/4 turn after nut contacts packings; about 145-155 in-lb (16-18 N·m).

Fluid
Integrator Hose

TSL

NOTICE
Do not assemble static mixer directly to the fluid manifold. Install static mixer after first 25 ft (7.5 m) of integrator hose to ensure material doses are completely integrated. Spraying poorly integrated material could require rework of parts sprayed.

2. Tighten all fittings.
NOTE: If using electric heated hose, see your electric heated hose manual for installation and operation instructions.
NOTE: If using a water heated hose, see your hopper and hose heat circulation manual for installation and operation instructions.
NOTE: If a recirculation remote mix manifold kit (273185) is used, see your Remote Recirculation Manifold for Installation and Parts and XM Mix Manifold Kits manual for operation instructions on priming and flushing. (Related Manuals, page 3).
NOTE: If using remote mix manifold, see your XM Mix Manifold Kits manual for operation instructions. (Related Manuals, page 3).

For pump and dosing valves, check packing nut tightness after first hour of operation and again after 24 hours. Then check when TSL discolors or seeps over packing nut. Also check tightness whenever sprayer is transported. Tighten packing nuts only when all fluid pres.ure is relieved. Continue to follow maintenance procedure intervals regarding all seals, page 64.

312359P

Basic Operation

Power On
(Alternator Power Supplied Systems for Hazardous Location Sprayers)
NOTE: The hazardous location XM model variants feature an intrinsically safe alternator powered by a compressed air-fed turbine as a power supply. Ensure your intrinsically safe alternator module is set to working pressure 18 +/- psi (12.6 +/- 10 kPa, 1.26 +/- 0.07 bar). Refer to your XM Proportioner Repair-Parts manual for additional instructions.
1. Set main pump air regulator (CD) to minimum setting.
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. See Run (Fluid Control) Screens, page 85.

2. Press

and

to change ratio.

3. When desired ratio is displayed, turn key to left. Yellow LED will turn off.

4. Change optional setup selections to desired parameters, as described in Set System Settings (Optional), page 33.

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

Power On
(Wall Power Supplied Systems)
Turn on main power (BB). Fluid Control screen will display after five seconds. See Run (Fluid Control) Screens, page 85.
Adjust Ratio and Setup
1. Turn key (DJ) to right (setup position). Yellow LED will flash and the Home Setup screen will display.

There are two levels of error codes: alarms and advisories. 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 64, for causes and solutions to each alarm code.
Clear Alarms

Press

to clear alarms and advisories. Press

to return the run (fluid control) screen.

For more information on alarms and alarm codes, see LED Diagnostic Information, page 62.

312359P

Basic Operation

Set System Settings (Optional)
For details regarding the user interface display screens see User Interface Display, page 75.
To set user interface parameters and USB parameters,

and

to move to the next digit in the field.

Press

to save the change.

press

from the Home Setup screen.

Set User Interface Parameters

Press

from the potlife/hose length screen to

move to the user interface parameters screen.

The following user interface parameters are configurable:

· date format · date (factory set) · time (factory set) · units of measurement for:
- fluid flow rate - pressure - temperature - hose length - weight

To change the date format, press to select the field.

Press

to open the drop down field. Press

and

to select the preferred format. Press

again to save that date format. Follow this procedure to

change the units of measurement formats as well.

Set USB Parameters

Press

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

to move

through each field. Press

to make a field

selectable. Press

and

to scroll through each

digit. Press

and

to move to the next digit

in each field. Press

to save the change.

To change the date and time, press

to select the

field. Press

to make the field selectable. Press

and

to scroll through each digit. Press

312359P

Basic Operation

Set Maintenance Parameters (Optional)
Prior to configuring system settings, follow Enable Setup Screens, page 81, to ensure screens shown in this section are viewable and configurable. If they are not, follow instructions in Enable Setup Screens to enable them.
For details regarding the user interface display screens see User Interface Display, page 75.
To set maintenance parameters for pumps and valves,

including maintenance schedules, press the Home Setup screen.

from

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

to move through each field, and press

make a field selectable. Press

to scroll through

each setpoint digit. Press

and

to scroll

through the optional values. Continue this process until

the desired setpoint is reached. Press that setpoint.

to save

Set Maintenance Schedule
To set the number of days between changing the incoming air filter that will result in a reminder advisory,

press

to move to the Maintenance Setup 2

screen. Press

to make the field selectable. Press

to scroll through each digit, and press

and

to scroll through the optional values. Press to save the number of days value.

312359P

Basic Operation

Set Sprayer Limits (Optional)

For details regarding the limits setup screens, see User Limits Setup Screens, page 83.
To set and adjust pump pressure limits and temperature limits:

1. Select in the Enable Setup 2 screen. Follow Enable Setup Screens, page 81, for instructions.

2. From the Home Setup screen press to the limits screens.

to jump

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

and

to move

through each field, and press

to make a field

selectable. Press

to scroll through each

pressure digit, and press

and

to scroll

through the optional values. Continue this process until

you reach the desired pressure limit. Press

save.

The B pump pressure always runs 10-20% higher than the A pump pressure.

Set Temperature Limits
Use the following instructions to set temperature limits that if met will issue an advisory and/or warning.

Press

to move to the temperature limits screen.

To set temperature limits, press

and

to move

through each field, and press

to make a field

selectable. Press

to scroll through each

temperature digit, and press

and

to scroll

through the optional values. Continue this process until

you reach your desired temperature limit. Press

save the value.

The allowable range for the temperature setpoint is 34° 160° F (1° - 71° C).

312359P

Prime
Prime
Prime A and B Fluids

4. Open ball valves into pumps, or turn the feed pump air valve to the open position and open the air regulator to start the feed pump.

To help prevent injury from solvents and heated fluids, wear gloves when using solvents and/or if fluid temperature exceeds 110° F (43° C). To avoid splashing, use the lowest pressure possible to prime.
NOTE: Do not install gun spray tip yet.
1. Condition materials prior to adding to hoppers. Ensure resin materials are thoroughly agitated, homogenous, and pourable prior to adding to hopper. Stir hardeners back into suspension prior to adding material to hopper.
2. Fill A and B hoppers with proper materials. Fill A side with major volume of material; fill B side with minor volume of material.

5. Turn mix manifold valves (AH, AJ) clockwise to close them.

B A

AJ AH
6. Open recirculation valves (AC, AD).

AC
WLD
25-Gallon Stainless Steel Hopper Shown 3. Move recirculation lines to empty containers.
36

AD 312359P

Prime

7. Turn on air supply. Set main pump air regulator (CD) to 20 psi (138 kPa 1.38 bar).
CD

10. Move recirculation line back to hopper.
11. Repeat for B side.
12. Dispense a small amount of each material through both sampling valves (AE, AF).
NOTE: Open sampling valves slowly to avoid splashing.

8. Use manual pump run mode.

NOTE: When run independently set to

Press

and

as needed to prime. Monitor

containers to avoid overflow.

9. Select Pump A

. Press

. 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.

When priming or flushing pumps, it is normal to get

cavitation or pump runaway alarms. Clear alarms

and press

again as necessary. These alarms

prevent excessive pump speeds, which will damage

pump packings.

13. Close both sampling valves (AE, AF).
NOTE: If a remote mix manifold is used, disconnect A and B hoses at remote mix manifold. Prime the A and B fluid lines with material. Reconnect hoses to remote manifold.
NOTE: If a recirculation remote mix manifold kit (273185) is used, see XM Mix Manifold Kits manual, (Related Manuals, page 3).

312359P

Prime
Prime Solvent Flush Pump
1. Connect ground wire to a metal pail of solvent. 2. Place siphon tube in the pail of solvent.

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 prevent splash back. Be careful to keep fingers away from front of gun.

3. Open solvent flush valve (AK) on mix manifold.

TI1950a

TI1953a

6. Open solvent pump air valve (CB). Pull out and slowly turn solvent pump air regulator (CG) clockwise to prime solvent pump and push air out of mix hose and gun. Trigger gun until all air is purged.

4. Ensure trigger lock is engaged. Remove spray tip.

7. Close solvent pump air valve (CB) and trigger gun to relieve pressure. Engage gun trigger lock.

TI1949a

TI1948a

TI1949a

312359P

Recirculate

Recirculate
With Heat
NOTE (Recirculating With Heat): Using recirculation mode when heating the material is required. Note the temperature at the top of the primary Viscon HF fluid heaters (outgoing or back to hopper). When the thermometer and display reach operating temperature, the material is ready to spray.

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.

Without Heat
NOTE (Recirculating Without Heat): If using a system that does not require heat, recirculation 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 36.
2. Close mix manifold valves (AH, AJ).

7. Run the pumps until the material has reached the desired temperature. Follow Heat Fluid, page 40.

8. Once desired temperature is reached, press

9. Turn off the main air shutoff valve (CA).

10. Close recirculation valves (AC, AD).

3. Ensure recirculation hoses are in the correct hoppers.
4. Open recirculation valves (AC, AD).
.

5. Select pumps to recirculate by pressing

scroll through:

, or

AD AC
11. Follow Spray, page 41.
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 excessive pump wear.
If you circulate the A side pump above 5200 psi (35.4 MPa, 354 bar), an alarm shuts the pump down to prevent accidentally spraying material while still in circulation mode.

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Recirculate

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 gpm (5 cycles/min.) to increase the heater outlet temperature to match the spray temperature.

NOTE: Circulating fluid too quickly without decreasing the circulation 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.

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Spray

3. Adjust pump air regulator to 30 psi (0.21 MPa, 2.1 bar).

To help prevent injury from solvents and heated fluids, wear gloves when using solvents and/or if fluid temperature exceeds 110° F (43° C).

NOTE: Ensure that the pump spray pressure regulator is set to at least 35 psi (2.4 bar) for spraying.

NOTE: Ensure that the first gauge (supply) stays above 80 psi (0.55 MPs, 5.5 bar) while spraying.

After the first day of spraying follow Pressure Relief Procedure, page 43, and then tighten throat seals on both pumps and dosing valves.

1. If heaters are used, use Primary Heater Switches (BC) on the heater junction box to turn them on. To adjust heater temperature, refer to the Viscon HF manual for instructions, and the Heat Fluid section, page 40.

4. Select

. Press

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 coating flows from the gun.

TI1950a
6. Engage trigger lock. Install tip on gun.

TI1953a

TI1949a
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.

WLD
2. Close recirculation valves and mix manifold flush valve. Open mix manifold valves A (blue) and B (green).
.

Resin Circulate

Hardener Circulate

Resin Valve
(Blue)

Hardener Valve (Green)

Also, look at bar graph to ensure mix manifold restriction adjustment is within optimal range. Refer to Batch Dispense or Ratio Test, page 54 and Adjust B Machine Outlet Restriction, page 42.
8. Follow Flush Mixed Manifold, Hose, and Spray Gun, page 44, or Park Fluid Pump Rods, page 50, when you are finished spraying or before potlife expires.
NOTE: Mixed material potlife or working time decreases with increased temperature. Pot life in hose is much shorter than dry time of coating.

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Adjust B Machine Outlet Restriction

· 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.

Adjust the restriction stem on mix manifold, or on restrictor valve if mix manifold is remote, to optimize the B side dosing control window. The goal is to create a near constant flow on the A side and frequent dosing or a near constant flow on the B side.

· It is 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 R4BE or R1BE. See Alarm Codes and Troubleshooting, page 64.

Mix Manifold Restriction Stem

· If the bar swings back and fourth and you are using feed pumps, the feed pressure may be too high. Keep feed pressure 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 dosing size

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 86. Check bar graph.

The ratio bar graph is shown when

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 to go to the restrictor adjustment screen.

Combined flow rate
The restrictor adjust bar graph is shown when is pressed. This screen is used to adjust the restrictor.
· At maximum fluid flow, the bar should be in the center.
· At flows less than maximum, the bar should be on the right side.
· The bar should never be on the left.
· 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 corner, will be minimum when the restrictor is adjusted correctly. Once the restrictor is set for a given ratio and material, it should be locked in place and left alone.

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Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

5. Disengage trigger lock.

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 this Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.
Relieve A and B Fluid Pressure
1. Engage trigger lock.

TI1950a
6. Hold a metal part of the gun firmly to a grounded metal pail with a splash guard in place. Trigger gun to relieve pressure in material hoses.
WLD
7. Engage trigger lock.

TI1949a

2. Press

3. If fluid heaters are used, use Primary Heater Switches (BC) on the junction box to turn them off.

WLD
4. If the feed pumps are being used, shut them off by closing the feed pump air regulator and close the feed pump air valve.

TI1949a
8. Close mix manifold valves (AH, AJ).
NOTICE
To prevent material from curing in the fluid lines and causing damage to the equipment, always flush the mix hose after relieving A and B fluid pressure through the mix manifold. Follow Flush Mixed Manifold, Hose, and Spray Gun, page 44, when you stop spraying or dispensing, and before cleaning, checking, servicing, or transporting equipment.

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Flush

Flush
Flush Mixed Manifold, Hose, and Spray Gun

3. Open solvent shutoff valve (AK) at mix manifold.
4. Verify that the solvent pump air regulator (CG) is at 0 psi, then open solvent pump air control (CB). Pull out and slowly turn solvent pump air regulator (CG) clockwise to increase air pressure. Use lowest possible pressure.

5. Disengage trigger lock. Hold a metal part of the gun firmly to a grounded metal pail with a splash guard in place.Use a pail lid with a hole in it to dispense through. Be careful to keep fingers away from the front of the gun. Trigger gun until clean solvent appears.

1. Press

to turn off system. Follow Pressure

Relief Procedure, page 43. Engage trigger lock.

Remove spray tip.

2. Make sure sampling valves (AE, AF) and mix manifold valves (AH, AJ) are closed.

6. Close solvent pump air valve (CB).
7. Hold a metal part of the gun against a grounded metal pail and trigger the gun to relive pressure. Close the solvent flush valve (AK) after relieving the pressure.

8. Engage trigger lock.

9. Disassemble and clean spray tip with solvent. Reinstall on the gun.

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Flush

Flush Hoppers

4. Turn the motor air pressure regulator (CD) fully counterclockwise to shut off.
CD

5. Move the recirculation lines (U) to separate grounded fluid containers.

WLE
6. Open the recirculation valves (AC, AD).

7. Open the feed pump air valve (EM) and begin to pump material out of the hopper. The feed pump may stall.
EM

WLD

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Flush

8. Select pumps to recirculate by pressing

13. Close the material drain (EH) and fill the hopper with

solvent.

scroll through:

, or

9. 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.

10. Run feed pumps until they are dry. Turn off the feed pump air valve (EM) and agitator air valve (EP).
EM

WLE
14. Return the circulation lines (U) to their respective hoppers.
15. Open on the agitator air valve (EP) and feed pump air valve (EM).

WLD
11. Run the main high pressure fluid pumps until the material has been emptied out of the system, press
.
12. Place a small pail under the hopper and open the material drain (EH) to fully drain the spray material.

WLD

16. Select pumps to recirculate by pressing

scroll through:

, or

17. Turn on the main air shutoff valve (CA). Use the

system air regulator (CD) to slowly increase the air

pressure to the pumps until they start running

slowly. Circulate for two to three minutes.

WLE

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18. Drain the material by moving circulation lines to a waste container or using the material drain (EH).

19. Repeat steps 13-18. Change the flushing solvent until it runs clean.
20. Turn off the main air shutoff valve (CA).
CA

Flush

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Flush

Empty and Flush Entire System (new sprayer or end of job)

?
To avoid fire and explosion, always ground equipment and waste container. To avoid static sparking and injury from splashing, always flush at the lowest possible pressure.
Hot solvent may ignite. To avoid fire and explosion:
· Flush equipment only in well-ventilated area.
· Ensure main power is off and heater is cool before flushing.
· Do not turn on heater until fluid lines are clear of solvent.
NOTE:
· If 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 solvent.
· Use the lowest possible pressure when flushing to avoid splashing.
· Before color change or shutdown for storage, flush at a higher flow rate and for a longer time.
· To flush only mix manifold, follow the Flush Mixed Manifold, Hose, and Spray Gun procedure on page 44.
Guidelines
Flush new systems if coating materials will be contaminated by 10W oil.
Flush system when any of the following situations occur. Flushing will help prevent materials from clogging the line between hoppers and pump inlets.
· Anytime sprayer will not be used for more than one week
· If materials used will settle
· If using thixotropic resins that require agitation

Procedure
1. Follow Pressure Relief Procedure, page 43, and Flush Mixed Manifold, Hose, and Spray Gun, page 44. Engage trigger lock. Turn main pump air regulator (CD) fully counter-clockwise to shut off.
CD
air regulator

NOTE: When flushing coating materials, remove pump fluid filters, if installed, and soak in solvent to decrease cleaning time. If flushing a new system, leave filters in place. Proceed with Step 2.
2. Move circulation return lines to separate fluid containers to pump remaining fluid out of system.
3. Increase main pump air regulator (CD) pressure to 30 psi (21 kPa, 2.1 bar).

4. Select

. Press

When running pumps independently set to

. Press

and

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 40 psi (28 kPa, 2.8 bar).

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Flush

5. Open recirculation valves (AC, AD) for respective pump dispense side. Run pumps until the A and B hoppers are empty. Salvage the material in separate, clean containers.

9. Close recirculation valves (AC, AD) and open mix manifold valves (AH, AJ). Dispense fresh solvent through mix manifold valves and out gun.

NOTE: When priming or flushing the pumps, it is normal to get cavitation or pump runaway alarms. Clear the

alarms

, and press

again as necessary.

These alarms prevent excessive pump speeds that can

damage pump packings.

6. Wipe hoppers clean, then add solvent to each. Move circulation lines to waste containers.
7. Repeat Step 4, page 48, to flush through each side until clean solvent exits recirculation hose.

8. Press

. Move recirculation hoses back to

hoppers. Continue recirculating until system is

thoroughly flushed.

10. Close mix manifold valves (AH, AJ).
11. Slowly open sampling valves (AE, AF) to flush solvent through until clean. Close sampling valves.

Press

12. Follow Park Fluid Pump Rods, page 50.

13. Remove pump fluid filters, if installed, and soak in solvent. Clean and replace filter cap. Clean filter o-rings and leave out to dry. Do not leave o-rings in solvent.

14. Close main air valve (E).

NOTE: Fill A and B pump packing nuts with TSL. Also, always 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.

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Park Fluid Pump Rods

Park Fluid Pump Rods
NOTICE If fluid is allowed to dry on the exposed displacement rod, damage to the throat packings may occur. To prevent damage, always stop the feed pump at the bottom of the stroke.
1. Relieve pressure. Follow Pressure Relief Procedure, page 43.

Shutdown Entire System
Follow this procedure prior to servicing equipment or shutdown.
1. Follow Flush Mixed Manifold, Hose, and Spray Gun, page 44.
2. Engage trigger lock, turn off air regulator, and close main air shutoff valve. Remove spray tip.

2. Press

3. Turn recirculation valves (AC, AD) counter clockwise to open them. Each pump will run through recirculation until they reach the bottom stroke, and then stop.

4. When each blue pump LED turns off, close the corresponding circulation valve.

3. If the unit will be shut down for more than 24 hours:
- Follow Park Fluid Pump Rods on page 50. - Cap fluid outlets to keep solvent in the lines. - Fill pump A and B packing nuts with throat seal
liquid (TSL).
4. If the unit will be shut down for more than one week, follow Empty and Flush Entire System (new sprayer or end of job) on page 48.

5. Shut off main pump air valve (CA) and air supply to entire system.
CA

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System Verification
Graco recommends running the following tests daily.
Mix and Integration Tests
Use the following tests to check for proper mix and integration.
Butterfly Test
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 pump have occurred. Fold the sheet of foil over the fluid then peel it back and look for unmixed material (appears marble-like).
Curing Test
Spray a single continuous pattern on foil at typical pressure setting, flow rate, and tip size until multiple changeovers 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 entire length of the test pattern at the time listed on the data sheet. NOTE: Spots that take longer to cure indicate insufficient integration.
Appearance Test
Spray material onto metal substrate. Look for variations in color, gloss, or texture that may indicate improperly catalyzed material.

System Verification
· Verifies that each pump holds fluid against the pump inlet valve by stalling on the down stroke.
· Verifies that each pump holds fluid against the pump piston valve and packings by stalling on the upstroke.
· Verifies that each dosing valve holds fluid, and that there are no external leaks between the pump and dosing valve.
· Verifies that the recirculation valves (AC, AD) are closed and do not leak.
· If system ratio mode is set by weight, this test calibrates the weight ratio.
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.
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 the Test Screens (see page 86).

2. Select

to run pump test.

Pump and Metering Test
This test checks the following items and should be run every time a new job is started, or if there is a suspected problem.
· Verifies that the pumps installed match the pumps selected on the Setup screen by dispensing exactly 750 ml of each material.

If the system ratio mode is by volume, either volumes or weights can be measured.

Press

to select this.

represents

volume, which is standard on XM systems.

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System Verification

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).

d. Slowly open and adjust sampling valve A (AE) to achieve desired flow. Pump stops automatically; twice during test and again when dispense completes. Pump A light (DK) turns off, Pump B light (DK) turns on.
5. Close sampling valve A (AE). 6. Dispense fluid B as follows:
a. Place a clean 1 quart (1000 cc) container under sampling valve B (AF).

4. Dispense fluid A:
a. Close recirculation valves (AC, AD), mix manifold valves (AH, AJ), and both sampling valves (AE, AF).
.

b. Place a clean 1 quart (1000 cc) container under sampling valve A (AE).

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).
7. 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 64
.

c. Press

. Pump A light (DK) comes on.

8. Return fluid used in test to corresponding fluid supply container.
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Confirm Pump and Metering Test
The Confirm Pump and Metering Test screen displays when the pump and metering test completes without error. Depending on the system ratio and test modes, the details of the screen can vary. See Appendix A, Test Screens (page 86) for these variations. The information here is for system ratio mode by volume and a test volume which is standard for XM systems. The screen displays the target volume of material dispensed into each beaker from each metering pump. To determine if the system is in ratio and have your test results entered in the downloadable USB log files, enter the two volumes.

System Verification

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System Verification

Batch Dispense or Ratio Test
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 container) 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 the Test Screens (page 86).

5. Close recirculation valves (AC, AD), mix manifold valves (AH, AJ), and sampling valves (AE, AF).
.

2. Select

to run batch dispense test.

6. Place a clean container under sampling valve A (AE).

3. Adjust dispense amounts from 500 ml to 2000 ml (in

250 ml increments) by pressing

to open the

drop-down box. Then press and

to select

the desired value. Press

to select that value.

4. 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).

7. Press

. Pump A light comes on.

8. 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.

9. Close sampling valve A (AE).

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10. Dispense fluid B as follows:
a. Batch dispense: move container under sampling valve B (AF).
Ratio check: place clean container under sampling valve B (AF).

System Verification
check in the box if it is within tolerance. The result of the test is also entered in the USB log.

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.

b. Slowly open and adjust sampling valve B (AF) to achieve desired flow. The pump stops automatically when dispense completes. Pump B light (DK) turns off.
c. Close sampling valve B (AF).
11. 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 metering pumps and the volume of material dispensed from each metering pump.
The gray at the bottom of the beaker represents the volume of material dispensed by metering pump A and the black at the top of the beaker represents the volume of material dispensed by pump B.
Enter the volume of each sample in the A and B input boxes. The system will calculate the ratio and display a

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 86. Select down stream valve leak test.

to run

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 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 indicating which side has a leak.

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Download Data from USB

Download Data from USB
To help prevent fire and explosion, do not connect USB device in explosive atmospheres.
USB Logs
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, follow Download Setup, page 56. This log can hold up to 18000 lines of data.
Ratio Log 1 (Default log for download.) The ratio log records date, time, machine number, job number, ratio target, ratio, batch volume, and ratio type (volume/weight) while the system is in Spray mode.
Spray Log 2 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.
Once the ratio or spray log is full, new data automatically overwrites old data.
After data in the ratio or spray log is downloaded it remains in the USB module until it is overwritten.
Event Log 3 The event log records all event codes generated over a two year period. This log should be used for troubleshooting purposes and cannot be deleted. This log can hold up 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 to download (default

is 768 hours), by pressing

and

to move

. Press

to make the field selectable.

Press

to scroll through each digit. Press

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.

Download Procedure
To help prevent fire and explosion, remove sprayer from hazardous location or provide proper ventilation to remove the explosive atmosphere and/or vapors before inserting, downloading, or removing USB flash drive.
1. Insert USB flash drive into USB port (DR). Use only Graco-recommended USB flash drives; see Recommended USB Flash Drive, page 92.
Inserting the USB flash drive while the sprayer is running will stop sprayer operation.
2. The USB download screen automatically displays, and the selected log(s) automatically downloads. The USB symbol flashes to indicate download is in process.

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Download Data from USB

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

, which

indicates the download was successful

4. Remove USB flash drive from USB port (DR).

To help prevent fire and explosion, 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 Windows® Explorer.

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 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.

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Maintenance

Filters
Once a week check, clean, and replace (if needed) the following filters. Be sure to follow the Flush, page 44, prior to performing filter maintenance.
· Both pump filters; see your pump manual for instructions.
· Main air inlet manifold filter; see your sprayer repair manual, Replace Air Filter Element section, for instructions.
· Air regulator filter (5 micron) on air control assembly; see your sprayer repair manual, Replace Air Filter Element section, for instructions.
· B side mix manifold strainer; see your mix manifold manual.
Seals
Once a week, check and tighten throat seals on both pumps and dosing valves. Be sure to follow Flush Mixed Manifold, Hose, and Spray Gun, page 44, prior to tightening seals.

Cleaning Procedure
1. Ensure all equipment is grounded. Follow , page 15. 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. Follow Flush Mixed
Manifold, Hose, and Spray Gun procedure on page 44. 5. Relieve pressure. Follow Pressure Relief Procedure, page 43. 6. Shutdown sprayer and turn off all power. Follow Shutdown Entire System, page 50. 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.

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Maintenance

Hopper
Clean Inlet Strainer Screen
The inlet strainers filter out particles that can plug the pump inlet check valves. Inspect the screens daily as part of the startup routine, and clean as required. 1. Ensure that all pumps are shut off and close the
Y-strainer valve (ES). 2. Place a container under the strainer base to catch
drain off when removing the strainer plug. 3. Remove the screen from the strainer manifold.
Thoroughly flush the mesh screen (MS) with compatible solvent and shake it dry.

Check Heating Fluid Level
Gradual fluid evaporation can occur. Check the level of heating fluid monthly. Add fluid as needed.
NOTICE
Freezing temperatures can cause damage that may result in the heating fluid leaking into the terminal enclosure. To avoid damage, do not expose the unit to freezing conditions.
Drain Heating Fluid
Replace heating fluid once a year to improve heating efficiency and increase heater element life. Keep the heating element above the sediment deposits. Sediment deposits will drain out from the heating fluid drain valve (EJ).

MS SG
SP

ES PP
WLD
4. Inspect the screen. No more than 25% of the mesh should be restricted. If more than 25% of the mesh is blocked, replace the screen. Inspect the gasket and replace as needed. See your heated hopper manual for replacement components.
5. Ensure that the pipe plug (PP) is screwed into the strainer plug (SP). Install the strainer plug (SP) with the mesh screen (MS) and gasket (SG) in place and tighten. Do not over tighten the strainer plug--let the gasket make the seal.
6. Open the Y-strainer valve (ES). Ensure that there are no leaks and wipe the equipment clean.

Maximum sediment
level
WLE
EJ NOTE: The immersion heater will not operate in sediment deposits.

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Maintenance

Feed Pumps

· Never leave the pump or hoses filled with water or air. To help prevent corrosion, flush the water and all air out of the system and leave it filed with mineral spirits or an oil-based solvent.

· Keep the packing nut/wet-cup half filled with Graco Throat Seal Liquid (TSLTM) or compatible solvent to help prolong packing life.
0.25 in. (6.3 mm) Diameter Rod
ti34523a
· Adjust the packing nut weekly so it is just tight enough to prevent leakage. Use a spanner wrench or a 0.25 in. (6.3 mm) diameter rod to tighten the nut. Do not over-tighten.

Agitators
NOTICE
To prevent air motor failure and possible damage to equipment, always keep the air motor properly lubricated using Air Motor Lubricant.
· After the first 100 hours, or two weeks of operation, change the gear reducer oil. After that, change the oil every 2500 hours, or six months (whichever comes first) of operation under normal conditions. More frequent oil changes are needed under severe operating conditions or in atmospheres containing excessive moisture or abrasives. See your agitator manual for the oil changing procedure.
· If the air motor is operating sluggish or inefficiently, flush the air motor (see your agitator manual).
· Every 2500 hours, or six months (whichever comes first) of operation, inspect the bearing block (see your agitator manual).

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XM Setup and Tips

Follow the Initial System Setup procedures starting on page 17 and Basic Operation procedures starting on page 32 to get the system ready to spray. Below are a few additional tips that will ensure your system keeps running smoothly
Air Supply
· Ensure that the solenoid air filter/regulator behind the air panel is set to at least 80-85 psi. See Alarm Codes and Troubleshooting on page 64.
· Check that the air filter element in the solenoid air filter/regulator behind the air panel is clean.
Calibration
· 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.
· Ensure dosing valve needle packing nuts are not adjusted too tight. They should be snug when there is no fluid pressure on the valve.

Motor Icing
Air motors accumulate ice in the exhaust valving and muffler under hot and humid conditions or under cold ambient conditions. It can cause pressure loss or motor 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.
· Ensure that the XL motor de-ice bleed valves are open to bleed warm air across the ice if icing becomes an issue.
· 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
· Always use filter screens in the XM pump lowers. Filter style pumps come with 60 mesh screens. Optional 30 mesh elements are also supplied.
· Always use a gun filter. 60 mesh is provided in the gun. Check that the static mixer is clean.
· 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.

312359P

XM Setup and Tips

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.
Early remote manifold machines didn't include the `B' restrictor valve from the factory. · Ensure that the `A' and `B' outlet hose sizes volume
balanced close to the mix ratio. Unbalanced hose sizes can cause off ratio slugs at the mix manifold during pressure and/or flow transitions. See XM Mix Manifold Kits manual.

· If a minimum of integration and mix hose is used, ensure that "Fast Dosing" is selected in the setup screens
Software Version
· Ensure all modules in the system use software from same token. Different software versions may not be compatible.
· The latest software version for each system can be found at Tech Support at www.graco.com.

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.

Module Status LED Signal Green on
Yellow Red solid
Red flashing fast Red flashing slow

Diagnosis System is powered up and power supply voltage is greater than 11 Vdc. Internal communication in progress Hardware failure
Uploading software Token error

Solution -
Replace display module, fluid control module, or USB module. Remove token and upload software token again.

312359P

Troubleshooting

NOTE: See your XM repair-parts manual for non-alarm based troubleshooting and repair instructions.
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.

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 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 goes 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.

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. This should be:
· Non-Hazardous PFP: 23-25 Volts · Hazardous PFP: 10-14 Volts
The middle line shows the voltage supplied to all sensors connected to the Advanced Fluid Control Module. 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)

Icon

Function Moving up
Moving down
Top changeover
Bottom changeover Both reed switches are active. Start of changeover or motor icing problem. Blank: No reed switch signal - error

Diagnose Alarms
See Alarm Codes and Troubleshooting for causes and solutions to each alarm code.
Clear Alarms

Press

to clear alarms and advisories. From the

alarm information screen, press run (fluid control) screen.

to return to the

312359P

Troubleshooting

Alarm Codes and Troubleshooting
See XM Plural-Component Sprayers Repair-Parts manuals for non-alarm based troubleshooting.

Alarm Code DAAX DABX DDAX DDBX
F7AX F7BX F8RX
P1AX P1BX
P4AX P4BX P4RE
P5RE
P9AX

Alarm Problem

When Active

Cause

Solution

Pump runaway, above 80 cpm for 10 sec.
Pump cavitation; dives more than 1/2 of stroke.

Always Spray

System Detects Unexpected Pump Movement (Fluid Flow).
No movement occurred in circulation mode

Spray Circulation

Pressure low.
Pressure high. Pressure high.

Spray, Pump Test, Leak Test
Always
Recirculation

Pressure high.

Recirculation

A pump pressure is abnormally low compared to B pump pressure.

Spray

No material in pump or lines; no fluid restriction.

Refill material in tank or hoses; install fluid tip.

No fluid or valve closed.

Refill supply and open inlet valve.

Material is too cold or thick.

Increase material temperature to reduce viscosity. Follow Heat Fluid, page 40. Shear material with agitation to reduce viscosity.

Pump inlet check valve not closing.

Clear debris from check valve. Or replace ball, seat, and seal.

Feed pump not providing material.

Check feed pump (if used).

Inlet strainer plugged (if used). Check and clean strainer. See your proportioner repair manual.

Recirculation valve or dosing valve open or leaking for more than five seconds.

Close or repair recirculation valve, and run Pump Test. Follow Pump and Metering Test, page 51.

Pump did not move for 5 seconds while in circulation. User may have attempted to spray in circulation mode.

Use spray mode for spraying.

Fluid pressure is below 1000 psi (7 MPa, 70 bar) for spray mode, or below 1500 psi (10.3 MPa, 103 bar) for test modes).

Increase main air regulator.

Fluid pressure is above maximum.

Decrease main air regulator.

Pressure is above maximum advisory limit of 3000 psi (21 MPa, 210 bar) on A side.

Decrease pump air regulator pressure.

Pressure is above maximum warning limit of 5200 psi (35.9 MPa, 359 bar) on A side.

Decrease pump air regulator pressure.

A air motor is icing up causing restriction and lower fluid pressure.

Open the air motor de-ice bleed air controls. Allow ice to melt. Dry compressed air. Heat compressed air.

Use a smaller tip.

A pump is binding.

Repair lower. See manual your proportioner repair.

A motor is hanging up.

Repair air motor. See your proportioner repair manual.

312359P

Troubleshooting

Alarm Code P9BX
QDAE
QTAE
R1BE

Alarm Problem

When Active

Cause

Solution

B pump pressure is abnormally low compared to A pump pressure.

Spray

Dosing size A alarm

Spray

Dosing size A advisory

Spray

Ratio Low B (under dose B); system delivering not enough B component.

Spray

B air motor is icing up causing restriction and lower fluid pressure.
B pump is binding.
The fluid dosing size is greater than 45 cc when fast dosing is turned off. The fluid dosing size is greater than 30 cc when fast dosing is turned on. The fluid dosing size is greater than 35 cc when fast dosing is turned off. The fluid dosing size is greater than 20 cc when fast dosing is turned on. B dosing valve will not open. B mix manifold valve closed. Pump filter plugged on B side.

Open the air motor de-ice bleed air controls. Allow ice to melt. Dry compressed air. Heat compressed air.
Use a smaller tip.
Repair lower. See your proportioner repair manual.
Adjust the B side fluid restriction. Follow Adjust B Machine Outlet Restriction, page 42.
Decrease the air motor velocity with a smaller tip.
Adjust the B side fluid restriction. Follow Adjust B Machine Outlet Restriction, page 42.
Decrease the air motor velocity with a smaller tip.
Check for air signal to valve.
Open green mix manifold valve.
Use alternate 30 mesh screen. See your pump manual for part number.
Clean B pump outlet filter. See your pump manual.

312359P

Troubleshooting

Alarm Code
R4BE

Alarm Problem
Ratio High B (Overdose B), system delivering too much B component.

When Active

Cause

Spray

B Dosing valve not closing.

No B restriction at mix manifold.
Pump filter plugged on A side.
Inlet air dropping below 80 psi (0.55 MPa, 5.5 bar) while spraying. B dosing valve not closing correctly.

Solution
Perform Pump Test to test for leakage. Follow Pump and Metering Test, page 51.
Loosen valve packing nut. See your proportioner repair manual.
Check air signal at valve top
Repair valve or air solenoid. See your proportioner repair manual.
Increase B Restriction by turning B restrictor stem clockwise. Follow Adjust B Machine Outlet Restriction, page 42.
Clean filter. See manual 311762.
Use alternate 30 mesh screen. See your pump manual for part number.
Check air filters. See manual 313289.
Use larger air hose.
Use larger compressor.
Use smaller gun tips or less guns to reduce flow rate.

R5BE

Dosing sizes are not optimized.

Spray

R5DX

Uncalibrated system in Weight Mode

Spray

R9BE

System detected five R4BE (ratio high B) or five R1BE (ratio low B) alarms within five minutes. Sprayer shuts down for five minutes to resolve problem.

Spray

Solenoid air regulator set below 80 psi (0.55 MPa, 5.5 bar) Dosing valve is operating near high or low timing limits.
System was not calibrated.
See R4BE or R1BE alarm causes.

Adjust air regulator.
Adjust mix manifold B restrictor stem clockwise or counter clockwise as indicated by bar graph on restrictor screen. Follow Adjust B Machine Outlet Restriction, page 42.
Run the Pump and Metering Test, page 51, and Batch Dispense or Ratio Test, page 54 to calibrate system for weight mode. Run system in volume mode.
Run system in volume mode.
See R4BE or R1BE alarm solutions. Flush mixed material if necessary, and purge off-ratio mixed material in hose.

312359P

Troubleshooting

Alarm Code DEAX DEBX DFAX DFBX
DGAX DGBX
CACP
DJAX DJBX
DKAX DKBX

Alarm Problem

When Active

Cause

Solution

Pump Test (Daily Check Recommended)

Pump does not move in 10 minutes.

Park or Pump Recirculation valves were not

Test

opened to allow flow.

Pump did not stall against Pump Test fluid pressure on up stroke only.

Pump piston check valve, piston packings, or dosing valve are not holding fluid pressure.

Pump did not stall against fluid pressure on down stroke only.

Pump Test

Pump inlet check or dose valve is fouled, or damaged.

General System Component Alarms

Open recirculation valves.
Flush pump. Follow Empty and Flush Entire System (new sprayer or end of job), 48. Recheck. Remove, clean, and repair lower. See manual 313289.
Remove inlet housing & clean and inspect.
See your proportioner repair manual.

Display has no signal.

Always

Pump motor linear sensor Always has no signal.

Pump motor linear sensor Always is out of range.

Pump motor reed switch failure; missing signals from both switches.

Always

No display communication signal.
Machine powered down in spray mode. No linear sensor signal from motor.
Linear sensor plugged in while power is on.
Bad connection inside fluid control module. Linear sensor is beyond range.
Sprayer is not properly grounded. Bad motor cable connections, or bad reed switch.
Reed switch cable is plugged in while power is on.
Bad connection inside fluid control module.

Check cable connections. Replace display.
See your proportioner repair manual.
Press stop button before turning off power.
Swap A and B sensors. Replace sensor if problem follows sensor. See your proportioner repair manual.
Power sprayer off and back on. Do not plug in linear sensor while power is on.
Replace fluid control module. See your proportioner repair manual.
Replace sensor or sensor magnet. See your proportioner repair manual.
See , page 15.
Swap A and B motor cables. Replace cable if problem persists. Otherwise replace reed sensor assembly. See your proportioner repair manual.
Power sprayer off and back on. Do not plug in reed switch cable while power is on.
Replace fluid control module. See your proportioner repair manual.

312359P

Troubleshooting

Alarm Code F6AK
F6BK
F6AJ F6BJ P6AX P6BX V2MX
*MAAX *MABX *MEAX *MEBX *MGPX *P5AX *P5BX

Alarm Problem

When Active

Cause

Solution

A air motor reed switch signal missing advisory.

Always

Reed switch does not see the Replace air motor reed switch

air motor magnet.

magnet.

Reed switches are bad. Air motor is icing up.

Replace air motor reed switch. Prevent air motor icing. See advisory P9A and P9B.

B air motor reed switch signal missing advisory.

Always

Reed switch does not see the Replace air motor reed switch

air motor magnet.

magnet.

Reed switches are bad. Air motor is icing up.

Replace air motor reed switch. Prevent air motor icing. See advisory P9A and P9B.

A air motor linear sensor Always jump advisory.

System ran out of fluid. Linear sensor is bad.

Add fluid to the system. Replace linear sensor.

B air motor linear sensor Always jump advisory.

System ran out of fluid. Linear sensor is bad.

Add fluid to the system. Replace linear sensor.

Pressure sensor failure; no signal.

Always

Pressure sensor or cable is bad on the side indicated.

Replace sensor and cable assembly. See your proportioner repair manual.

Voltage low control.

Always

Voltage dropping below 9 Vdc from power supply.

Change air filter in control filter regulator. See your proportioner repair manual.

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 your proportioner repair manual.

Optional User-Settable Maintenance Warnings

Maintain pump. Maintain dosing valve.

Always, if enabled
Always, if enabled

Maintain air filter.

Always, if enabled

Pressure exceeded alarm Spray limits.

Pump usage exceeds user-set limit. Maintenance due.
Dosing valve usage exceeds user-set limit. Maintenance due.
Air filter exceeds user-set limit. Maintenance due.
Pressure exceeded high or low alarm limits for more than 15 seconds.

Service pump. See your proportioner repair manual.
Service dosing valve. See your proportioner repair manual.
Service main air filter and control filter regulator. See your proportioner repair manual.
Adjust pump pressure regulator, change tips, or adjust target set point.

312359P

Troubleshooting

Alarm Code

Alarm Problem

*P2AX P2BX

Pressure exceeded advisory limits.

*QPDX

Pot life timer expired. Mixed fluid will cure in hoses, mixer, and gun.

*T2DA T2DB
*T5DA T5DB

Temperature exceeded advisory limits.
Temperature exceeded alarm limits.

When Active

Cause

Solution

Optional User-Settable Spray Limits

Spray

Pressure exceeded high or low advisory limits for more than 15 seconds.

Spray

Have not sprayed enough volume to keep fresh mixed fluid in the integration hose, mixer, whip hose, and spray gun.

Spray

Fluid temperature exceeded high or low limits for more than four minutes.

Spray

Fluid temperature exceeded high or low alarm limits for more than four minutes.

Same as P5A or P5B above.
Spray fluid, or flush. Resets when you leave spray mode. Follow Spray, page 41, or Flush, page 44.
Same as T5A or T5B above.
If fluid temperature is too low, return to circulation mode to increase fluid temperature. Adjust heater set point if needed. Follow Heat Fluid, page 40. If fluid temperature is too high, lower heater set point, and return circulation mode to cool. Follow Heat Fluid, page 40. Adjust temperature target setpoint. Follow Heat Fluid, page 40.

312359P

Troubleshooting

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
Park Circulation Pump Test

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. If fluid pressure is more than 103% of allowed maximum, air motor shuts off until fluid pressure drops. If is pressure more than 110% of allowed maximum, STOP. Dosing valve A opens, and dosing valve B cycles to maintain ratio. A and B blue lights illuminate when dosing valves are operating. If there is not enough B component to hold ratio, dosing valve A closes momentarily. If A or B component is more than 5% off ratio setpoint, STOP. If A dose size is too large, STOP. A and B dosing valves close momentarily at each pump changeover. Spray mode turned on with system in Weight Mode and uncalibrated. 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. 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, receive yellow light advisory. If fluid pressure exceeds 5600 psi (39.2 MPa, 392 bar) on the A pump, STOP. If no movement in 10 minutes, turn off air to both motors. Pump did not move for 5 seconds while in circulation mode. Both dosing valves close; green light blinks. If fluid pressure is under 1000 psi (7.0 MPa, 70 bar), STOP. If pumps move (indicating leakage) STOP. Turn on A blue light, open A dosing valve, user opens sampling valve. Close A dosing valve on upstroke; check for no movement. Close A dose valve on down stroke; check for no movement. Open A dose valve and dispense total of 750 ml material, close valve, turn off blue light. Repeat for B side. If both pumps pass pump test, display shows two beakers of 750ml each.

Alarms --
P1AX F7AX, F7BX
None
P4BX ---
R5BE
R1BE, R4BE QDAE -R5DX ---
DEAX, DEBX --
P4AX
P4AX
DEAX, DEBX F8RX --
P1AX, P1BX F7AX, F7BX
-DFAX DGAX
--
DFBX, DGBX --

312359P

Troubleshooting

Mode Batch Dispense Test
Valve Test

Control Logic
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. If fluid pressure is not 1000 psi (7 MPa, 70 bar), STOP. Check for no movement of pumps (stall within 10 seconds).

Alarms ---
--
-P1AX, P1BX F7AX, F7BX

312359P

Troubleshooting

Alarm And Advisory Code Key
Use the following table as a quick guide to determine alarm codes.

EVENT

MODE

LOCATION

ZONE

A Current

1 Low Alarm

A Material A

1 Tank A

F Flow

2 Low Deviation

B Material B

2 Tank B

L Tank Level

3 High Deviation

C Controller

A Heater A

P Pressure

4 High Alarm

D Output Discharge B Heater B

R Ratio

5 Calibration

F Input Feed

C Level Sensor A

T Temperature

6 Sensor Failure

M Pneumatic Supply D Level Sensor B

V Voltage

7 Unexpected Non-Zero Value P Pneumatic Supply E Hose

8 Unexpected Zero Value

R Recirculation

H Heater Hose

9 Unstable

J Linear Sensor

C Communication A Loss

K Reed Switch

D Pump

A Runaway

P Display

D Cavitation

X System

E Time-out

F Stall Up

G Stall Down

J Linear Sensor

K Reed Switch

M Maintenance

A Pump

E Valve

G Filter

Q Proportioning

D Overdose

P Potlife

T Dosing Time

312359P

Accessories and Kits

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 your hopper manual for more information.
Hopper Heater Kit (240V), 256257
For heating fluid in a 20-gallon hopper. See your hopper manual 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 your hopper manual for more information.
Universal Hopper Mounting Kit, 256259
For mounting a 20-gallon hopper to the side or back of an XM sprayer. See your hopper manual for more information.
Twistork® Agitator Kit, 256274
For mixing viscous materials held within a 20-gallon hopper. See your feed pump and agitator manual for more information.
T2 Feed Pump Kit, 256275
For supplying viscous material from a 20-gallon hopper to an XM sprayer. See your feed pump and agitator manual for more information.
5:1 Feed Pump Kit, 256276
For supplying viscous materials from a 20-gallon hopper to an XM sprayer. See your feed pump and agitator manual for more information.

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 your hopper kit manual 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 your feed pump and agitator manual 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 XM sprayer. See your feed pump and agitator manual for more information.
Hopper/Hose Heat Circulation Kit, 256273
For circulating heated water through 20-gallon hoppers, heated hose, and Viscon HP heater. See your hopper or hose heat circulation kit manual for more information.
Desiccant Dryer Kit, 256512
For use with 20-gallon hoppers. See desiccant kit manual for more information.
Caster Kit, 256262
For mounting casters on XM sprayer frame. See your caster kit manual for more information.
Hose Rack Kit, 256263
For mounting to side, front, or back of XM sprayer frame. See your hose rack kit manual for more information.
Lower Strainer and Valve Kit, 256653
For straining material from a feed pump to an XM sprayer fluid inlet. See lower strainer and valve kit manual for more information.

312359P

Accessories and Kits

Electric Heated Hose Power Supply Kit, 256876
For monitoring and controlling fluid temperature in low-voltage heated hoses. See your electric heated hose power supply kit manual for more information.

5000 psi Two-Component Main Heated Hose Set Kit
Electric heated hose set for adding additional sections.

Part 248907
248908

Description
Heated hose set; 1/4 in. ID x 3/8 in. ID; 50 ft.
Heated hose set; 3/8 in. ID x 3/8 in. ID; 50 ft.

Xtreme Pump Wetcup Wrench, 15T258

Xtreme Pump Filter Wrench, 16G819

10:1 Drum Feed Kit, 256433
For supplying highly viscous material from a 55-gallon drum to an XM sprayer. See your feed pump and agitator kit manual for more information.

Shutoff/Check Valve Kit, 255278
For replacing shutoff valve or check valve. See your high flow severe duty shutoff check valve manual for more information.

Alternator Conversion Kit, 256991
For converting an XM sprayer from wall power supply to intrinsically safe alternator power supply. See your alternator conversion kit manual for more information.
Mix Manifold Kit, 255684
See your mix manifold kit manual for more information.
Remote Mix Manifold and Carriage Kit, 256980
For converting to a remote mix manifold kit with a protective guard. See your mix manifold kit manual 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 42.
Remote Recirculation Mix Manifold Kit, 273185

312359P

Appendix A

User Interface Display
The user interface display is divided into three main functions: Setup, Command, and Automatic.
Setup Mode Screens (key to right)
The setup functions enable users to: - change between volume and weight ratio - set desired mix ratio by volume or weight - set weight ratio and tolerance for ratio checks - configure system settings - set potlife parameters - enable/disable functions, displays, and display components - set which USB logs to download - schedule maintenance parameters for alarms and advisories - set pressure and temperature limits - set tank "fill" and "full" levels
Some setup functions must be enabled from the Enable Setup screens before users can change or set configurations. Follow Enable Setup Screens, page 81, for instructions.

Operator Command Mode Screens (key to left or removed) Use these screens 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
Automatically Displayed Screens These screens are shown when
- The potlife timer alarms to notify the user that material is about to cure in the system.
- download USB logs.
Change a Setting
All settings are changed in the same manner:
1. Navigate to the desired screen. Follow Operator Command Mode Screens, or Setup Mode Screens.
2. Once in the desired screen, use the arrow keys to navigate to the item that you wish to change.
3. Press enter to enter editing mode.
4. Use the arrow keys to change the selection or value.

5. Press enter again to save the change or press to cancel the change.

312359P

Appendix A
Setup Mode Screens
Setup mode screens are divided into five major sections: home, limits, maintenance, enable, and system. The following figure demonstrates the flow of the Setup mode screens beginning with the Home screen.

Temperature

Software Versions

Ratio Test

Enable Options 3

Maintenance 2

Pressure

System/USB

Enable Options 2

Home / Volume Mix Ratio

Maintenance 1

Potlife/Hose Length Date/Time/Units

Enable Options 1

(From All Screens)

312359P

Home Setup Screens (Key Switch On)
Home

.Software Versions

Appendix A

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.

Icon

Function

Increase or decrease mix ratio. Press and to change the mix ratio. Navigate to jump to system setup screens.

This screen displays the versions and part number of the system components. Refer to the following table for

details. To access this screen, press Home Setup screen.

from the

Icon

Function

Display module version (Vs) and part number

Advanced fluid control module version (Vs) and part number

USB version (Vs) and part number USB Configuration (Vc) and part number

Navigate to enable/disable options screens.
Navigate to maintenance setup screens.

Navigate to pressure and temperature limits setup screens.

312359P

Appendix A

System Setup Screens
System Setup enables users to configure system settings for fluid control and operator interaction. Refer to the following table for details.
Some system settings must be enabled from the Enable Setup screens before users can change or set configurations. Follow Enable Setup Screens, page 81, for instructions.

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 to indicated total hose volume.
Set calendar date and format.

Set time.

Set USB language.

Set units of measurement desired for display, such as fluid and temperature.
Set sprayer number if using more than one sprayer.
Set how often data will record to USB ratio and spray logs.
Set number of hours of recorded data to download to USB flash drive. Set the A and B side metering pump sizes.

Potlife/Hose Length
This screen enables users to set the potlife timer, and length of each mixed material hose specific to the system. The total mixed material volume is then calculated and displayed on the page. The potlife time displays in the upper right corner.
When the fluid flow stops the displayed potlife time counts down in one minute intervals. The timer automatically resets when the calculated mixed fluid volume is dispensed.
Date/Time/Units 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.

Volume ratio reference

Weight ratio reference

Ratio Pass Tolerance

312359P

Appendix A

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 33, for instructions.
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 81.
NOTICE Changing the pump size settings may cause the system to spray off ratio. Set Pump Sizes

size. A new pump volume entry field will appear as

shown below. Press and

to select the volume

entry field. Press

to begin editing.

Enter the pump size in cubic centimeters (cc). To enter

a number press Press press

and and

to change numbers. to move between

digits. Press

to exit the field.

The entered pump volume will be saved by the system, but it will only be used when CUSTOM is selected. Pump A and pump B volume are entered separately.

The standard pump sizes of 290 cc, 250 cc, and 220 cc have maximum pressure limits of 5600 psi (38.6 MPa, 386 bar), 5600 psi (38.6 MPa, 386 bar), and 6000 psi (41.4 MPa, 414 bar), respectively. Other pump sizes and the custom pump size (for any volume entered) have a maximum pressure limit of 7000 psi (48.3 MPa, 483 bar).

To change the pump size, press and

to select

the field. Press

to open the drop down field.

Press

and

to select the preferred pump size.

Press

again to save the change.

Ratio Test

Set Custom Pump Sizes
Custom pump sizes can also be entered. In the pump size box describes above, select CUSTOM as the pump

For Ratio by Volume Mode, use this screen to set the ratio by weight (middle number), and the ratio tolerance (bottom number). The values determine whether the ratio test passes. The ratio by volume (top number) is displayed but cannot be changed on this screen. Follow

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Appendix A

Home screen, on page 77, to change the ratio by volume.
For Ratio by Weight Mode, use this screen to set the ratio by weight tolerance (bottom number). The ratio by weight (top number) is displayed but cannot be changed

on this screen. Follow Home screen, on page 77, to change the ratio by weight.

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Appendix A

Enable Setup Screens
Enable Setup allows users to enable and disable functionalities, 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

from the Home Setup screen.

Once in the Enable Setup screen, press

and

to scroll through each subscreen. Press

and

to scroll through each field within the

subscreens, and press

to enable or disable each.

Press

to return to the Home Setup screen

Icon

Function

Enable or disable dosing valve maintenance setup screen.

Enable or disable incoming air filter maintenance setup screen.
Enable or disable limits (pressure and temperature) screens.

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.

Icon

Function

USB data download function. Disable this function to prevent operators from changing USB settings.

Even if this function is disabled, selected USB logs will still be downloaded.

Enable or disable Totalizer screens.

Enable or disable batch Totalizer clear function.
Display potlife timer on all screens. Enable or disable potlife timer setup screen.
Display flow rates on run screens

Display A and B pressures on run screens.

Enable or disable USB log files (1-3) to download.

Selects system ratio by volume or ratio

by weight

mode. Only one of these

modes can be enabled at one time.

Fast Dosing Function

Fast Dosing on off

Advisory QTAE Alarm QDAE

20 cc

30 cc

35 cc

45 cc

Enable Setup 1 (Shown with factory default settings.)

Display A and B temperatures on run screens.
Enable or disable ability to change 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.

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Appendix A

Enable Setup 2 (Shown with factory default settings.)
Enable Setup Screen 3 (Shown with factory default settings.)
NOTE: The machine will be shipped in Volume Mode.

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 indicates the amount of material dispensed, counting up to the setpoint requiring maintenance.
Icon Function
Set amount of material moved through pump that will result in a maintenance warning.
Set amount of material moved through dosing valve that will result in a maintenance warning.
Set number of days between changing the main incoming air filter before a reminder advisory is issued.
Maintenance Setup 1

Maintenance Setup 2

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Appendix A

User Limits Setup Screens
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.
NOTE: The B metering pump pressure always runs 10-20% higher than the A metering pump pressure.
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.

Process Pressure Limits (for spray mode) Process Temperature Limits (for spray mode)

Set and adjust limits above or below target value that if exceeded will issue an advisory. Used with pressure and temperature limits.
Set and adjust limits above and below target value that if exceeded will issue a alarm. Used with pressure and temperature limits.

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Appendix A
Operator Command Mode Screens
Command mode screens are divided into three major sections: run (fluid control), test, and alarm control. The following figure demonstrates the flow of the Command mode screens beginning with the run (fluid control) screens.

Run (Fluid Control) Screens
(Spray Mode shown)

Test Screens
(Pump Volume Test shown)

Information Screens Alarm Information

Park Pump Pump Mode Spray Mode
Ratio

Valve Test Batch Test Pump Test

Restrictor

Weight/Volume

Maintenance 1

Maintenance 2

Totalizer

Go to primary screen in each section

Alarm Log

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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: pressure, temperature and flow rate if these functions are selected.
The ratio screen displays the current ratio and monitors the B side restriction adjustment.

Icon

Function

Spray: proportion and spray material.

Icon at bottom of screen: Select which metering pumps are active. Press repeatedly to cycle through metering pump A, metering pump B, and both metering pumps. Icon in rectangle: Operate both metering pumps.
Operate the A metering pump only (priming, flushing).
Operate the B metering pump only (priming, flushing).
Park Metering Pumps: run metering pumps to bottom of the stroke.
Ratio: jump to ratio screen.

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 pumps for priming or flushing. Press the button below the pump icon to enter this mode. Continue pressing the pump icon button to cycle through pump A, pump B, and both pumps.

Power On/Enter Mode Power On/Enter Mode is the default screen when users enter Fluid Control.
This screen remains blank until a mode is selected.

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Appendix A

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

The bar graph

indicates whether the B restriction adjustment should be turned clockwise or counter clockwise. See Adjust B Machine Outlet Restriction, page 42.

The ratio displayed is the weight ratio if the machine is in Ratio by Weight Mode. The ratio displayed is the volume ratio if the machine is in Ratio by Ratio Mode.

If the

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.

Test Screens
Test screens enable users to run batch dispense tests, pump tests, and down stream valve leak tests.

Icon

Function

Pump Test: dispenses 750cc of each A and B; verifies pump selection, operation, and metering. In system weight mode, this calibrates the system by entering weights.

Batch Dispense: dispenses proportioned amounts of A and B with a selectable total.

Down Stream Valve Leak Test: test if valves after the dosing valves hold pressure.

Test Mode Selection: Switch between volume and weight test mode.

Pump Test/Calibrate
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.

If the system ratio mode is by volume, pressing will allow the test to be run either by measuring volumes or weights. If system ratio mode is by weight, then the displaced materials must be measured by weight.

Restrictor Screen

Icon

Function

Display Ratio: show the accuracy of the fluid mix ratio.

Display Restrictor Adjust: Adjust the restrictor to optimize the mix ratio. · At the maximum fluid flow, the bar
should be in the center. · At less than maximum flow, the bar
should be on the right side.

Confirm Pump and Metering Test
This screen displays when the pump test completes without error. There are three variations that affect how the screen is used.

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Appendix A

Ratio by Volume Mode - Test by Volume
Enter the volumes of each dispensed material 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 77. The tolerance is set on the Setup Ratio Test screen on page 79.

Once entered, a check will appear in the box. There will still be an X through the scale in the upper right corner until a Ratio Test is performed successfully.

System Ratio Mode by Weight

System Ratio Mode by Volume - Test by Volume
Ratio by Volume Mode - Test by Weight
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.
The target ratio by weight for this test and tolerance is set on the Setup Ratio Test screen on page 79.

System Ratio Mode by Volume - Test by Weight
Ratio by Weight Mode
This screen displays two boxes where the A and B sample weights are entered to calibrate the machine to run in Ratio by Weight Mode. The weights must be entered in grams.
The target ratio by weight for this test is set on the Setup Home screen on page 77. The tolerance is set on the Setup Ratio Test screen on page 79.

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Appendix A

Batch Dispense or Ratio 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 displays in gray on the screen.
If the system ratio mode is by volume, pressing will allow the test to be run either by measuring volumes or weights. If system ratio mode is by weight, then the displaced materials must be measured by weight.

Ratio by Volume Mode - Test by Weight
Enter the weights of each dispensed material in the respective input boxes on this screen. If 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 weight for this test and tolerance is set on the Setup Ratio Test screen on page 79.

System Ratio Mode by Volume - Test 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 pumps and the volume of material dispensed from each pump. The gray at the bottom of the beaker represents 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.
There are three variations that affect how the screen is used:
Ratio by Volume Mode - Test by Volume
Enter the volumes of each dispensed material 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 77. The tolerance is set on the Setup Ratio screen on page 79.

Ratio by Weight Mode Enter the weights of each dispensed material in the respective input boxes on this screen. The weights must be entered in grams. If 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 weight for this test is set on the Setup Home screen on page 77. The tolerance is set on the Setup Ratio Test screen on page 79
System Ratio Mode by Weight

System Ratio Mode by Volume - Test by Volume 88

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Appendix A

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 shutoff/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.
Confirm Valve Leak Test This screen displays when the valve leak test completes and indicates whether the test was successful.

Information Screens
Use this screen to view 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.
If the potlife timer is enabled the Flush Confirm icon,
displays.
Alarm
The Alarm screen displays the specific alarm code. There are two levels of error codes: alarms and advisories. 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 top view and side view of the system. Refer to the following table and subsections for more details.
The first number below the alarm code is the main power supply voltage used by the electronic modules. The voltage should read between 23 VDC - 25 VDC for non-hazardous location systems, and 10-14 VDC for the hazardous location systems.
The second number below the alarm code is the power supply voltage used by the system sensors. 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.

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Appendix A

Icon

Function

Totalizers and Job Number

Go to Alarm log. Use up and down arrows Use this screen to view the grand and batch totals for

to scroll through list of the past 16 errors.

each pump and both pumps combined. The units of

Go to Totalizer screen. Allows users to view the grand and batch totals for each pump and both pumps combined.

measurement are displayed on the bottom of the screen and displayed in the units of measurement selected during setup.

Go to maintenance screen. Allows user to view maintenance information but not make changes. Follow Maintenance Setup 2, page 82.

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.

Flush confirm. Use when the potlife timer is enabled. Press button to confirm flush before a potlife advisory is issued.

A job number can be entered at the beginning of each spray job. This helps to organize the USB spray log.

Amount of material moved through pump that will result in a maintenance warning.

Clear Batch Totalizer To clear the batch Totalizer values for A, B, and A+B,

Amount of material moved through dosing valve that will result in a maintenance warning.

press

to set all values to zero.

Number of days between maintenance cycles that will result in a reminder advisory.

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.

Icon

Press

to access the alarm log. The press and

to scroll through each page of alarms.

Function
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.
Number of hours system has been running

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Appendix A

Change Job Number

1. Press

to highlight the first digit. Press

and

to change the number and

and

to move to the next digit. Press

save the number or

to cancel.

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.

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 and

to scroll through and select the

maintenance field to reset.

2. Press zero.

to reset the maintenance counter to

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Appendix A

Automatically Displayed 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.

Icon

Function

Advisory has been issued.

Potlife timer is enabled.

USB Screen
The USB screen automatically displays and the selected log(s) automatically starts downloading when the USB flash drive is inserted into the USB port (DR).
Inserting the USB flash drive while the sprayer is running 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 following table for more details.

Time after potlife expires. Starts at 0.00

Icon

and counts down in negative one minute

intervals.

Press to mute advisory buzzer.

Press to confirm that mixed hose has been flushed. Resets potlife timer.

Function Flashes while data download is in process.

Check mark appears after download completes. Indicates download was successful. If download was not

successful,

appears.

Displays total memory to download and

remaining memory left to download.

Displays time remaining for log download

to complete.

Press to cancel download. If download is canceled, remove USB flash drive.

Indicates which log(s) is being downloaded.

Recommended USB Flash Drive
Use the USB flash drive (17L724) included with the XM sprayer for data download.

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Appendix B

Metering Diagrams
Metering Diagram without Remote Mix Manifold

XM Metering Diagram

Linear Transducers

Recirculation Back Pressure Control

NXXL T 6500 Air Motor

Reed Switches

Air Reg Double Motor Pilots
Controls

NXLXT 6500 Air Motor

250 HF or 180 HP

R
Gravity Feed

Pump Feed

Circulation Shut/Check

Control Valves
psi

F L U S H psi

rtd

220 HF or 145 HP

Sample & Test Valves

Mix Manifold

Mix Manifold Shut-off & Check Valves
Settable `B' Balancing Restriction

Appendix B

312359P

Fluid Line Control cable Air Signal

Integration Hose
3/8 x 25 ft minimum

Note: Additional guns may only be added after the integration hose and mixer

Spray Gun 3

Mixers

Spray Gun

Spray Gun 2 Whip Hose

Appendix B

Metering Diagram with Remote Mix Manifold

Linear Transducers

Recirculation Back Pressure Control

NXLXT 6500 Air Motor

XM Metering Diagram with Remote Mix Manifold

Reed Switches

Air Reg
Double Motor Pilot

NXLXT 6500 Air Motor

Controls

H O P P E R
Gravity Feed or Pump Feed

250 HF or 180 HP
A

H
Control
E Valves A T E R

psi

Circulation On / Off

Sample & Test Valves

rtd

Shut-off & Hose Isolation Check Valves

F L U S H
Remote Shut-off & Check Valves

220 HF or 145 HP

These hose isolation check valves must be added when mix manifold is remote. This insures that pressure transducers read pump output and cavitation, and not just dampened hose pressure.

Fluid Line Control cable Air Signal
94

Mix Manifiold

Settable `B' Balancing Restriction
Integration Hose 3/8 x 25 ft minimum

Note: Additional guns may only be added after the integration hose and mixer

Mixers

Spray Gun 3 Spray Gun Spray Gun 2

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Appendix C

Power Cord Guidelines
Use the guidelines listed in the following table to determine the power cord needed for your specific system.

Table 6: Base System Maximum Current Draw XM_L00

Power Supply

Wall

Configuration Options:

Controls

1 A, 90-240 Vac

Full Load Peak Amperes at 240 V, 1 Phase

1 A

Full Load Peak Amperes (A):

240 V, 1 Phase

240 V, 3 Phase

380 V, 3 Phase

480 V

100-240 V, 1 Phase

XM_N00 Alternator
N/A 0 A (air only)
0 0 0 0 0

Wired by user if ordered. Cord size determined by user.
Full load amperes with all components operating at maximum capabilities. Fuse requirements for various flow rates and heater temperature settings may be less.

Junction Box 240 V, 1 Phase

Table 7: Models with 240 Volt Viscon HF Fluid Heater

Full Load Peak Amperes (A) XM_ _ 00 XM _ _ 0W XM_ _ 0E XM_ _ 20 XM_ _ 2W

240 V, 3 Phase

380 V, 3 Phase

480 V

100-240 V, 1 Phase

Models XM_P, XM_J only

XM_ _ 2E 84 73 48

Junction Box 240 V, 1 Phase

Table 8: Models with 480 Volt Viscon HF Fluid Heater
Full Load Peak Amperes (A) XM_ _ 00 XM _ _ 0W XM_ _ 0E XM_ _ 20 XM_ _ 2W

240 V, 3 Phase

380 V, 3 Phase

480 V

100-240 V, 1 Phase

Models XM_ K, XM_F, only

XM_ _ 2E 27

312359P

Dimensions
Dimensions
XM System Dimensions without Hoppers (Non-Hazardous Locations)
$
&

Ref.

Dimensions

39.5 in.

100.3 cm

36.0 in.

91.4 cm

72.5 in.

184.1 cm

38.0 in.

96.5 cm

WLD

312359P

Dimensions
XM System Dimensions without Hoppers (Hazardous Locations)
A
C

Ref.

Dimensions

39.5 in.

100.3 cm

36.0 in.

91.4 cm

79.0 in.

200.6 cm

38.0 in.

96.5 cm

312359P

D
97

Dimensions
10-Gallon Rear Mount Steel Tank
Non-Hazardous Locations
$

Hazardous Locations
$

% &
(

% &

WLD

(

Ref.

Dimensions

Non-Hazardous Locations

Hazardous Locations

47.5 in. (120.6 cm)

36.0 in. (91.4 cm)

38.5 in. (97.7 cm)

43.5 in. (110.4 cm)

38.0 in. (96.5 cm)

72.5 in. (184.1 cm)

79.0 in. (200.6 cm)

312359P

25-Gallon Rear Mount Steel Tank
Non-Hazardous Locations
$

Dimensions
Hazardous Locations
$

' %WL[[[[D

WLD

Ref.

Dimensions

Non-Hazardous Locations

Hazardous Locations

72.5 in. (184.1 cm)

79.0 in. (200.6 cm)

50.75 in. (128.9 cm)

38.5 in. (97.7 cm)

43.5 in. (110.5 cm)

312359P

Dimensions
System Dimensions with Hoppers
Two 20-Gallon Hoppers Side Mounted

72.5 in. (184.2 cm)

98.6 in. (255.4 cm)
Two 20-Gallon Hoppers Rear Mounted (Top View)

WLE

54.0 in. (137.2 cm)

49.7 in. (126.2 cm)

43.1 in. (109.5 cm)

62.8 in. (159.5 cm)

38.5 in. (975.4 cm)

56.2 in. (142.8 cm)

ti21283a

100

312359P

System Dimensions with Hoppers
One 20-Gallon Hopper and One 7-Gallon Hopper
72.5 in. (184.2 cm)

43.1 in. (109.4 cm)
Two 7-Gallon Hoppers

79.1 in. (200.9 cm)

Dimensions
70.0 in. (178.8 cm)
33.4 in. (84.8 cm)
70.0 in. (178.8 cm)

312359P

59.7 in. (151.6 cm)

33.4 in. (84.8 cm)
ti21284a
101

Pump Performance Charts

Calculate Fluid Outlet Pressure
To calculate fluid outlet pressure (MPa/bar/psi) at a specific fluid flow (lpm/gpm) and operating air pressure (MPa/bar/psi), use the following instructions and pump data charts.

Calculate Pump Air Consumption
To calculate pump air consumption (m3/min or scfm) at a specific fluid flow (lpm/gpm) and air pressure (MPa/bar/psi), use the following instructions and pump data charts.

1. Locate desired flow along bottom of chart.
2. Follow vertical line up to intersection with selected fluid outlet pressure curve. Follow left to scale to read fluid outlet pressure.

1. Locate desired flow along bottom of chart.
2. Follow vertical line up to intersection with selected air consumption curve. Follow right to scale to read air consumption.

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.

7000 (49.0, 490)

XM50 Fluid Performance and Air Consumption

180 (5.0)

Fluid Pressure in psi (MPa, bar)

Air Consumption in SCFM (m3/min)

5000 (35.0, 350)
3000 (21.0, 210)

A B

1000 (7.0, 70)
0.0 KEY: A = 100 psi (0.7 MPa, 7 bar) B = 70 psi (0.48 MPa, 4.8 bar)

1.0 (3.8)

2.0 (7.6)

Fluid Flow in gpm (lpm)

3.0 (11.4)

140 (3.9)
100 (2.8)
60 (1.7)
20 (0.6)

Fluid Pressure in psi (MPa, bar)

7000 (49.0, 490)
5000 (35.0, 350)
3000 (21.0, 210)

XM70 Fluid Performance and Air Consumption

A B

1000 (7.0, 70)
0.0 KEY: A = 90 psi (0.62 MPa, 6.2 bar) B = 70 psi (0.48 MPa, 4.8 bar)

1.0 (3.8)

2.0 (7.6)

Fluid Flow in gpm (lpm)

3.0 (11.4)

102

180 (5.0) 140 (3.9) 100 (2.8) 60 (1.7) 20 (0.6)
312359P

Air Consumption in SCFM (m3/min)

Technical Specifications

XM Plural-Component Sprayers

Metric

Mixed Ratio Range

1:1-10:1 (in 0.1 increments)

Ratio Tolerance Range (before alarm)

+/- 5%

Fluid Viscosity Range

200-20,000 cps (heavier viscosities can be mixed using heat, circulation, and/or pressure feeding)

Fluid filtration, standard on pump outlets*

60 mesh

238 micron

Air Filtration

40 micron main filter, 5 micron control air filter; see Pump Performance Charts, page 102

Weight

Weight: Base sprayer

(XM1L00, XM1N00 models) Add component weights to base sprayer weight for your specific model weight.

742 lb

336.87 kg

Dimensions

See Dimensions, page 96

Inlet/Outlet Sizes

Air inlet size Fluid inlet size, without feed kits

3/4 in. npt(f) 1 1/4 npt(m)

Ambient temperature range

Operating Storage

32-130 °F 30-160 °F

0-54 °C -1-71 °C

Maximum fluid working pressure of mixed material

50:1 70:1

5200 psi 6300 psi

35.8 MPa, 358 bar 43.5 MPa, 435 bar

Maximum Pump Inlet Fluid Feed Pressure

250 psi

1.7 MPa, 17 bar

Maximum Fluid Temperature

160 °F

71 °C

Maximum pump air set pressure

50:1 70:1

100 psi 90 psi

0.68 MPa, 6.8 bar 0.62 MPa, 6.2 bar

Air Supply Pressure Range

50-150 psi

0.35-1.0 MPa, 3.5-10.3 bar

Maximum Air Consumption at 100 psi (0.7 MPa, 7.0 bar) in scfm (m^3/min.)

70 scfm per gpm (1.96 m3/min. per lpm)

Flow Rates

Minimum* *

1 quart per minute

0.95 liters per minute

Maximum Notes

3 gallons per minute

11.4 liters per minute

Heavier viscosities can be mixed using heat, circulation, and pressure feeding.

* Filter assembly is not included on some models.

* * Minimum flow rate is dependent on material being sprayed and mixing capability. Test your material specific to flow rate. Environmental conditions rating

Indoor/outdoor use

Altitude Maximum relative humidity

Up to 4000 m

To 99% up to 130°F

To 99% up to 54°C

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103

Technical Specifications

XM Plural-Component Sprayers

Metric

Pollution degree

Installation category

Wetted Parts

Suction Tubes

aluminum

Flush Pump

carbide, PTFE, stainless steel, UHMWPE

Hoses

nylon

Pumps (A and B)

carbon steel, alloy steel, 303, 440, 17-ph grades stainless steel, zinc and nickel plating, ductile iron, tungsten carbide, PTFE

Metering Valves

carbon steel, nickel plating, carbide, polyethylene, leather

Manifold

carbon steel, nickel plating, carbide, 302 stainless steel, PTFE, UHMWPE

Mixer

stainless steel housing with acetal elements

Spray Gun

Refer to spray gun manual

Noise dB(A)

Operating Pressure 70 psi (0.48 MPa, 4.8 bar)

Sound pressure Sound power measured per ISO 3744 Operating Pressure 100 psi (0.7 MPa, 7 bar)

84.8 dB(A) 95.1 dB(A)

Sound pressure Sound power measured per ISO 3744 Notes

91.7 dB(A) 102.0 dB(A)

All trademarks or registered trademarks are the property of their respective owners.

104

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California Proposition 65
California Proposition 65
CALIFORNIA RESIDENTS WARNING: Cancer and reproductive harm www.P65warnings.ca.gov.

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105

Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco's written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, 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 WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco's sole obligation and buyer's sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost 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 entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com. For patent information, see www.graco.com/patents. 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.
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 2021, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com Revision P, February 2021

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