Graco 332564B Promix Pd2K Proportioner Users Manual 332564B, For Automatic Spray Applications, Operation, English

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Operation

ProMix® PD2K Proportioner for

Automatic Spray Applications 332564B

EN

Electronic positive displacement proportioner for fast-setting two-component materials. Automatic

system with Advanced Display Module. For professional use only.

Important Safety Instructions

Read all warnings and instructions in this manual and in your

installation, repair, and associated component manuals.

Save these instructions.

See page 3 for model part numbers and

approvals information.

PROVEN QUALITY. LEADING TECHNOLOGY.

Contents

Related Manuals ..................................................3

Models................................................................. 4

Warnings ............................................................. 6

Important Isocyanate (ISO) Information .................. 9

General Information ............................................ 10

Advanced Display Module (ADM) ........................ 11

ADM Display................................................ 11

USB Download Procedure............................ 11

USB Upload Procedure ................................ 12

ADM Keys and Indicators ............................. 13

Soft Key Icons ............................................. 14

Navigating the Screens ................................ 16

Screen Icons ............................................... 16

Pre-Operation Tasks........................................... 17

Pre-operation Checklist ................................ 17

Power On .................................................... 17

Initial System Setup ..................................... 18

Flush Before Using Equipment...................... 18

Valve Settings.............................................. 18

Pressure Relief Procedure .................................. 19

Without Color Change .................................. 19

With Color Change....................................... 19

Operation Using Automatic Display Module

(ADM)................................................... 20

Prime and Fill the System............................. 20

Spraying...................................................... 21

Purging ....................................................... 22

Shutdown .................................................... 23

Operation Using a Programmable Logic

Controller (PLC) .................................... 24

Network Communications and Discrete

I/O ................................................. 24

Discrete I/O ................................................. 24

Communication Gateway Module (CGM)

Details ........................................... 27

Network Communication I/O Data Map ........... 28

Operation Flow Charts ................................. 42

Network Communication - Dynamic

Command Structure (DCS) ............. 47

Flow Control System .................................... 57

Run Mode Screens ............................................. 58

Opening Screen........................................... 58

Home Screen .............................................. 58

Spray Screen............................................... 62

Fill Screen ................................................... 63

Usage Screen.............................................. 64

Jobs Screen ................................................ 65

Errors Screen .............................................. 65

Events Screen ............................................. 65

Setup Mode Screens .......................................... 66

Password Screen......................................... 66

System Screen 1 ......................................... 67

System Screen 2 ......................................... 68

System Screen 3 ......................................... 69

System Screen 4 ......................................... 70

System Screen 5 ......................................... 71

Recipe Screen ............................................. 72

Flush Screen ............................................... 73

Pump Screen 1............................................ 74

Pump Screen 2............................................ 75

Pump Screen 3............................................ 76

Pressure Alarm and Deviation Limits............. 76

Calibration Screens...................................... 77

Maintenance Screens................................... 80

Advanced Screen 1...................................... 82

Advanced Screen 2...................................... 83

Advanced Screen 3...................................... 83

Calibration Checks.............................................. 84

Pump Pressure Check ................................. 84

Pump Volume Check.................................... 85

Solvent Meter Calibration ............................. 86

Color Change .....................................................87

Single Color Systems ................................... 87

Multiple Color Systems................................. 87

System Errors ....................................................88

To Clear Error and Restart............................ 88

Gun Trigger Input Function ........................... 88

Error Codes................................................. 89

Maintenance .................................................... 102

Preventive Maintenance Schedule .............. 102

Flushing .................................................... 102

Cleaning the ADM...................................... 102

Technical Data ................................................. 103

Graco Standard Warranty.................................. 104

2332564B

Related Manuals

Related Manuals

Current manuals are available at www.graco.com.

Manual No. Description

332709 ProMix PD2K Proportioner for

Automatic Spray Applications,

Repair-Parts

332458 ProMix PD2K Proportioner for

Automatic Spray Applications,

Installation

332339 Dosing Pumps, Instructions/Parts

332454 Color/Catalyst Dispense Valves,

Instructions/Parts

Manual No. Description

332455 Color Change Kits, Instructions-

Parts

333282 Color Change and Remote Mix

Manifold Kits, Instructions-Parts

332456 Pump Expansion Kits,

Instructions-Parts

332564B 3

Models

Models

See Figs. 1–6 for component identification labels, including approval information and certification.

Part No. Series Maximum Air Working

Pressure

Maximum Fluid Working

Pressure

Location of PD2K and

Electrical Control Box

(ECB) Labels

AC1000 A100 psi (0.7 MPa,

7.0 bar)

300 psi (2.068 MPa, 20.68 bar)

AC2000 A100 psi (0.7 MPa,

7.0 bar)

1500 psi (10.34 MPa,

103.4 bar)

0359 II 2 G

Figure 1 Model AC1000 (Low Pressure) Identification

Label

Figure 2 24M672 Control Box Identification Label

Continued on the next page.

4332564B

Models

Figure 3 Model AC2000 (High Pressure)

Identification Label

Figure 4 Non-Intrinsically Safe Color Change Control (Accessory) Identification Label

Figure 5 Intrinsically Safe Color Change Control

(Accessory) Identification Label

Figure 6 Pump Expansion Kit (Accessory) Identification Label

332564B 5

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 symbol refers to procedure-specific

risks. When these symbols appear in the body of this manual or on warning labels, refer backtothese

Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout

the body of this manual where applicable.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help

prevent fire and explosion:

• 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 arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable

fumes are present.

• Ground all equipment in the work area. See Grounding instructions.

•Useonly

grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless

they are antistatic 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.

• Keepaw

orking fire extinguisher in the work area.

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can

cause electric shock.

•Turn

off and disconnect power at main switch before disconnecting any cables and before

servicing or installing equipment.

• Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes

and regulations.

6332564B

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.

• Be sure your installation complies with national, state, and local codes for the installation of

electrical apparatus in a Class I, Group D, Division 1 (North America) or Class I, Zones 1

and 2 (Europe) Hazardous Location, including all of the local safety fire codes (for example,

NFPA 33, NEC 500 and 516, OSHA 1910.107, etc.).

• 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 the 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.

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, 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.

• Do not point dispensing device at anyone or at any part of the body.

•Donotp

ut your hand over the fluid outlet.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning,

checking, or servicing equipment.

•Tight

en 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.

•Pres

surized equipment can start without warning. Before checking, moving, or servicing

equipment, follow the Pressure Relief Procedure and disconnect all power sources.

TOXIC FLUID OR FUMES

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin,

inhaled, or swallowed.

• Read MSDSs to know the specific hazards of the fluids you are using.

•St

ore hazardous fluid in approved containers, and dispose of it according to applicable

guidelines.

• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning

equipment.

332564B 7

Warnings

WARNING

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury,

including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective

equipment includes but is not limited to:

•Protectivee

yewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent

manufacturer.

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 Data in all equipment manuals.

•Usefluids

and solvents that are compatible with equipment wetted parts. See Technical Data

in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete

information about your material, request MSDS 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.

•Checkeq

uipment 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 youareusingit.

•Useequ

ipment 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.

•Keepc

hildren and animals away from work area.

• Comply with all applicable safety regulations.

8332564B

Important Isocyanate (ISO) Information

Important Isocyanate (ISO) Information

Isocyanates (ISO) are catalysts used in two

component materials.

Isocyanate Conditions

Spraying or dispensing materials containing

isocyanates creates potentially harmful mists,

vapors, and atomized particulates.

Read and understand material manufacturer’s

warnings and material MSDS to know specific

hazards and precautions related to isocyanates.

Prevent inhalation of isocyanate mists, vapors,

and atomized particulates by providing sufficient

ventilation in the work area. If sufficient ventilation

is not available, a supplied-air respirator is required

for everyone in the work area.

To prevent contact with isocyanates, appropriate

personal protective equipment, including

chemically impermeable gloves, boots, aprons,

and goggles, is also required for everyone in the

work area.

Keep Components A and B Separate

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.

Moisture Sensitivity of Isocyanates

Exposure to moisture (such as humidity) will cause

ISO to partially cure; forming small, hard, abrasive

crystals, which become suspended in the fluid.

Eventually a film will form on the surface and the ISO

will begin to gel, increasing in viscosity.

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.

NOTE: The amount of film formation and rate of

crystallization varies depending on the blend of ISO,

the humidity, and the temperature.

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.

•Alw

ays clean the fluid inlet strainers after

flushing.

•Che

ck with your material manufacturer for

chemical compatibility.

•Wh

en 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

oftenhaveaminesontheA(resin)side.

332564B 9

General Information

General Information

• Reference numbers and letters in parentheses

in the text refer to numbers and letters in the

illustrations.

• Be sure all accessories are adequately sized and

pressure-rated to meet system requirements.

• To protect the screens from paints and solvents,

clear-plastic protective shields (10 per pack) are

available. Order Part No. 197902 for the Advanced

Display Module. Clean the screens with a dry cloth

if necessary.

10 332564B

Advanced DisplayModule(ADM)

Advanced Display Module (ADM)

ADM Display

The ADM display shows graphical and text

information related to setup and spray operations.

For detail on the display and individual

screens, see Run Mode Screens, page 58,or

Setup Mode Screens, page 66.

Keys are used to input numerical data, enter setup

screens, navigate within a screen, scroll through

screens, and select setup values.

NOTICE

To prevent damage to the softkey buttons, do not

press the buttons with sharp objects such as pens,

plastic cards, or fingernails.

1 2 3

4 5 6

7 8 9

0 .

Figure 7 Advanced Display Module

USB Download Procedure

Use the USB port on the ADM to download or upload

data.

1. Enable USB downloads. See

Advanced Screen 3, page 83.

2. Remove the cover from the USB port on the

bottom of the ADM. Insert the USB drive.

3. During the download, USB BUSY appears on the

screen.

4. When the download is complete, USB IDLE

appears on the screen. The USB drive may then

be removed.

NOTE: If the download operation takes longer

than 60 seconds, the message disappears. To

determine if the USB is busy or idle, check the

Error Status bar on the screen. If idle, remove

the USB.

5. Insert the USB flash drive into the USB port of

the computer.

6. The USB flash drive window automatically opens.

If it does not, open the USB flash drive from

within Windows® Explorer.

7. Open Graco folder.

8. Open system folder. If downloading data from

more than one system, there will be more than

one folder. Each folder is labeled with the

corresponding serial number of the ADM. (The

serial number is on the back of the ADM.)

9. Open DOWNLOAD folder.

10. Open LOG FILES folder labeled with the highest

number. The highest number indicates the most

recent data download.

11. Open logfile. LogfilesopeninMicrosoft®

Excel® by default if the program is installed.

They also can be opened in any text editor of

Microsoft® Word.

NOTE: All USB logs are saved in Unicode

(UTF-16) format. If opening the log file in

Microsoft Word, select Unicode encoding.

12. Always reinstall the USB cover after removing

the USB, to keep the drive free of dirt and dust.

332564B 11

Advanced DisplayModule(ADM)

USB Upload Procedure

Use this procedure to install a system configuration

file and/or a custom language file.

1. If necessary, follow the USB Download

Procedure, to automatically generate the proper

folder structure on the USB flash drive.

2. Insert the USB flash drive into the USB port of

the computer.

3. The USB flash drive window automatically opens.

If it does not, open the USB flash drive from

within Windows Explorer.

4. Open the Graco folder.

5. Open the system folder. If working with more

than one system, there will be more than one

folder within the Graco folder. Each folder is

labeled with the corresponding serial number of

the ADM. (The serial number is on the back of

the module.)

6. If installing the system configuration settings file,

place SETTINGS.TXT file into UPLOAD folder.

7. If installing the custom language file, place

DISPTEXT.TXT file into UPLOAD folder.

8. Remove the USB flash drive from the computer.

9. Install the USB flash drive into the USB port of

the ProMix PD2K system USB port.

10. During the upload, USB BUSY displays on the

screen.

11. Remove the USB flash drive from the USB port.

NOTE: If the custom language file was installed,

users can now select the new language from the

Language drop-down menu in the Advanced Setup

Screen 1.

12332564B

Advanced DisplayModule(ADM)

ADM Keys and Indicators

NOTICE

To prevent damage to the softkey buttons, do not

press the buttons with sharp objects such as pens,

plastic cards, or fingernails.

Table 1 : ADM Keys and Indicators

Key Function

Startup/Shutdown

Key and Indicator

Press to startup or shutdown the pump/motor.

• Solid green indicates that power is applied to the motor.

• Solid yellow indicates that power to the motor is off.

• Blinking green or yellow indicates that the system is in Setup mode.

Stop

Press to immediately stop the system and remove motor power.

Soft Keys

Press to select the specific screen or operation shown on the display directly next to

each key. The top left soft key is the Edit key, which allows access to any settable

fields on a screen.

Navigation Keys

•

Left/Right Arrows:

Use to move from screen to screen.

•

Up/Down Arrows:

Use to move among fields on a screen, items on a dropdown

menu, or multiple screens within a function.

Numeric Keypad Use to input values. See ADM Display, page 11.

Cancel

Use to cancel a data entry field.

Setup

Press to enter or exit Setup mode.

Enter

Press to choose a field to update, to make a selection, to save a selection or value, to

enter a screen, or to acknowledge an event.

332564B 13

Advanced DisplayModule(ADM)

Soft Key Icons

The following icons appear in the ADM display,

directly to the left or right of the soft key which

activates that operation.

NOTICE

To prevent damage to the softkey buttons, do not

press the buttons with sharp objects such as pens,

plastic cards, or fingernails.

Table 2 : Soft Key Functions

Key Function

Enter Screen

Press to enter screen for editing. Highlights editable

data on a screen. Use Up/Down arrows to move

between data fields on the screen.

Exit Screen

Press to exit screen after editing.

Accept

Press to accept calibration value.

Cancel

Press to cancel or reject calibration value.

Prime Pump

Press to start a pump priming procedure.

Line/Fill/Run

Press to start a line fill procedure.

Mix

Press to start a spray procedure.

Purge

Press to start a purge procedure.

14332564B

Advanced DisplayModule(ADM)

Key Function

Standby

Stop

Press to stop all pumps and put system in Standby.

Pressure Check

Presstostartapumppressurecheck.

Volume Check

Press to start a pump volume check.

Job Complete

Press to log the material usage and increment the

job number.

Counter Reset

Press to reset the current usage counter.

Move Cursor to Left

Appears on the User ID Keyboard screen. Use to

move cursor to the left.

Move Cursor to Right

Appears on the User ID Keyboard screen. Use to

move cursor to the right.

Erase All

Appears on the User ID Keyboard screen. Use to

erase all characters.

Backspace

Appears on the User ID Keyboard screen. Use to

erase one character at a time.

Upper Case/Lower Case

Appears on the User ID Keyboard screen. Use to

change case (upper/lower).

332564B 15

Advanced DisplayModule(ADM)

Navigating the Screens

There are two sets of screens:

• The Run screens control mixing operations and

display system status and data.

•TheSetupscr

eens control system parameters and

advanced features.

Press on any Run screen to enter the Setup

screens. If the system has a password lock, the

Password screen displays. If the system is not locked

(password is set to 0000), System Screen 1 displays.

Press on any Setup screen to return to the

Home screen.

Press the Enter soft key to activate the editing

function on any screen.

Press the Exit soft key to exit any screen.

Use the other softkeys to select the function adjacent

to them.

Screen Icons

As you move through the screens, you will notice

that icons are used frequently to simplify global

communication. The following descriptions explain

what each icon represents.

Screen Icons

User ID

Job Number

Potlife Target Ratio

Recipe Number Flow Rate

Pressure Volume

Material A

Material B

Material A+B

Solvent

Calendar Time

Alarm/Advisory

Deviation

16 332564B

Pre-Operation Tasks

Pre-OperationTasks

Pre-operation Checklist

Go through the Pre-Operation Checklist daily, before

each use.

✔Checklist

System grounded

Verify all grounding connections

were made. See Grounding in the

Installation manual.

All connections tight and correct

Verify all electrical, fluid, air, and

system connections are tight and

installedaccordingtotheInstallation

manual.

Fluid supply containers filled

Check component A and B and

solvent supply containers.

Dose valves set

Check that dose valves are set

1–1/4 turns open. Start with

the settings recommended in

Valve Settings, page 18, then adjust

as needed.

Fluid supply valves open and

pressure set

The recommended component A and

B fluid supply pressures are 1/2 to 2/3

of the target spray pressure.

NOTE: Low pressure systems may

be set within a range of ± 100 psi (0.7

MPa, 7 bar); high pressure systems

may be set within a range of ± 300 psi

(2.1 MPa, 21 bar). If the inlet pressure

is higher than the outlet pressure,

ratio accuracy may be affected.

Solenoid pressure set

85-100 psi inlet air supply (0.6-0.7

MPa, 6-7 bar).

Power On

1. Turn the AC Power Switch (P) ON (I = ON,

0=OFF).

2. The Graco logo will display while the system

initializes, followed by the Home screen.

3. Press the Start key . The system status will

change from “System Off” to “Startup.” Once

the pumps are powered and are in the Home

position, the system status will change from

“Startup” to “Standby.”

Figure 8 Power Switch

332564B 17

Pre-Operation Tasks

Initial System Setup

1. Change optional setup selections to

desired parameters, as described in

Setup Mode Screens, page 66.

2. Set recipe and flush information as

described in Recipe Screen, page 72 and

Flush Screen, page 73.

Flush Before Using Equipment

The pump fluid section was tested with lightweight

oil, which is left in the fluid passages to protect parts.

To avoid contaminating your fluid with oil, flush the

equipment with a compatible solvent before using

the equipment.

Valve Settings

Dose valves and purge valves are factory set with the

hex nut (E) 1-1/4 turns out from fully closed.

Figure 9 Valve Adjustment

18 332564B

Pressure Relief Procedure

Pressure Relief Procedure

Follow the Pressure Relief Procedure

whenever you see this symbol.

This equipment stays pressurized until pressure

is manually relieved. To help prevent serious

injury from pressurized fluid, such as skin injection,

splashing fluid and moving parts, follow the

Pressure Relief Procedure whenyoustopspraying

and before cleaning, checking, or servicing the

equipment.

Without Color Change

NOTE: The following procedure relieves all fluid and

air pressure in the system. Use your control interface

to issue the necessary commands to your system.

1. Turn off the supply pumps. Open the drain valve

on the supply line fluid filter to relieve pressure

in the supply line.

2. Command the system to Standby. Trigger the

spray device to relieve pressure.

3. Flush the remote mix manifold and spray device.

See Flush Mixed Material, page 22.

4. Shut off the solvent supply pump. To relieve

pressure, command the system to Purge and

trigger the spray device. When the pressure is

relieved, command the system to Standby to

avoid getting a Purge Incomplete alarm.

5. If pressure remains in the solvent line between

the solvent supply pump and the solvent valve:

• VERY SLOWLY loosen a fitting to relieve

pressure gradually.

• Loosen the fitting completely.

With Color Change

NOTE: The following procedure relieves all fluid and

air pressure in the system.

1. Turn off the supply pumps. Open the drain valve

on the supply line fluid filter to relieve pressure in

the supply lines. Do this for each color.

If using an electrostatic gun, shut off the

electrostatics before flushing the gun.

2. Trigger the gun to relieve pressure. From

Maintenance Screen 4 on the ADM, check the

box in the field labeled Gun for each color in the

system.

3. Command the system to Purge. Hold the gun

trigger open after the solvent valve shuts off to

relieve all pressure.

4. Set the system to Recipe 0 to flush the pumps

and to purge to the spray device. When flushing

is complete the system will go to Standby.

5. Shut off the solvent supply pump. Set the system

to Recipe 0 to flush solvent from the pumps and

to purge to the spray device. Command the

system to Standby after just a couple of seconds,

to avoid getting a Purge Incomplete alarm.

6. If pressure remains in the solvent line between

the solvent supply pump and the solvent valve:

•VERY

SLOWLY loosen a fitting to relieve

pressure gradually.

• Loosen the fitting completely.

7. Verify on the ADM Home Screen that neither

pump is showing any pressure.

NOTE: If pressure remains in the solvent line

between the solvent supply pump and the solvent

valve,VERYSLOWLYloosenafittingtorelieve

pressure gradually.

332564B 19

Operation Using Automatic Display Module (ADM)

Operation Using Automatic Display Module (ADM)

Prime and Fill the System

NOTE: See Run Mode Screens, page 58, for further

screen information, if needed.

NOTE: You must prime the input lines to the pumps

or the inputs to the color change valves before

priming the pump and filling the entire system.

1. If using an electrostatic gun, shut off the

electrostatics before filling the lines.

2. Adjust the main air pressure. To ensure proper

operation, set the main air pressure as close to

100 psi (0.7 MPa, 7.0 bar) as possible. Do not

uselessthan85psi(0.6MPa,6.0bar).

3. If this is the first time starting up the system, or if

lines may contain air, purge as instructed under

.Flush the System, page 23 The equipment

was tested with lightweight oil, which should be

flushed out to avoid contaminating your material.

4. If the system is powered down, press on the

ADM. Make sure that the system is in Standby

mode.

5. Verify that the recipes and the flush sequences

are programmed correctly by checking

the Recipe Screen, page 72 and the

Flush Screen, page 73.

6. Enable the manual override on System Screen 5.

7. Go to the Fill Screen, page 63.

8. Select the desired color to load. Press the Prime

Pump key . The color will load the pump

through the color stack and out the outlet stack

dump valve.

NOTE: In a single color system, skip step 7 and

prime the pump out to the gun.

9. Press the Fill Line key to run color out to

the remote mix manifold. The pump will run until

you press the Stop key to stop the pump.

10. Trigger the gun into a grounded reservoir or

purge receptacle until the line is full, then press

the Stop key .

11. Repeat for all material lines.

20 332564B

Operation Using Automatic Display Module (ADM)

Spraying

To spray in a multiple color system, also see

Multiple Color Systems, page 87.

NOTE: See Run Mode Screens, page 58,forfurther

screen information, if needed.

1. Command the system to Mix. The system will

load the correct mixed material volume.

NOTE: The system will automatically run a Mix

Fill if the recipe is not currently loaded into the

system. The Mix Fill volume calculation includes

the remote mix manifold volume and the mixed

material hose volume. The mixed material hose

volume is determined by the gun hose length and

diameter entered in System Screen 3, page 69,

and the remote to mix hose length and diameter

also entered in System Screen 3, page 69.

2. Adjust the flow rate by changing the target

pressure (in Pressure Mode)orthetargetflow

rate (in Flow Mode) on the Spray Screen or

through the PLC. The fluid flow rate shown on the

Spray screen is the combined total of component

A and B out of the spray device.

NOTE: If spray pressure is adjusted at the ADM

while spraying, it is not saved in the recipe until

the system is put in Standby. This changes the

pressure in the desired recipe.

3. Turn on atomizing air to the gun. Check the spray

pattern as instructed in your spray gun manual.

NOTICE

Do not allow a fluid supply tank to run empty.

This can damage the pumps and lead to the

proportioning of fluid and air that meets the ratio

and tolerance settings of the equipment. This can

further result in spraying uncatalyzed or poorly

catalyzed material.

332564B 21

Operation Using Automatic Display Module (ADM)

Purging

To purge one color and fill with a new color, see

Color Change, page 87.

Flush Mixed Material

There are times when you only want to purge the

remote mix manifold and the spray device, such as:

• end of potlife

• breaks in spraying that exceed the potlife

• overnight shutdown or end of shift

• before servicing the remote mix manifold, hose or

gun.

1. Command the system to Standby.

2. Ifyouareusingahighpressurespraydeviceor

an electrostatic gun, shut off the atomizing air.

To reduce risk of fire and explosion, if using

an electrostatic gun, shut off the electrostatics

before flushing the gun.

3. Trigger the spray device to relieve pressure.

4. Set the solvent supply pressure regulator at the

lowest pressure possible. Generally a setting

of 25–50 psi (0.18–0.35 MPa, 1.8–3.5 bar) is

sufficient.

5. CommandthesystemtoPurgeAorPurgeB.

Trigger the spray device into a grounded metal

pail until the purge sequence is complete. When

done purging, the system automatically switches

to Standby mode, signalling the spray device to

stop spraying.

6. If the system is not completely clean, repeat Step

5.

NOTE: For optimal efficiency, adjust purge

sequence times so only one cycle is required.

7. Trigger spray device to relieve pressure.

8. Adjust the solvent supply regulator back to its

normal operating pressure.

NOTE: The remote mix manifold and gun remain full

of solvent after purging.

22332564B

Operation Using Automatic Display Module (ADM)

Flush the System

To avoid fire and explosion, always ground

equipment and waste container. To avoid injury

from splashing, always flush at lowest possible

pressure.

Follow this procedure before:

• the first time material is loaded into the equipment

•servicing

• shutting down equipment for an extended period

of time

• putting equipment into storage

Single Color System

1. Relieve the pressure. See

Pressure Relief Procedure, page 19.

2. Disconnect the color and catalyst supply lines

from the pump inlet manifolds, and connect

regulated solvent supply lines.

3. Set the solvent supply pressure regulator at the

lowest pressure possible. Generally a setting

of 25–50 psi (0.18–0.35 MPa, 1.8–3.5 bar) is

sufficient.

4. Enable manual override on

System Screen 5, page 71.

5. On the ADM, go to the Fill screen. Set the

Material to Color (A). Press . The system

will pump solvent through pump A all the way to

the gun.

6. Hold a metal part of the spray device firmly to a

grounded metal pail. Trigger the spray device

until clean solvent dispenses.

7. On the ADM, go to the Fill screen. Set the

Material to Catalyst (B). Press .The

system will pump solvent through pump B all the

way to the gun.

8. Relieve the pressure. See

Pressure Relief Procedure, page 19

Color Change System

1. Relieve the pressure. See

Pressure Relief Procedure, page 19.

2. Attach regulated solvent supply lines as follows:

•Multiple color/single catalyst system: On the

color side, do not disconnect the color supply

line from the inlet manifold of Pump A. Instead,

connect a regulated solvent supply line to the

designated solvent valve on the color valve

manifold. On the catalyst side, disconnect

the catalyst supply line from the inlet manifold

of Pump B, and connect a regulated solvent

supply line.

•Multiple color/multiple catalyst system:

Connect regulated solvent supply lines to

the designated solvent valves on the color

and catalyst valve manifolds. Do not connect

solvent supply lines directly to the inlet

manifolds of the pumps.

3. Set the solvent supply pressure regulator at the

lowest pressure possible. Generally a setting

of 25–50 psi (0.18–0.35 MPa, 1.8–3.5 bar) is

sufficient.

4. On the ADM, go to the Fill screen. Set the

Material to Solvent. Press . The system

will pump solvent from the color valve inlet all the

way to the gun.

5. Hold a metal part of the gun firmly to a grounded

metal pail. Trigger the gun until clean solvent

dispenses.

6. Repeat for each color line.

7. Relieve the pressure. See

Pressure Relief Procedure, page 19

Shutdown

1. Flush out the mixed material to avoid potlife errors

and fluid setup in the lines. See Purging, page 22.

2. Follow the Pressure Relief Procedure, page 19.

3. Close the main air shutoff valve on the air supply

line and on the control box.

4. Press on the Display Module to turn off

power to the pumps.

5. Shut off system power (0 position).

332564B 23

Operation Using a Programmable Logic Controller (PLC)

Operation Using a Programmable Logic Controller

(PLC)

Network Communications and

Discrete I/O

The ProMix PD2K Automatic system does not use

a Booth Control module. Instead, it uses Network

Communications and has optional Discrete I/O

features to drive the system remotely.

Some automation control elements of the

ProMix PD2K can be driven by a discrete

input

or

network communications. These

options need to be configured at the ADM (see

System Screen 5, page 71). The following features

can be set to ‘Discrete’ or ‘Network’:

•Flow Control – Means of adjusting the control set

point (see Flow Control Set Point below).

•Gun Trigger – Means of signaling the ProMix PD2K

when the spray device is triggered.

NOTE: The Manual Override check box enables a

user to operate the system before the automation

(PLC) is available. Manual Override can be used to

run all functions of the system if a proper gun trigger

signal is provided. It is not intended to be the main

mode of control. Graco recommends that Manual

Override be disabled during normal operation to

avoid driving the system in a way that conflicts with

the automation sequence.

Discrete I/O

The ProMix PD2K does not supply power for

Discrete I/O. A clear understanding of these inputs

is necessary to properly integrate the ProMix PD2K

with the PLC or networking device. Input and output

connections are made at the Discrete I/O terminal

strips on the Enhanced Fluid Control Module (EFCM)

inside the control box.

Table 3 and Figure 2 show where discrete I/O

connections are made on the ProMix PD2K.

Table 3 PD2K Discrete I/O Connections

I/O

Description

EFCM

Connector

Pins Type

Gun Trigger

Input

61,2

Normally Open

Contact

ControlSet

Point

71,2 4-20 mA Input

Safety

Interlock

Input

711,12 Normally Open

Contact

24332564B

Operation Using a Programmable Logic Controller (PLC)

Digital Inputs

•Safety Interlock: This normally open contact works

like a soft emergency stop button. If the ProMix

PD2K reads the input as CLOSED it interrupts

system operation and removes power from the

pumps regardless of the current operating mode.

If the input is read as OPEN, the system operates

normally

NOTE: This digital input is always enabled.

Do not toggle this input to put the system into

Standby mode.

•Gun Trigger: This normally open (maintained)

contact provides a signal to the system to indicate

whether or not a spray device is triggered. This

input provides timing for alarm functions and also

drives the flow control algorithm. If the input is

OPEN the system operates as though the spray

device is off. The input must be maintained

CLOSED to signal that the spray device is

triggered.

NOTE: The Gun Trigger discrete input must be

enabled via Configure Screen 5 on the ADM. If it

is set to ‘Network’ the discrete input is ignored and

the spray device trigger signal is handled via the

network communications.

If enabled, it is imperative that this signal be sent

any time the spray device is triggered. Without the

signal, the flow control features will not work.

Analog Inputs

Flow Control Set Point: When enabled, this 4-20mA

signal input is used to set and adjust the operating

flow control set point. The ProMix PD2K scales the

set point linearly from 0 to the Max Set Point setting

(see System Screen 5, page 71).

Examples

,

•In Flow Control Mode: If the Max Set Point is 500

cc/min, a 4mA signal is 0 cc/min and a 20mA signal

is 500 cc/min.

•In Pressure Control Mode: If the Max Set Point is

500 psi, a 4mA signal is 0 psi and a 20mA signal

is 500 psi.

NOTE: The Flow Control discrete input must be

enabled via Configure Screen 5 on the ADM. If

set to ‘Network’ the discrete input is ignored and

set point adjustment is handled via the network

communications.

4–20 mA Flow Control Set Point Input

PD2K Discrete Input PLC (4–20 MA Signal)

Figure10

O = Output

R=Return

332564B 25

Operation Using a Programmable Logic Controller (PLC)

Discrete I/O Connections on EFCM

Figure 11

KEY

A1 Gun Trigger Input

B1 Analog Set Point Input

C1 Safety Interlock Input

26 332564B

Operation Using a Programmable Logic Controller (PLC)

Communication Gateway Module (CGM) Details

CGM Overview

The CGM provides a control link between the PD2K

system and a selected fieldbus. This linkage provides

the means for remote monitoring and control by

external automation systems.

NOTE: The following system network configuration

files are available at www.graco.com.

• EDS file: DeviceNet or Ethernet/IP fieldbus

networks

• GSD file: PROFIBUS fieldbus networks

• GSDML file: PROFINET fieldbus networks

CGM Kits

The PD2K system comes with a Modbus TCP CGM.

Kits for other communication protocols are available.

Each kit includes all parts needed to install the

CGM, along with Manual 334494, which contains

installation instructions applicable to any kit. See

Manual 312864 or Manual 334183 for information

specific to each protocol, plus repair parts for each

assembly.

CGM Part No. Fieldbus Manual

CGMDNO DeviceNet 312864

CGMEPO EtherNet/IP 312864

CGMPBO PROFIBUS 312864

CGMPNO PROFINET 312864

24W462 Modbus TCP 334183

332564B 27

Operation Using a Programmable Logic Controller (PLC)

Network Communication I/O Data Map

ProMix PD2K Network Outputs

The ProMix PD2K Network Outputs are Read-Only

and should be treated as inputs to a PLC

or other networking device. These registers

provide various system and component status,

measurement, and set point values. See

Network Output Data Map (Read Only), page 33.

OUTPUT REGISTER 00: Current System Mode

The Current System Mode register contains a number that indicates the current operation mode of the PD2K

system.

Number Operation Mode Description

1Pump Off The pumps are currently powered down and the system is not in

operation.

2Recipe Change The system is in the process of a color change sequence.

3Recipe Change: Purge

A

The system is purging material A as part of a recipe change.

4Recipe Change: Purge

B

The system is purging material B as part of a recipe change.

5Recipe Change: Fill The system is filling the hose from the remote valves to the mix

manifold with material as part of a recipe change.

6MixFil

lThe system is mixing material at ratio through the mix manifold

and out the gun.

7Mix The system is currently mixing/spraying material.

8MixI

dle The system has paused mix operation due to the absence of a gun

trigger signal.

9 Purge A The system is purging material A while in Standby.

10 Purge B The system is purging material B while in Standby.

11 Standby: Mix Ready The system has a valid recipe loaded out to the gun.

12 Standby: Fill Ready The system has a valid recipe loaded in the pumps, but not in the

gun.

13Standby: Mix Not Ready The system requires that a recipe change operation be completed.

14 Standby: Alarm The system has an active alarm.

28 332564B

Operation Using a Programmable Logic Controller (PLC)

OUTPUT REGISTERS 01, 02, 03, and 04: Pump

Status

ThePumpStatu

s registers contain a number that

indicates the state of Pumps 1 — 4. This status can

be used for general monitoring of the pump state,

or as an indicator for driving independent pump

operations. See INPUT REGISTER 02: Flush/Prime

Pump Command, page 36.

Table4PumpS

tates for Output Registers 01–04

Nu-

m-

ber

Pump

State

Description

0Off The pump is powered down or

not enabled.

1Standby The pump is powered but not

currently active.

2 Busy The pump is currently in

arecipec

hange or mixing

operation.

3 Flushing The pump is currently flushing

with solvent

4 Priming The pump is currently priming

with material.

OUTPUT REGISTER 05: Actual Mix Flow

The Actual Mix Flow register reports back the

instantaneous mixing flow rate in cc/min.

NOTE: This register is valid only during a mix

operation.

OUTPUT REGISTER 06: Actual Mix Ratio

The Actual Mix Ratio register contains the

instantaneous calculated mix ratio.

• The value reported is the ratio antecedent

multiplied by 100. The ratio consequent is always

1.

Example

: Value = 250 >> A mix ratio of 2.5:1

(Material A to Material B)

•Ift

he current recipe ratio is 0:1 (1K recipe) this

value will be 0.

This register is valid only during a mix operation.

OUTPUT REGISTER 07: Actual Mix Potlife

Remaining

The Actual Potlife Remaining register contains

the current amount of time remaining in the active

recipe’s potlife in seconds.

NOTE: If potlife is disabled for the active recipe or at

initial startup this value will be 0xFFFFFFFF.

OUTPUT REGISTER 08: Active Recipe Number

TheActiveR

ecipe Number register contains the

number of theactiverecipe(1–60).

• This value is 0 if the system was flushed.

• This value is 61 if the system does not know the

current loaded recipe, if the recipe is invalid, or at

initial startup.

OUTPUT REGISTER 09: Active Recipe Material A

The Active Recipe Material A register contains the

number of the Color (1 – 30) that is associated with

the current recipe.

• This value is 0 if the system was flushed.

• This value is 61 if the current recipe is invalid or at

initial startup.

OUTPUT REGISTER 10: Active Recipe Material B

The Active Recipe Material B data register contains

the number of the Catalyst (31 – 34) that is associated

with the current recipe.

• This value is 0 if the system was flushed.

• This value is 61 if the current recipe is invalid or at

initial startup.

• This value is 0 if the current recipe ratio is 0:1 (1K

recipe).

OUTPUT REGISTER 11: Active Recipe Material A

Flush Sequence

The Active Recipe Material A Flush Sequence

register contains the number of the Flush Sequence

(1 – 5) that is associated with the Color pump of the

current recipe.

If the current recipe is invalid this value reflects the

Flush Sequence associated with Material A pump

of recipe 0.

332564B 29

Operation Using a Programmable Logic Controller (PLC)

OUTPUT REGISTER 12: Active Recipe Material B

Flush Sequence

The Active Recipe Material B Flush Sequence

register contains the number of the Flush Sequence

(1 – 5) that is associated with the Catalyst pump of

the current recipe.

• If the current recipe is invalid this value reflects the

Flush Sequence associated with Material B pump

of recipe 0.

• This value is 0 if the current recipe ratio is 0:1 (1K

recipe)

OUTPUT REGISTER 13: Active Recipe Ratio Set

Point

The Active Recipe Ratio Set Point data register

contains the ratio set point associated with the

current recipe.

• The value reported is the ratio antecedent

multiplied by 100. The ratio consequent is always

1.

Example

: Value = 250 >> A mix ratio of 2.5:1

(Material A to Material B)

• This value is 0 if the current recipe ratio is 0:1 (1K

recipe)

OUTPUT REGISTER 14: Active Recipe Potlife

Timeout Set Point

The Active Recipe Potlife Timeout Set Point register

contains the set point for the potlife time associated

with the current recipe in minutes.

• This value is 0 if the potlife time is disabled for the

current recipe.

OUTPUT REGISTER 15: Actual Pump 1 Flow Rate

OUTPUT REGISTER 16: Actual Pump 2 Flow Rate

OUTPUT REGISTER 17: Actual Pump 3 Flow Rate

OUTPUT REGISTER 18: Actual Pump 4 Flow Rate

These registers contain the instantaneous flow rate

of Pumps 1–4 in cc/min.

This is NOT the mix flow rate. For mix flow rate see

Actual Mix Flow

.

OUTPUT REGISTER 19: Actual Pump 1 Fluid

Pressure

OUTPUT REGISTER 20: Actual Pump 2 Fluid

Pressure

OUTPUT REGISTER 21: Actual Pump 3 Fluid

Pressure

OUTPUT REGISTER 22: Actual Pump 4 Fluid

Pressure

These registers contain the instantaneous fluid

pressure on the outlet of pumps 1–4 in PSI.

OUTPUT REGISTER 23: Gun 1 Trigger Input Status

The Gun 1 Trigger Input Status register contains the

status of the Gun Trigger Discrete Input.

•Thevaluei

s0iftheinputisOPEN(gunnot

triggered).

•Thevalue

is 1 if the input is CLOSED (gun

triggered).

This data register is valid only for systems configured

to use the discrete input for the Gun Trigger.

See

Gun Trigger Signal, page 71

.

OUTPUT REGISTER 24: Gun 2 Trigger Input Status

OUTPUT REGISTER 25: Gun 3 Trigger Input Status

OUTPUT REGISTER 26: Gun 4 Trigger Input Status

These registers are not used.

OUTPUT REGISTER 27: Safety Interlock Input

Status

The Safety Interlock Input Status register contains

the status of the Safety Interlock Discrete Input.

• The value will be 0 if the input is OPEN (Normal).

• The value will be 1 if the input is CLOSED (Safety

Stop).

See Safety Interlock in Digital Inputs, page 25

.

OUTPUT REGISTERS 28 – 36: DCS Command

Structure

See Dynamic Command Description, page 47.

30 332564B

Operation Using a Programmable Logic Controller (PLC)

OUTPUT REGISTER 37: Time

TheTimeregis

ter contains a count of total seconds

since the Unix Epoch (January 1, 1970).

• The actual value reported is not important. This

register should be used for diagnosing status of

communication between the ProMix PD2K and the

networking device.

This register is NOT currently available with the

Modbus Communications Gateway Module.

OUTPUT REGISTER 38 – 40: Software Version

The Software Version registers contain the “major,”

“minor,” and “build” revisions of the ADM software.

These registers are NOT currently available with the

Modbus Communications Gateway Module.

332564B 31

Operation Using a Programmable Logic Controller (PLC)

Notes

32 332564B

Operation Using a Programmable Logic Controller (PLC)

Network Output Data Map (Read Only)

Network

Output ID

Modbus

Register

Parameter Name Data Type Units Range

1=PumpOff

2 = Recipe Change

3 = Recipe Change:

Purge A

4=RecipeCh

ange:

Purge B

5 = Recipe Change: Fill

6=MixFil

l

7=Mix

8=MixIdle

9=PurgeA

10 = Purge B

11 = Standby: Mix Ready

12 = Standby: Fill Ready

13 = Standby: Mix Not

Ready

00 40100 Current System

Mode

uint32 NONE

14 = Standby: Alarm

0=Off

1 = Standby

2=Busy

3=Flushing

01 40102 Pump 1 Status uint32 NONE

4 = Priming

0=Off

1 = Standby

2=Busy

3 = Flushing

02 40104 Pump 2 Status uint32 NONE

4 = Priming

0=Off

1 = Standby

2=Busy

3 = Flushing

03 40106 Pump 3 Status uint32 NONE

4 = Priming

332564B 33

Operation Using a Programmable Logic Controller (PLC)

0=Off

1 = Standby

2=Busy

3 = Flushing

04 40108 Pump 4 Status uint32 NONE

4 = Priming

05 40110 Actual Mix Flow uint32 cc/min 1 - 1600

06 40112 Actual Mix Ratio uint32 NONE 0 - 5000

07 40114 Actual Mix Potlife

Remaining

uint32 sec 0 – 59940

08 40116 Active Recipe

Number

uint32 NONE 0-61

09 40118 Active Recipe

Material A

uint32 NONE 1-30,61

10 40120 Active Recipe

Material B

uint32 NONE 31 - 34, 61

11 40122 Active Recipe

Material A Flush

Sequence

uint32 NONE 1-5

12 40124 Active Recipe

Material B Flush

Sequence

uint32 NONE 1-5

13 40126 Active Recipe

Ratio Set Point

uint32 NONE 0 - 5000

14 40128Active Recipe

Potlife Time Set

Point

uint32 min 0 - 999

15 40130 Actual Pump 1

Flow Rate

uint32 cc/min 0 - 800

16 40132 Actual Pump 2

Flow Rate

uint32 cc/min 0 - 800

17 40134 Actual Pump 3

Flow Rate

uint32 cc/min 0-800

18 40136 Actual Pump 4

Flow Rate

uint32 cc/min 0 - 800

19 40138 Actual Pump 1

Fluid Pressure

uint32 PSI 0 - 1500

2040140 Actual Pump 2

Fluid Pressure

uint32 PSI 0-1500

21 40142 Actual Pump 3

Fluid Pressure

uint32 PSI 0 - 1500

22 40144 Actual Pump 4

Fluid Pressure

uint32 PSI 0 - 1500

34 332564B

Operation Using a Programmable Logic Controller (PLC)

0 = Gun not triggered

23 40146 Gun 1 Trigger

Input Status

uint32 NONE

1 = Gun triggered

0 = Gun not triggered

24 40148 Gun 2 Trigger

Input Status

uint32 NONE

1 = Gun triggered

0=Gunnottr

iggered

25 40150 Gun 3 Trigger

Input Status

uint32 NONE

1 = Gun triggered

0 = Gun not triggered

26 40152 Gun 4 Trigger

Input Status

uint32 NONE

1=Guntri

ggered

0=Open

27 40154 Safety Interlock

Input Status

uint32 NONE

1 = Closed

0:=NOP

1=BUSY

2=ACK

3=NAK

28 40200 Command

Acknowledge

uint32 NONE

4=ER

R

29 40202 Command Return

0

uint32 N/A N/A

30 40204 Command Return

1

uint32 N/A N/A

31 40206 Command Return

2

uint32 N/A N/A

32 40208 Command Return

3

uint32 N/A N/A

33 40210 Command Return

4

uint32 N/A N/A

34 40212 Command Return

5

uint32 N/A N/A

35 40214 Command Return

6

uint32 N/A N/A

36 40216 Command Return

7

uint32 N/A N/A

37 N/A Time uin32 sec 0 – 4,294,967,295

38 N/A Software Version

–Major

uint32 NONE 0–99

39 N/A Software Version

–Minor

uint32 NONE 0–99

40 N/A Software Version

– Build

uint32 NONE 0–999

These registers are not used. DCS Register

332564B 35

Operation Using a Programmable Logic Controller (PLC)

ProMix PD2K Network Inputs

The ProMix PD2K Network Inputs are Write-Read capable, but should be treated as outputs from a PLC or

other networking device. These registers allow the user to control system operation and configure system

settings remotely. Invalid values (i.e. out of bounds or not consistent with system configuration) will be ignored

by the ProMix PD2K. All values must be written as integers. Floating point numbers are not supported.

Do not rely on these registers for Read status, other than to confirm data that has been written and accepted.

NOTE: The PD2K system does not refresh the values for these registers. At power up all input registers

initialize to invalid values.

INPUT REGISTER 00: System Mode Command

The System Mode Command register accepts a number that represents a command to the PD2K system

to initiate a particular operation. Some operation modes may be initiated only under certain conditions (see

Figures 5 – 9 for details).

Number Operation Mode Description

1No OP The system takes no action.

2 Power Pumps The system powers on or powers off the pumps.

3Remote Stop The system stops all current operations and turns off power to the

pumps.

4Recipe Change The system initiates a recipe change. (See also Register 7.)

5Mix Fill The system fills the mix manifold and gun with material at ratio for

a valid recipe.

6Mix Thesy

stem initiates a mix/spray cycle.

7Purge A The system purges only Material A out through the gun.

8 Purge B The system purges only Material B out through the gun.

9Standby The system puts all active pumps into Standby mode.

36 332564B

Operation Using a Programmable Logic Controller (PLC)

INPUT REGISTER 01: Pump Flush Sequence/Prime

Material Selection

ThePumpFlushSequence/Prime Material Selection

register is used in conjunction with the Flush/Prime

Pump Command register (see INPUT REGISTER 02

below) to independently prime or flush an inactive

pump.

• Write a value between 1 and 5 if flushing a pump.

• Write a value between 1 and 30 if priming a Color

pump.

• Writeavaluebetween31and34ifpriminga

Catalyst pump.

NOTE: It is important that the user know which

material is assigned to each pump. An invalid

selection will be ignored by the ProMix PD2K.

INPUT REGISTER 02: Flush/Prime Pump Command

The Flush/Prime Pump Command register is used in

conjunction with the Pump Flush Sequence/Prime

Material Selection register (see INPUT REGISTER

01) to independently prime or flush an inactive pump.

The desired pump MUST be in Standby mode.

Confirm by reading the corresponding Pump Status

output register (see OUTPUT REGISTERS 01 – 04).

If an invalid Flush Sequence or invalid material

number is written to the Pump Flush Sequence/Prime

Material Selection register then the Flush/Prime

command will be ignored. The user must know

what material is assigned to each pump. (See

Color Change Kits Instruction Manual 332455 for

color/catalyst pump mapping.)

NOTE: If two pumps are currently mixing and an

inactive pump is commanded to flush or prime it will

continue its operation to completion without affecting

the system mode status. When the mixing operation

is complete, the system status will reflect Standby

mode while the flushing/priming pump completes its

operation.

INPUT REGISTER 03: Mix (Pump 1) Control Set

Point

The Mix Control Set Point register is used to set and

adjust the mixing fluid control set point. It also is used

as the fluid control set point for pump 1 when running

a1Krecipe. Itcan be changed at any time, and the

system will immediately adjust to the new set point.

• If the system is configured for Flow Control this

value can be set between 5 and 1600 cc/min for a

2K recipe, and between 5 and 800 for a 1K recipe.

See Fluid Control on System Screen 5, page 71.

• If the system is configure for Pressure Control this

value can be set between 0 and the maximum

pump pressure in PSI. See Fluid Control on

System Screen 5, page 71.

NOTE: The Flow Control must be configured to

‘Network’ via System Screen 5 on the ADM. If set

to ‘Discrete’ this register is ignored and set point

adjustment is handled via the discrete input. See

Analog Inputs, page 25.

INPUT REGISTER 04: Pump 2 Control Set Point

INPUT REGISTER 05: Pump 3 Control Set Point

INPUT REGISTER 06: Pump 4 Control Set Point

These registers are not used.

INPUT REGISTER 07: Go to Recipe Number

The Go to Recipe Number register is used as a

queue for the next recipe to be loaded when a recipe

change is initiated. A number between 0 and 60 can

be written to this register. However, a recipe must be

enabled via the ADM before it can be loaded. See

Recipe Screen, page 72.

NOTE:Writing to this register does not trigger a recipe

change.

See Color Change Sequence, page 44.

332564B 37

Operation Using a Programmable Logic Controller (PLC)

INPUT REGISTER 08: Clear Active Alarm

The Clear Active Alarm register is used to

acknowledge an alarm remotely so that the system

may resume operation. Be sure that the alarm

condition has been alleviated. Write a 1 to this

register to acknowledge the latest active alarm. If

more than one alarm is currently active only the most

recent alarm will be acknowledged. A repeated write

should be performed to clear any remaining active

alarms. See figure 9.

(See System Errors, page 88 for more information

on clearing alarms.)

NOTE: This register is not polled by the ProMix

PD2K. An alarm is cleared only when a value of ‘1’

is written to this register. It is recommended that the

automation reset this register by writing a 0 to it at all

other times to avoid inadvertently clearing an alarm.

INPUT REGISTER 09: Job Complete

The Job Complete register is used to log the current

job remotely. Write a ‘1’ to the register to command

theProMixPD2Ktoflagajobcomplete.

(See Usage Screen, page 64 for more information on

Job Logs and Job Complete.)

NOTE: This register is not polled by the ProMix

PD2K. A job is logged only when a value of ‘1’

is written to this register. It is recommended the

automation reset this register by writing a 0 to it at all

other times to avoid inadvertently logging a job.

INPUT REGISTER 10: Gun 1 Trigger

TheGun1Trigg

er register is used to signal the

ProMix PD2K when the automatic spray device is

triggered. This signal should be sent any time the

spray device is triggered. The state of this register

provides timing for alarm functions and also drives

the flow control algorithm.

NOTE: If enabled, it is imperative that this signal be

sent any time the spray device is triggered. Without it

the flow control features will not work.

• Write a value of ‘1’ to signal that the gun is

triggered.

• Write a value of ‘0’ to signal that the gun is NOT

triggered.

NOTE: This register is used only if the Gun Trigger

is set to ‘Network’ via System Screen 5 on the ADM.

If it is set to ‘Discrete’ this register is ignored and

gun trigger is handled via the discrete input. See

Digital Inputs, page 25.

NOTE: Because timing is so

critical for flow control Graco recommends that users

provide a discrete input to minimize latency effects.

Input Register 10

Gun Trigger

Discrete Signal

10 1 0

ProMix PD2K

Gun Trigger State

Figure 12 Gun Trigger Timing (Network and Discrete

Signals Shown

INPUT REGISTER 11: Gun 2 Trigger

INPUT REGISTER 12: Gun 3 Trigger

INPUT REGISTER 13: Gun 4 Trigger

These registers are not used.

INPUT REGISTERS 14 – 21: DCS Command

Structure

SeeDynamic Command Description, page 47.

38 332564B

Operation Using a Programmable Logic Controller (PLC)

Notes

332564B 39

Operation Using a Programmable Logic Controller (PLC)

Network Input Data Map (Write/Read)

Network

Input ID

Modbus

Register

Parameter Name Data

Type

Units Range

0=No

1=PowerPump

s

2=RemoteStop

3 = Recipe Change

4 = Mix Fill

5=Mix

6=PurgeA

7=PurgeB

00 40156 System Mode Command uint32 NONE

8 = Standby

01 40158 Pump Flush Sequence #/Prime

Material#

uint32 NONE 1 - 5, 1 - 34

0=NoOP

1=Flus

hPump1

2=PrimePump1

3=FlushPump2

4=Pri

me Pump 2

5=FlushPump3

6=PrimePump3

7=Fl

ush Pump 4

02 40160 Flush/Prime Pump Command uint32 NONE

8=PrimePump4

03 40162 Mix (Pump 1) Control Set Point uint32 cc/min or

PSI

1 - 1600

04 40164 Pump 2 Control Set Point uint32 cc/min or

PSI

1-1600

05 40166 Pump 3 Control Set Point uint32 cc/min or

PSI

1 - 1600

06 40168 Pump 4 Control Set Point uint32 cc/min or

PSI

1 - 1600

0740170 Go to Recipe Number uint32 NONE 0,1-60

08 40172 Clear Active Alarm uint32 NONE 1 = Clear Active Alarm

09 40174 Job Complete uint32 NONE 1 = Trigger job complete

0 = Gun not triggered

10 40176 Gun 1 Trigger uint32 NONE

1 = Gun triggered

0 = Gun not triggered

11 40178 Gun 2 Trigger uint32 NONE

1 = Gun triggered

40 332564B

Operation Using a Programmable Logic Controller (PLC)

0 = Gun not triggered

12 40180 Gun3Trigger uint32 NONE

1 = Gun triggered

0 = Gun not triggered

13 40182 Gun4Trigger uint32 NONE

1 = Gun triggered

14 40184 Command Argument 0 uint32 NONE N/A

15 40186 Command Argument 1 uint32 NONE N/A

16 40188 Command Argument 2 uint32 NONE N/A

17 40190 Command Argument 3 uint32 NONE N/A

18 40192 Command Argument 4 uint32 NONE N/A

19 40194 Command Argument 5 uint32 NONE N/A

20 40196 CommandArgument6 uint32 NONE N/A

21 40198 DCS Command uint32 NONE See Command Table

These registers are not used. DCS Register

332564B 41

Operation Using a Programmable Logic Controller (PLC)

Operation Flow Charts

Purge Mode Sequence

YES

YES

YES YES

NO

NO

NO

NO

Purge A System Command

Write ‘6’ to Input Register 00

Is system in Standby or

Pumps Off?

Is solvent flow switch 1 ON?

Purge time expired?

System Mode = Standby: Mix Not Ready

(Output Register 00 = ‘13’)

System closes color solvent valve at remote stack.

Purge no flow timeout expired?

No solvent flow detected.

Generate alarm.

System Mode = Purge A

(Output Register 00 = ‘9’)

System opens color solvent valve at remote stack to allow

solvent flow through mix manifold and out gun.

Purge time set according to the flush sequence assigned to

material A in recipe.

No action taken.

Either pumps are currently

running or an alarm condition

exists.

NOTE: Purge B command works

similarly with the catalyst lines and

solvent flow switch 2.

42332564B

Operation Using a Programmable Logic Controller (PLC)

Inactive Pump Flush and Prime Sequences

YES YES

YES

YESYES

NO NO

NONO

NO

Write Flush Sequence #

(1-5) to Output Register 01

Write

Flush Pump Command

(1,3,5,7) to Input Register 02

Write

Prime Pump Command

(2,4,6,8) to Input Register 02

Is requested pump

status* = Standby?

(Output Register* = ‘1’)

Pump is flushed using

assigned sequence number.

Pump Status = Flushing

(Output Register* = ‘3’)

Pump is primed using

assigned material.

Pump Status = Priming

(Output Register* = ‘4’)

Pump is either Off or Busy

(Output Register* = ‘0’ or ‘2’)

Busy refers to a pump that is

currently involved in a mixing

operation. No action taken.

NOTE: Be sure to read to

appropriate Output Register*

for the desired pump status:

Register 01 - Pump 1

Register 02 - Pump 2

Register 03 - Pump 3

Register 04 - Pump 4

Is requested pump

status* = Standby?

(Output Register* = ‘1’)

Is selected material valid

for requested pump?

Invalid request.

No action taken.

Write Prime Material #

(1-34) to Output Register 01

Is Flush complete? Is Prime complete?

Pump is returned to Standby.

Pump Status = Standby

(Output Register* = ‘1’)

332564B 43

Operation Using a Programmable Logic Controller (PLC)

Color Change Sequence

YES

YES YES

NO

NO

NO

NO

YES NO

YES

YES

Write Goto Recipe Number

(0,1 - 60) to Input Register 07

Recipe Change System

Command

Write ‘3’ to Input Register 00

Is system in Standby

with no alarm conditions?

Is purge complete and

are pumps primed?

Is material filled out to

mix manifold?

Fill material out to mix

manifold.

System Mode = Recipe

Change: Fill

(Output Register 00 = ‘5’)

No action taken.

Either pumps are currently

running or an alarm condition

exists.

System Mode = Recipe

Change

(Output Register 00 = ‘2’)

Purge Material B out gun.

System Mode = Recipe

Change: Purge B

(Output Register 00 = ‘4’)

Pump will flush then prime.

Purge Material A out gun.

System Mode = Recipe

Change: Purge A

(Output Register 00 = ‘3’)

Pump will flush then prime.

Is Material B

changing?

Is Material A

changing? Is mix fill complete?

NO

Mix material out to gun.

System Mode = Mix Fill

(Output Register 00 = ‘6’)

System Mode = Standby:

Mix Ready

(Output Register 00 = ‘11’)

44332564B

Operation Using a Programmable Logic Controller (PLC)

Mixing Sequence

YESYES

NO

NO

YES

NO

NO

YES

Mix System Command

Write ‘5’ to Input Register 00

System Mode =

Standby: Fill Ready?

A recipe is loaded in the

pumps but not yet filled out

to the gun. Mixed material is

pumped out to the gun.

No action taken.

System is not in valid state

for mixing. Confirm pumps

are on, a recipe is loaded,

and there are no existing

alarm conditions.

System Mode = Mix

(Output Register = ‘7’)

Gun Trigger = ON? Mix Idle Timeout

expired?

Stem Mode =

Standby: Mix Ready?

No gun trigger signal for

longer than Mix Idle Timeout.

System Mode = Mix Idle

(Output Register = ‘8’)

NOTE: System will remain in

Mix mode until a STANDBY

command is issued or an alarm

condition exists.

332564B 45

Operation Using a Programmable Logic Controller (PLC)

Alarm Clearing Sequence

NO

Clear Active Alarm

Write ‘1’ to Input Register 08

NOTE: If an alarm condition is

active the System Mode will either

be Pump Off or Standby: Alarm.

(Output Register 00 = ‘1’ or ‘14’)

No action taken.

Clear active alarm.

Clear most recent active

alarm.

Remaining alarm(s) still

active.

Is there an active

alarm?

Is there more than 1

active alarm?

YES

YES

NO

NOTE: If more than 1 active

alarm exists a repeated write

of ‘1’ to Input Register 08 is

required for each.

46 332564B

Operation Using a Programmable Logic Controller (PLC)

Network Communication - Dynamic Command Structure (DCS)

Dynamic Command Description

The Dynamic Command Structure (DCS) is used to 1) access data that requires some form of

argument(s) or 2) consolidate data that requires multiple registers. The DCS uses a static set of network

communication input and output registers (see Network Input Data Map (Write/Read), page 40 and

Network Output Data Map (Read Only), page 33.

Use the following sequence for the DCS.

1. Write the appropriate command arguments to INPUT REGISTERS 14 – 20. These commands may be

written sequentially or sent all at once.

2. Once all arguments have been passed, write the command ID to INPUT REGISTER 21.

3. TheProMixPD2Kwillrespondtoavalidcommandbywritinga2(Acknowledge) to OUTPUT REGISTER

28.

4. The ProMix PD2K will write appropriate return values to OUTPUT REGISTERS 29 – 36.

INPUT REGISTER 14

ProMix PD2K Inputs

(PLC Outputs)

ProMix PD2K Outputs

(PLC Inputs)

[arg_0]

INPUT REGISTER 14+n[arg_n]

INPUT REGISTER 21

OUTPUT REGISTER 28

OUTPUT REGISTER 29

OUTPUT REGISTER 29+n

[id]

ACK = 2

[rtn_0]

[rtn_n]

Can be written together

or sequentially.

Figure

13 Dynamic Command Structure Timing

332564B 47

Operation Using a Programmable Logic Controller (PLC)

List of DCS Commands

Table 5 Dynamic Commands with Command ID

ID Command

0No OP

1 Write User ID

2WriteRecip

e

3Write Flush Sequence

4Write Fluid Control Mode

10 Read User ID

11 Read Recipe

12 Read Flush Sequence

13 Read Fluid Control Mode

14 Read JobInfo

15 Read Alarm Info

16 Read Event Info

Write User ID

The Write User ID command allows users to assign a User ID to a Job Log. See Usage Screen, page 64,for

more details on Job Log and User ID. The User ID can be up to ten ASCII characters in length and is packaged

as three little endian segments of ASCII characters. The return registers will echo the arguments received.

NOTE: The User ID character string must be terminated with a null character.

Example: Write a User ID of “John Doe” to the ProMix PD2K.

DCS Register Parameter Description Data

Type

Units Value Range

DCS

Command

Write User ID uint32 NONE 10-1

6

Argument 0 User ID characters [3:0]

(ASCII)

uint32 NONE 0x6E686F4A = [‘n’,

’h’, ’o’, ’J’]

N/A

Argument 1 User ID characters [7:4]

(ASCII)

uint32 NONE 0x656F4420 = [‘e’,

’o’, ’D’, ’ ‘]

N/A

Argument 2 User ID characters [9:8]

(ASCII)

uint32 NONE 0x0 = [null] N/A

Acknowledge Command Acknowledged uint32 NONE 2 = ACK 0-4

Return 0 User ID characters [3:0]

(ASCII)

uint32 NONE 0x6E686F4A N/A

Return 1 User ID characters [7:4]

(ASCII)

uint32 NONE 0x656F4420 N/A

Return 2 User ID characters [9:8]

(ASCII)

uint32 NONE 0x0 N/A

48 332564B

Operation Using a Programmable Logic Controller (PLC)

Write Recipe

The Write Recipe command allows users to configure an entire recipe remotely. See Recipe Screen, page 72,

for more details on recipes and recipe parameters. The return registers will echo the arguments received.

NOTE: The recipe must be enabled via the ADM before it can be loaded for mixing.

Example: Configure Recipe 6 for

Color = 2, Catalyst = 1, Color Flush Sequence = 2, Catalyst Flush Sequence

= 3, Mix Ratio Set Point = 1.50:1, and Potlife = 10 minutes.

DCS Register Parameter Description Data

Type

Units Value Range

DCS

Command

Write Recipe uint32 NONE 20-16

Argument 0 Recipe Number uint32 NONE 60-60

Argument 1 Material A uint32 NONE 20–30

Argument 2 Material B uint32 NONE 31 0, 31 – 34

Argument 3 Material A Flush Sequence uint32 NONE 21-5

Argument4 Material B Flush Sequence uint32 NONE 31-5

Argument 5 Mix Ratio Set Point uint32 NONE 150 = 1.50:1 0 - 5000

Argument 6 Potlife Time Set Point uint32 min 10 0 - 999

Acknowledge Command Acknowledged uint32NONE 2 = ACK 0-4

Return 0 Recipe Number uint32 NONE 60-60

Return 1 Material A uint32 NONE 20–30

Return 2 Material B uint32 NONE 31 0, 31–34

Return 3 Material A Flush Sequence uint32 NONE 21–5

Return 4 Material B Flush Sequence uint32 NONE 31–5

Return 5 Mix Ratio Set Point uint32 NONE 150 0- 5000

Return 6 Potlife Time Set Point uint32 min 10 0 - 999

332564B 49

Operation Using a Programmable Logic Controller (PLC)

Write Flush Sequence

The Write Flush Sequence command allows users to configure an entire flush sequence remotely. See

Flush Screen, page 73, for more details of flush sequence parameters. The return registers will echo the

arguments received.

Example: Configuring Flush Sequence 4 for Gun Purge Time = 10 sec, Initial Flush Volume = 125 cc, Final

Flush Volume = 250 cc, Wash Cycles = 1, Strokes per Cycle = 2.

DCS Register Parameter Description Data

Type

Units Value Range

DCS

Command

Write Flush Sequence uint32 NONE 30-16

Argument 0 Flush Sequence # uint32 NONE 41-5

Argument 1 Gun Purge Time uint32 sec 10 0 - 999

Argument 2 Initial Flush Volume uint32 cc 125 0 - 9999

Argument 3 Final Flush Volume uint32 cc 250 0 - 9999

Argument4 #WashCycles uint32 NONE 10-99

Argument 5 StrokesperWashCycle uint32 NONE 20-99

Acknowledge Command Acknowledged uint32 NONE 2 = ACK 0-4

Return0 Flush Sequence # uint32NONE 41-5

Return 1 Gun Purge Time uint32 sec 10 0 - 999

Return 2 Initial Flush Volume uint32 cc 125 0 - 9999

Return 3 Final Flush Volume uint32 cc 250 0 - 9999

Return 4 #WashCycles uint32 NONE 10-9

9

Return 5 Strokes per Wash Cycle uint32 NONE 20-99

50 332564B

Operation Using a Programmable Logic Controller (PLC)

Write Fluid Control Mode

The Write Fluid Control Mode command allows users to remotely change Fluid Control between ‘Flow’ and

‘Pressure’. See System Screen 5, page 71, for more details on Fluid Control mode. The return registers will

echo the arguments received.

NOTE: The Fluid Control mode should be changed only when the system is in Standby or when the pumps are

powered off. Do not change Fluid Control modes during a mix operation.

Example: Change to Flow Control mode.

DCS Register Parameter Description Data

Type

Units Value Range

DCS

Command

Write Fluid Control Mode uint32 NONE 40-16

0=FlowArgument 0 Fluid Control Mode uint32 NONE 0 = Flow Mode

1=Pressure

Acknowledge Command Acknowledged uint32 NONE 2 = ACK 0-4

0=FlowReturn 0 Fluid Control Mode uint32 NONE 0

1=Press

ure

Read User ID

The Read User ID command reads back the current User ID. See Usage Screen, page 64, for more details

on Job Log and User ID. The User ID can be up to ten ASCII characters in length and is packaged as three

little endian segments of ASCII characters. No arguments are required.

Example: Read User ID that is currently “John Doe”.

DCS Register Parameter Description Data

Type

Units Value Range

DCS

Command

Read User ID uint32 NONE 10 0 - 16

Acknowledge Command Acknowledged uint32 NONE 2 = ACK 0-4

Return 0 User ID characters [3:0]

(ASCII)

uint32 NONE0x6E686F4A = [‘n’,

’h’,’o’,’J’]

N/A

Return 1 User ID characters [7:4]

(ASCII)

uint32 NONE 0x656F4420 = [‘e’,

’o’, ’D’, ’ ‘]

N/A

Return 2 User ID characters [9:8]

(ASCII)

uint32 NONE 0x0 = [null] N/A

332564B 51

Operation Using a Programmable Logic Controller (PLC)

Read Recipe

The Read Recipe command returns all configured recipe parameters for a desiredrecipenumber. The

number of the recipe to be read is the only argument.

Example: Read Recipe 5 data as it is currently configured with Color = 3, Catalyst = 2 (32), Color Flush

Sequence = 1, Catalyst Flush Sequence = 4, Mix Ratio Set Point = 3.25:1, and Potlife = 35 min.

DCS Register Parameter Description Data

Type

Units Value Range

DCS

Command

Read Recipe uint32 NONE 11 0 - 16

Argument 0 Recipe # uint32 NONE 50-60

Acknowledge Command Acknowledged uint32 NONE 2 = ACK 0-4

Return 0 Recipe # uint32 NONE 50-60

Return 1 Material Auint32 NONE 3 0 - 30, 61

Return 2 Material B uint32 NONE 32 0, 31 - 34, 61

Return 3 Material A Flush Sequence uint32 NONE 11-5

Return 4Material B Flush Sequence uint32 NONE 41-5

Return 5 Mix Ratio Set Point uint32 NONE 325 0 - 5000

Return 6 Potlife Time Set Point uint32 min 35 0 - 999

Read Flush Sequence

The Read Flush Sequence command returns all configured parameters for a desired flush sequence. The

number of the flush sequence to be read is the only argument.

Example: Read Flush Sequence 1 as it is currently configured with Gun Purge Time = 20 sec, Initial Flush

Volume = 0 cc, Final Flush Volume = 500 cc, Wash Cycles = 2, and Strokes per Cycle = 1.

DCS Register Parameter Description Data

Type

Units Value Range

DCS

Command

Read Flush Sequence uint32 NONE 12 0 - 16

Argument 0 Flush Sequence # uint32 NONE 11

-5

Acknowledge Command Acknowledged uint32 NONE 2 = ACK 0-4

Return 0 Flush Sequence # uint32 NONE 11-5

Return 1 Gun Purge Time uint32 sec 20 0 - 999

Return 2 Initial Flush Volume uint32 cc 00-9999

Return 3 Final Flush Volume uint32 cc 500 0 - 9999

Return 4 #WashCycles uint32 NONE 20-99

Return 5 Strokes per Wash Cycle uint32 NONE 10-99

52 332564B

Operation Using a Programmable Logic Controller (PLC)

Read Fluid Control Mode

The Read Fluid Control Mode command is used to

read the current Fluid Control mode of the system

is currently operating under. No arguments are

required.

Example: Read Fluid Control as currently set to

Pressure mode.

DCS Register Parameter Description Data

Type

Units Value Range

DCS

Command

Read Fluid Control Mode uint32 NONE 13 0 - 16

Acknowledge Command Acknowledged uint32 NONE 2 = ACK 0-4

0=FlowReturn 0 Fluid Control Mode uint32 NONE 1 = Pressure

1=Pressure

332564B 53

Operation Using a Programmable Logic Controller (PLC)

Read Job Info

The Read Job Info command is used to access data from any of the most recent 200 job logs. The argument is

the

chronological index

of the job log, where 0 is the most recent job log and 199 is the 200th most recent.

The date is returnedasfour-bytepacketwitheachbyteholdingatwo-digitvaluefor(from MSB to LSB) year,

month, day, and day of the week (Monday = 01).

The time is returned as a three-byte packet with each byte holding a two-digit value. Starting from the MSB,

the first byte can be ignored, then hour, minute, and second.

NOTE: The argument is an index not a job number. The actual job number will, however, be one of the

returned parameters. These records will match what is reported on the Jobs screen of the ADM.

(See Usage Screen, page 64, for more details on Job Log)

Example: Read back the most recent job log, job 25, which ran recipe 2 for a totalof1234cc’sofmaterial

under User ID “John Doe”. The job was logged on Thursday May 29, 2014 at 11:22:14 AM.

DCS Register Parameter Description Data Type Units Value Range

DCS

Command

Read Job Info uint32 NONE 14 0 - 16

Argument 0 Job Index uint32 NONE 00–199

Acknowledge Command

Acknowledged

uint32 NONE 2 = ACK 0-4

Return 0Job Dateuint32 [YY:MM:DD-

:DW]

0x0E051D04 =

[14:05:29:04]

N/A

Return 1 Job Time uint32 [xx:HH:MM-

:SS]

0x0B160E =

[11:22:14]

N/A

Return 2 Job Number uint32 NONE 25 0 - 9999

Return 3 Recipe # uint32 NONE 20-60

Return 4 A+B Volume uint32 cc 1234 N/A

Return 5 User ID [3:0] (ASCII) uint32 NONE 0x6E686F4A = [‘n’,

’h’, ’o’, ’J’]

N/A

Return 6 User ID [7:4] (ASCII) uint32 NONE 0x656F4420 = [‘e’,

’o’, ’D’ ‘ ’]

N/A

Return 7 User ID [9:8] (ASCII) uint32 NONE 0N/A

54 332564B

Operation Using a Programmable Logic Controller (PLC)

Read Alarm Info

The Read Alarm Info command allows remote access to any of the last 200 alarms logged by the ProMix

PD2K. The argument is the

chronological index

of the alarm log, where 0 is the most recent alarm and 199 is

the 200th most recent.

The date is returned as a four-byte packet with each byte holding a two-digit value for (from MSB to LSB) year,

month, day, and day of the week (Monday = 01).

Thetimeisreturnedasathree-bytepacketwitheachbyteholdingatwo-digit value. Starting from the MSB,

the first byte can be ignored, then hour, minute, and second.

The alarm code is a four-character little endian ASCII string

See System Errors, page 88, for more details on these Event Types.

An example decoding algorithm is provided below.

Example: Read back the second most recent alarm, which was a Position Pump 1 (DK01) recorded on

Tuesday June 3, 2014 at 8:11 AM.

DCS Register Parameter Description Data

Type

Units Value Range

DCS

Command

Read Alarm Info uint32 NONE 15 0 - 16

Argument 0 Alarm Index uint32 NONE 10-199

Acknowledge Command Acknowledged uint32 NONE 2 = ACK 0-4

Return 0Alarm Date uint32 [YY:MM:DD:DW] 0x0E060302 =

[14:06:03:02]

N/A

Return 1 Alarm Time uint32 [xx:HH:MM:SS] 0x080B0B =

[08:11:11]

N/A

Return 2 Alarm Code Char[3:0] uint32 NONE 0x31304B44 = [‘1’,

’0’, ’K’, ’D’]

N/A

Example ASCII Character String Decode Algorithm:

character_str[0] = Return_2 & 0xFF;

character_str[1] = (Return_2 >> 8) & 0xFF;

character_str[2] = (Return_2 >> 16) & 0xFF;

character_str[3] = (Return_2 >> 24) & 0xFF;

character_str[4] = ‘\0’;

332564B 55

Operation Using a Programmable Logic Controller (PLC)

Read Event Info

The Read Event Info command allows remote access to any of the last 200 events logged by the ProMix

PD2K. The argument is the

chronological index

of the events log, where 0 is the most recent event and

199 is the 200th most recent.

Thedateisret

urned as a four-byte packet with each byte holding a two-digit value for (from MSB to LSB) year,

month, day, and day of the week (Monday = 01).

The time is returned as a three-byte packet with each byte holding a two-digit value. Starting from the MSB,

the first byte can be ignored, then hour, minute, and second.

The event code is a four-character little endian ASCII string.

The example decoding algorithm provided above for the Alarm Code may be used for Events equivalently.

Example: Read back the fifth most recent event, which was a Setup Value(s) Changed (EC00) recorded

on Tuesday June 3, 2014 at 8:11 AM.

DCS Register Parameter Description Data

Type

Units Value Range

DCS

Command

Read EventInfo uint32 NONE 16 0 - 16

Argument 0 Event Number uint32 NONE 40-199

Acknowledge Command

Acknowledged

uint32 NONE 2 = ACK 0-4

Return 0 Event Date uint32 [YY:MM:DD-

:DW]

0x0E060302 =

[14:06:03:02]

N/A

Return1 Event Time uint32[xx:HH:MM:SS] 0x080B0B =

[08:11:11]

N/A

Return 2 Event Code Char[3:0] uint32 NONE 0x30304345 = [‘0’,

’0’, ’C’, ’E’]

N/A

56 332564B

Operation Using a Programmable Logic Controller (PLC)

Flow Control System

Overview

Flow control is an optional feature that precisely

regulates the flow of material to an automatic spay

device, to help ensure adequate coverage and avoid

sags or runs in the finish coat. The ProMix PD2K

system can control fluid flow by directly controlling

the proportioning pumps. The pumps accurately

dispense a fixed volume of fluid during each stroke.

For this reason, the flow rate of a given pump is

directly proportional to the velocity of the pump. As

long as the gun is open and the system is stable, flow

control is the most effective method for controlling

flow rate.

The flow control system relies on two main inputs for

controlling flow rate: Gun Trigger and Control Set

Point.

NOTE: These inputs are timing critical. Graco

recommends that users wire them discretely to the

controller.

Alternatively these two inputs can be

driven by the network communications, but latency

could be an issue for systems requiring precise

timing.

See System Screen 5, page 71, for more details on

configuring these options for ‘Discrete’ or ‘Network’.

NOTE: Flow control cannot be selected with a

manual gun system.

Normal Flow Control

The ProMix PD2K will directly control the speed of

the pump(s) to the programmed flow control set point

to maintain accurate flow rate and ratio. The flow

control set point is set by Network Communications

or the Discrete Input.

The system is considered to be stable when the

pressure readings do not fluctuate and the flow rate

is maintained. While the system is considered stable

it will store (“learn”) the associated pump pressures

to a table that is used if the gun trigger signal is lost

or removed.

Pressure Control

When the gun trigger signal is removed the system

automatically switches to pressure control mode to

avoidoverpressurizingthefluidlinesandtoallow

smooth transition to flow control if the gun trigger

signal returns. It also works to maintain a consistent

flow rate even though it has transitioned to pressure

control mode if the gun trigger signal is inadvertently

lost.

Gun On/Off Prediction

The pressure table also is used to predict if the gun

has been turned on or off (without a change to the

gun trigger input). The flow control system continually

monitors the desired outlet pressure compared to the

actual outlet pressure. If the actual pressure remains

50% higher than the desired pressure for longer than

10msec, then the system predicts that the gun trigger

has been released. If the actual pressure drops

below the desired pressure longer than 10msec, then

the system predicts that the gun has been triggered.

The gun on/off prediction is used in the flow control

algorithmtopreventthefluidpressurefrombecoming

too high or too low due to a system disturbance. For

example, if a gun off prediction occurs while the gun

trigger input is high, the system will begin to control

to the pressure value last stored in the pressure table

for the current flow set point.

System Startup and Defaults

The pressuretableisstoredinvolatilememory,so

the table values will be lost after a power cycle of the

ProMix PD2K controller. This issue is not significant

because the system generally is able to recalculate

new pressure table values within a few seconds

(depending on the stability of the fluid system).

332564B 57

Run Mode Screens

RunModeScree

ns

NOTE: Selection fields and buttons that are

grayed-out on the screens are not currently active.

Opening Screen

At power up, the Graco logo will display for

approximately 5 seconds, followed by the Home

screen.

Figure 14 Opening Screen

Home Screen

The Home screen displays the current status of the

system. The following table details the information

shown.

To view pump flow rates and pressures

(as shown), select “Diagnostic Mode” on

System Screen 1, page 67.

Figure 15 Home Screen, in Mix Mode with

Diagnostics On

58 332564B

Run Mode Screens

Home Screen Key

Key Description Details

A Date and Time See Advanced Screen 1, page 82,toset.

B Menu Bar Run Screens. Use left and right arrow keys to scroll through the

different Run screens:

• Home (shown in Diagnostic Mode)

• Spray (see Spray Screen, page 62)

• Fill (see Fill Screen, page 63), available only if manual override

is enabled on System Screen 5, page 71.

• Usage (see Usage Screen, page 64)

•Jobs(seeJobs Screen, page 65)

•Errors(seeErrors Screen, page 65)

• Events (see Events Screen, page 65)

System Status: Displays the current mode of operation:

C Status Bar

•PumpOff

• Standby

•Startup

•Mix

• Fill

• Purge

• Shutdown

• Change Recipe

•Idle

• Prime Pump

• Calibrate

•StallTest

• Maintenance Test

DError Status Displays any active error code.

332564B 59

Run Mode Screens

Key Description Details

E Pump Animation and

Diagnostic Information

FPump Number (1–4)

G Material (A or B)

HAvailable Colors

JPump Inlet Color

L Pump Flow Rate

MPump OutletColor

NPump Outlet Pressure

P Pump Indicator Light

• Clear = power off

• Yellow = standby

•Green=active

SSolven

tFlowRate Shows solvent flow rate, if a solvent meter is attached.

Shows mixed material in the spray device and displays active

recipe at the spray device. Gun animation changes to show:

TSpray Device Animation

•

(Mix Fill)

•

(Mix With Gun Triggered)

•

(Recipe Standby)

•

(Purge)

•

• (Solvent Standby)

•(Mix With

Gun Not Triggered)

60 332564B

Run Mode Screens

Key Description Details

UActive Recipe ( )

VCurrent Ratio ( )

WPotlife Time Remaining ( )

XTotal Volume for the Current

Job ( )

YCurrent Flow Rate ( )

ZCurrent Pressure ( )

332564B 61

Run Mode Screens

Spray Screen

NOTE: In normal operating mode, controlled by a

PLC, the Spray Screen is display only. No changes

can be made. This section provides information

about the Spray Screen if manual override is enabled

on System Screen 5, page 71. The screens show a

system in manual override mode.

The Spray screen includes the following information:

• Active Recipe (can be changed on this screen)

• Target Ratio

• Actual Ratio

• Target Pressure (if Pressure Mode is selected on

System Screen 5) or Target Flow (if Flow Mode is

selected). Target pressure or flow can be changed

on this screen).

• Actual Pressure

• Actual Flow

• Potlife Remaining

• Gun Animation

In addition, the Spray screen includes three soft keys:

Press to put the system in

Standby.

Press to spray mixed material.

Press to purge the gun.

Figure 16 Spray Screen, in Standby Mode

Figure 17 Spray Screen, in Mix Mode

Figure 18 Spray Screen, in Idle Mode

62 332564B

Run Mode Screens

Fill Screen

NOTE: This screen is visible only if manual override

is enabled on System Screen 5, page 71.

The Fill screen displays the following information for

the pump assigned to the current color:

• Material. Select Color (A), Catalyst (B), or Solvent.

The pump animation at the top of the screen will

show the selected material.

• Flush Line (only for systems with color change).

Select this box if you want to flush the specified

material line. The system uses flush sequence 1.

To prime the pumps and fill the lines, first read

Prime and Fill the System, page 20.

1. Press the Edit softkey to open the screen

for editing.

2. Select Color (A).

3. If the selected material is not already loaded,

press the Prime softkey . The system will

prime Color (A) into the selected pump through

the selected color valve and out the outlet dump

valve.

4. Press the Fill softkey . The system will

attempt to fill the Color (A) lines until the user

presses Stop . Trigger the gun into a waste

container.

5. Repeat for Catalyst (B).

Figure 19 Fill Screen, Color (A) Selected

Figure 20 Fill Screen, Solvent Selected

332564B 63

Run Mode Screens

Usage Screen

The first Usage screen displays the current job usage

and grand total usage of component A, B, A+B,

and solvent (S). Edits may be made only if manual

override is enabled on System Screen 5, page 71.

The second Usage screen displays the total volume

pumped for all available materials.

1. Press the Edit softkey to open the screen

for editing.

2. To enter or change the User ID ( ), select the

field to open the User ID Keyboard screen,

and enter the desired name (10 characters

maximum).

3. To log the current job, press the Job Complete

softkey . This will clear the current usage

fields and increment to the next job number.

The Grand Totals cannot be cleared. See the

Jobs Screen, page 65, to review past jobs.

4. Press the Edit softkey to close the screen.

Figure 21 Usage Screen

Figure 22 User ID Keyboard Screen

Figure 23 Usage Log

64 332564B

Run Mode Screens

Jobs Screen

The Jobs screen displays the 200 most recent job

numbers, recipes, and A+B volumes in a log, with

date, time, and User ID.

Figure 24 Jobs Screen

Errors Screen

The Errors screen displays the 200 most recent Error

Codes in a log, with date, time, and description.

Figure 25 Errors Screen

Events Screen

The Events screen displays the 200 most recent

Event Codes in a log, with date, time, and description.

Figure 26 Events Screen

332564B 65

Setup Mode Screens

SetupModeScr

eens

Press on any Run screen to enter the Setup

screens.

NOTE: Selection fields and buttons that are

grayed-out on the screens are not currently active.

If the system has a password lock, the Password

screen displays. See Password Screen, page 66.

Password Screen

Figure 27 Password Screen

Enter the 4 digit password, then press .System

screen 1 will open, allowing access to the other

Setup screens.

Entering an incorrect password clears the field.

Reenter the correct password.

To assign a password, see

Advanced Screen 1, page 82.

66 332564B

Setup Mode Screens

System Screen 1

System screen 1 includes the following fields which

define your system.

Figure 28 System Screen 1, During Standby

Diagnostic Mode

Select this box to display flow rate and pressure for

eachpumpontheHome Screen, page 58.

Color Pumps

Enter the number of color pumps in your system.

Catalyst Pumps

Enter the number of catalyst pumps in your system.

Non-Mix Pressure

Enter a lower pressure for use when not mixing and

spraying (for example during fill or flushing).

NOTE: Low pressure systems may be set 100 psi

(0.7 MPa, 7 bar) lower than target pressure; high

pressure systems may be set 300 psi (2.1 MPa, 21

bar) lower than target pressure.

Solvent Meter

Select this box if your system uses a solvent meter.

The Solvent K-Factor field will then become active.

SolventK-Factor

Enter the solvent meter K-Factor.

332564B 67

Setup Mode Screens

System Screen 2

System screen 2 sets the following system operating

parameters.

Figure 29 System Screen 2, in Standby Mode

Mix Pressure Tolerance

The pressure of one component must be within

a percentage (±) of the pressure of the other

component during spray or mix. Set the desired Mix

Pressure Tolerance in this field. The default is 75%.

Stall Test Pressure

Set the minimum stall test pressure. The setting

should be approximately 50 psi (0.35 MPa, 3.5 bar)

higher than the highest inlet pressure.

Pump Stall Test

Set the duration for the pump stall test. See

Calibrate Screen 1, page 77.

Maximum Leak Rate

Enter the maximum allowable leak rate for a pump

stall test.

Mix Idle Timeout

The Gun Trigger Input signals that the device is

triggered. If you are not using a gun trigger signal,

the system does not know if the spray device is

spraying. If a pump failed you could spray pure resin

or catalyst without knowing. This should be caught

by the Mix No Flow Timeout; the default is 5 seconds.

The Mix Idle Timeout will trigger Idle mode, which

will run a pump stall test to check for leaks, then put

the pumps in Standby (holding their current position)

after the designated period of time. Enter the desired

Mix Idle Timeout in this field.

See Digital Inputs, page 25.

Mix No Flow Timeout

The Gun Trigger Input signals that the gun is

triggered. If the Gun Trigger Input indicates that the

gun is triggered, but there is no fluid flow through a

pump, you could spray pure resin or catalyst without

knowing. The Mix No Flow Timeout will cause the

system to shutdown after the designated period of

time. The default is 5 seconds. Enter the desired

shutdowntimeinthisfield.

See Digital Inputs, page 25.

Low Flow Tolerance

This field is active in systems set to Flow Control.

The system will detect if the flow rate falls below a

designated percentage of the target flow rate. Set

that percentage in this field. For example, you might

want the system to time out if it detects a flow rate

that is 10 percent of the target, rather than waiting

until a no flow timeout occurs.

Low Flow Timeout

The low flow timeout causes the system to shut down

after the designated period of time if the flow rate

continues to be at or below the low flow tolerance set

in the previous section. The default is 5 seconds.

Enter the desired shutdown time in this field.

68 332564B

Setup Mode Screens

System Screen 3

System screen 3 sets the following system operating

parameters.

Figure 30 System Screen 3

Gun Hose Length

Enter the length of the hose from the remote mix

manifold to the spray device.

Gun Hose Diameter

Enter the diameter of the hose from the remote mix

manifold to the spray device. The minimum diameter

is 1/8 in. (3 mm).

Mix At Wall

This field is always enabled in Automatic systems.

Hose Length and Diameter

Enter the length and diameter of the hose from the

remote color stack to the remote mix manifold, for

both A and B hoses.

332564B 69

Setup Mode Screens

System Screen 4

System screen 4 sets the following system operating

parameters.

Figure 31 System Screen 4

Gateway ID

Select the desired Gateway ID from the dropdown

menu.

Enable

Uncheck Enable while setting the IP Address, Subnet

mask, Gateway, DNS1 or DNS2. When the settings

are loaded, check the Enable box to write the new

settings to the selected Gateway.

Checkthisb

ox to enable the selected Gateway so

that the PLC can communicate with it.

DHCP

Select this box if your system has a Dynamic Host

ConfigurationProtocol(DHCP).Thisprotocolassigns

unique IP addresses to devices, then releases and

renews these addresses as devices leave and rejoin

the network. If selected, the IP Address, Subnet, and

Gateway fields will not be editable and will display

the addresses supplied by the DHCP.

TCP/IP

Use the remaining fields to set the IP address, subnet

mask, Gateway, DNS1, and DNS2.

70 332564B

Setup Mode Screens

System Screen 5

System screen 5 sets the following system operating

parameters.

Figure 32 System Screen 5

Fluid Control

Select the desired operating mode (pressure or flow),

using the pull-down menu.

•InPressure Mode, the motor will adjust the pump

speed to maintain the fluid pressure set by an

external control device.

•InFlow Mode, the motor will maintain a constant

speed to maintain the target flow rate set by an

external control device.

Manual Override

Check this box to give users system control at the

ADM. Leave the box unchecked if all system settings

are controlled through a PC, PLC, or other networked

device.

Gun Trigger Signal

Select the format of the signal indicating whether the

spray device is triggered.

• Discrete — the signal is sent via a direct,

hard-wired connection

•Network—th

esignalissentviaaPC,PLC,or

other networked device.

Flow Control (Setpoint Signal)

Select the format of the signal that indicates system

flow rate or pressure.

• Discrete — the signal is sent via a direct,

hard-wired connection. This selection will make

the Max Rate field active.

• Network — the signal is sent via a PC, PLC, or

other networked device.

Stepup Gain and Stepdown Gain

These fields are active only for systems set to flow

control on System Screen 5. Enter a value from 1 to

100tooptimizesystemresponsetimetoachange

in fluid flow setpoint. Use the Stepup Gain field for

increases in fluid flow setpoint. Use the Stepdown

Gain field for decreases in fluid flow setpoint.

332564B 71

Setup Mode Screens

Recipe Screen

Figure 33 Valid Recipe Screen

Recipe

Enter the desired recipe number (1-60).

Recipe 0

UseRecipe0toflushthesystem.

•If a recipe (1–60) is loaded: Select Recipe 0 to flush

the previously active pumps and purge the gun.

•If Recipe 0 or 61 is loaded: Select Recipe 0 to

flush all pumps and purge the gun.

Enabled

Selecting “Enabled” makes the selected recipe

accessible from the Spray screen on the ADM or to

the PLC.

Note: Recipe 0 is always enabled.

Color (A) Valve

Enter the desired color valve number (1-30).

NOTE: If you enter a number which is not valid in

your system configuration, the field will be highlighted

and the recipe becomes invalid. For example, if your

configuration has 8 color valves and you enter 30,

the field will appear as shown below.

Figure 34 Invalid Recipe Screen

Catalyst (B) Valve

Enter the desired catalyst valve number (1-4).

NOTE: If you enter a number which is not valid in

your system configuration, the field will be highlighted

and the recipe is invalid. For example, if your

configuration has 1 catalyst valve and you enter 4,

the field will be highlighted and the recipe is invalid.

Flush Sequence

Enter the desired flush sequence (1-5) for the color

(A) valve and the catalyst (B) valve. The gun purge

time for each material depends on the flush sequence

assigned to each. See Flush Screen, page 73.If

materials A and B require different purge times,

assign separate flush sequences. Set the necessary

gun purge time for each. For hard to flush colors,

select a longer sequence. 1 is the default, and should

be designated for the longest, most thorough flush

duration.

Mix Ratio

Enter the desired mix ratio (0 to 50.0):1.

Potlife Time

Enter the potlife time (0 to 999 minutes). Entering

0 disables this function.

72332564B

Setup Mode Screens

Flush Screen

Figure 35 Flush Screen

Flush Number

Enter the desired flush sequence (1-5). For hard

to flush colors, select a longer sequence. 1 is the

default, and should be designated for the longest,

most thorough flush duration.

Gun Purge Time

Enter the spray device purge time (0 to 999 seconds).

Initial Flush

Enter the initialflushvolume(0to9999cc).

Final Flush

Enter the final flush volume (0 to 9999 cc).

Wash Cycles

AWashCycleactivates the pump with the valves

closed, to use pumping motion to thoroughly clean

the pump. Enter the desired number of wash cycles

(0 to 99). Entering a number will make the Strokes

per Cycle field active.

Strokes per Wash Cycle

Enter the desired pump strokes per wash cycle (0

to 99). Default is 1.

332564B 73

Setup Mode Screens

Pump Screen 1

NOTE: Your system may include 2, 3, or 4 pumps.

Information for each pump is accessible under a

separate tab in the menu bar at the top of the screen.

Select the tab for the desired pump. Each pump has

three screens. Only the screens for Pump 1 are

shown here, but the same fields appear on all.

Pump screen 1 includes the following fields which

define the pump.

Figure 36 Pump Screen 1

Pump Size

Select 35cc or 70cc, as appropriate.

Inlet Pressure

Select one of the following:

• Disabled

• Monitor, to track inlet pressure

Select Color Change

Select this box if your system uses color change.

Materials

Enter the number of materials used in your system.

Each color change module controls 8 colors.

Hose Length

Compute the length of the hoses from the supply

stack to the pump and from the pump to the outlet

stack. Enter the total length.

Hose Diameter

Enter the diameter of the supply and output hoses.

Available Colors

The module displays the number of colors available

in your system. This field is not editable.

74332564B

Setup Mode Screens

Pump Screen 2

Pump screen 2 sets the pressure transducer settings

for the pump.

Figure 37 Pump Screen 2, Default Settings Enabled

Figure 38 Pump Screen 2, Default Settings Disabled

Default Settings Selected

When the “Use Default Settings” box is selected,

default settings are used for the calibration values,

and the fields are grayed out.

Default Settings Not Selected

When the “Use Default Settings” box is not selected,

the following calibration values must be entered.

Invalid values will be over-ridden and the system will

automatically select the default settings.

•InletOffs

et Factor: This field is only used if Inlet

Pressure inPump Screen 1, page 74 is set to

Monitor; it is grayed out if set to Disabled. The

valid range is -01.20 to +01.20 mV/V.

•InletSen

sitivity Factor: This field is only used if

Inlet Pressure in Pump Screen 1, page 74 is set

to Monitor; it is grayed out if set to Disabled. The

valid range is 18.80 to 21.20 mV/V.

•OutletO

ffset Factor: The valid range is -01.20 to

+01.20 mV/V.

•OutletS

ensitivity Factor: The valid range is 18.80

to 21.20mV/V.

332564B 75

Setup Mode Screens

Pump Screen 3

Pump screen 3 sets the pressure alarm limits for the

pump.

When Inlet Pressure in Pump Screen 1, page 74 is

set to Disabled, the inlet limit fields are grayed

out and only the outlet limit fields are active. See

Pressure Alarm and Deviation Limits, page 76.

Figure 39 Pump Screen 3, Pressure Monitoring

Disabled

When Inlet Pressure in Pump Screen 1, page 74 is

set to Monitor, all fields are active. See

Pressure Alarm and Deviation Limits, page 76.

Figure 40 Pump Screen 3, Pressure Monitoring

Enabled

Pressure Alarm and Deviation Limits

Inlet fields are only active if Inlet Pressure

in Pump Screen 1, page 74 is set to Monitor; they

are grayed out if set to Disabled. Outlet fields are

active at all times.

• Alarm and Deviation ranges are 0-300 psi for

low pressure systems, and 0-1500 psi for high

pressure systems.

• Setting to 0 will disable the alarm. The Inlet Alarm

High and Outlet Alarm High cannot be disabled.

• Alarms and Deviations will display when the inlet

or outlet pressure drops below the low limit or

exceeds the high limit.

76 332564B

Setup Mode Screens

Calibration Screens

Calibrate Screen 1

Calibrate Screen 1 initiates a pump pressure check

(stall test) for the selected pump. During the test, the

Stall Test screen will appear.

The pump and lines must be primed with color

or catalyst before doing the stall test. See

System Screen 2, page 68 to set test parameters.

See Pump Pressure Check, page 84 for complete

test instructions.

To initiate the test, press the Pressure Check

button for the desired pump. The pump will build

pressure in the line to a minimum of the Stall Test

Pressure. The pump will then move to the center

stroke position and stall test the upstroke, followed

by the downstroke.

NOTE: TheLastPassedlogcanonlyberesetby

successfully completing the test.

The screen displays the number of days since the

last stall test was passed for each pump.

Figure 41 Calibrate Screen 1

Figure 42 Stall Test Screen

332564B 77

Setup Mode Screens

Calibrate Screen 2

Calibrate Screen 2 initiates a volume test for the

selected pump. During the test, the Volume Check

screen will appear.

The pump and lines must be primed with color

or catalyst before doing the Volume Check. See

Pump Volume Check, page 85 for complete test

instructions.

To initiate the test, press the Volume Check

button for the desired pump.

The screen displays the volume dispensed. Press

to end the test.

Press and hold the Reset button for 1-2

seconds to reset the volume counter.

Figure 43 Calibrate Screen 2

Figure 44 Volume Check Screen

78 332564B

Setup Mode Screens

Calibrate Screen 3

Calibrate Screen 3 initiates a calibration of an

accessory solvent meter. During the test, the Volume

Verification screen will appear.

The meter and lines must be primed with

solvent before doing the calibration. See

Solvent Meter Calibration, page 86 for complete

instructions.

To initiate the calibration, press the Volume Check

button.

The screen displays the volume dispensed. Enter

the amount of solvent dispensed in the Measured

Volume field, or press to end the test.

After the Measured Volume is entered, the Accept

Calibration window will appear. Press to accept

the calibration. Press to cancel the calibration

and retain the previous K-factor.

Press and hold the Reset button for 1-2

seconds to reset the volume counter.

Figure 45 Calibrate Screen 3

Figure 46 Enter Measured Volume of Solvent

Figure 47 Accept Calibration

332564B 79

Setup Mode Screens

Maintenance Screens

Maintenance Screen 1

Use this screen to set maintenance intervals. Set

to 0 to disable the alarm.

NOTE: The Pump Stall Test cannot be disabled. You

must enter a value other than 0.

Figure 48 Maintenance Screen 1, Interval Settings

Maintenance Screen 2

Maintenance screen 2 shows the current interval

status of the solvent meter, fluid filter, and air filter.

Press and hold the Reset button for 1-2

seconds to clear the alarm and reset the counter.

Figure 49 Maintenance Screen 2, Current Status

Maintenance Screen 3

Maintenance screen 3 shows the current interval

status of the pump maintenance tests.

Press and hold the Reset button for 1-2

seconds to clear the alarm and reset the counter.

NOTE: ThePumpStallTestcanonlyberesetby

successfully completing the test.

Figure 50 Maintenance Screen 3, Current Pump

Status

80 332564B

Setup Mode Screens

Maintenance Screen 4

Maintenance screen 4 displays cycle counts for a

selected color, catalyst, or solvent valve.

Press and hold the Reset button for 1-2

seconds to reset the counter.

If the system is in Standby, valves can be opened

or closed by selecting or deselecting the box for the

corresponding valve.

Figure 51 Maintenance Screen 4, Color Valve Resets

Figure 52 Maintenance Screen 4, Solvent Valve

Resets

NOTE: In Fig. 48, the number to the right of “Solvent”

is the pump number, not the material number.

332564B 81

Setup Mode Screens

Advanced Screen 1

Advanced screen 1 sets the following display

parameters.

Figure 53 Advanced Screen 1

Language

Defines the language of the screen text. Select:

• English (default)

• Spanish

•French

•German

• Japanese

• Chinese

• Korean

•Dutch

• Italian

•Port

uguese

•Swedish

•Russian

Date Format

Select mm/dd/yy, dd/mm/yy, or yy/mm/dd.

Date

Enter the date, using the format selected. Use two

digits for the month, day, and year.

Time

Enter current time in hours (24 hour clock) and

minutes. Seconds are not adjustable.

Password

The password is only used to enter Setup mode.

The default is 0000, which means no password is

required to enter Setup. If a password is desired,

enter a number from 0001 to 9999.

NOTE: Be sure to write down the password and keep

it in a secure location.

Screen Saver

Select the desired screen timeout in minutes (00-99).

5isth

e default. Select zero (0) to disable the screen

saver.

SilentMode

Select Silent Mode to disable the alarm buzzer and

audible feedback.

82 332564B

Setup Mode Screens

Advanced Screen 2

Advanced screen 2 sets display units (US or metric).

Figure 54 Advanced Screen 2

Display Units

Select the desired display units:

• Grand Total Volume (US gallon or liter)

• Pressure (psi, bar, or MPa)

• Length (ft or m)

Advanced Screen 3

Advanced screen 3 enables USB downloads and

uploads.

Figure 55 Advanced Screen 3

Enable USB Downloads/Uploads

Select this box to enable USB downloads and

uploads. Enabling USB activates the Download

Depth field.

Download Depth

Enter the number of days for which you want to

retrieve data. For example, to retrieve data for the

previous week, enter 7.

Log 90% Full Advisory Enabled

This selection is enabled by default. When enabled,

the system will issue an advisory if the memory log

has reached 90% of capacity. Perform a download to

avoid loss of data.

Advanced Screen 4

Advanced screen 4 displays the software part

numbers and versions for the system components.

This is not an editable screen.

Figure 56 Advanced Screen 4

332564B 83

Calibration Checks

Calibration Checks

Pump Pressure Check

NOTE: Enter the transducer calibration data before

doing the pressure check.

Perform the pressure check:

• The first time the system is operated.

• Whenever new materials are used in the system,

especially if the materials have viscosities that

differ significantly.

• At least once per month as part of regular

maintenance.

• Whenever a pump is serviced or replaced.

During each pressure test, the dose valve will close

during an up stroke and a down stroke (in either

order). This test is to verify that the valves are

seating properly and not leaking. If leaking occurs,

the system will alarm after the test for that particular

pump direction.

NOTE: Do not trigger the spray device during the

pressure check.

1. The pump and lines must be primed with color or

catalyst before doing the Pressure Check. See

PrimeandFilltheSystem,page20.

2. If the display is on a Run Mode screen, press

to access setup screens.

3. Scroll to Calibrate to display

Calibrate Screen 1, page 77.

4. Press the Pressure Check button for the

desired pump. The pump will build pressure in

the line to a minimum of the Stall Test Pressure.

The pump will then move to the center stroke

position and stall test the upstroke, followed by

the downstroke.

5. The pressure and flow that the unit measured

are displayed on the screen. Compare

with the maximum leak rate entered on

System Screen 2, page 68. If the values are

substantially different, repeat the test.

NOTE: The stall test pressure set point is a

minimum. The system may stall at a higher

pressure depending on hose lengths and fluid

composition.

84 332564B

Calibration Checks

Pump Volume Check

1. The pump and lines must be primed with color or

catalyst before doing the Volume Check. See

Prime and Fill the System, page 20.

2. If the display is on a Run Mode screen, press

to access setup screens.

3. Scroll to Calibrate in the menu bar.

4. Scroll to Calibrate Screen 2, page 78.

5. Press the soft key for the pump you want

to check.

NOTE: For maximum accuracy, use a gravimetric

(mass) method to determine the actual volumes

dispensed. Verify that the fluid line is filled and

at the proper pressure before checking. Air in

thelineorpressurethatistoohighmaycause

incorrect values.

6. Press the Reset key . The volume counter

will reset to 0.

7. Trigger the gun into a graduated cylinder.

Dispense a minimum of 500cc of material.

8. The volume that the unit measured displays on

the screen.

9. Compare the amount on the screen to the

amount in the graduated cylinder.

NOTE: If the value is substantially different,

repeat the test. If the dispensed volume and

measured volume still do not match, check that

theAandBpumppositionsarenotreversed.

NOTE: Stop triggering the gun and press

to cancel the test.

332564B 85

Calibration Checks

Solvent Meter Calibration

1. The meter and lines must be primed with

solvent before doing the calibration. See

PrimeandFilltheSystem,page20.

2. If the display is on a Run Mode screen, press

to access setup screens.

3. Scroll to Calibrate in the menu bar.

4. Scroll to Calibrate Screen 3, page 79.

5. Press the soft key to initiate the calibration.

NOTE: For maximum accuracy, use a gravimetric

(mass) method to determine the actual volumes

dispensed.

NOTE: Verify that the fluid line is filled and at the

proper pressure before calibrating. Air in the line

or pressure that is too high may cause incorrect

calibration values.

6. Trigger the gun into a graduated cylinder.

Dispense a minimum of 500cc of material.

7. The volume that the unit measured displays on

the screen.

8. Compare the amount on the screen to the

amount in the graduated cylinder.

NOTE: If the value is substantially different,

repeat the calibration process.

9. Enter the amount of solvent dispensed in the

Measured Volume field on the screen.

10. After the measured volume is entered, the

controller calculates the new solvent meter

K-factor and displays it on the screen. The

standard meter K-factor is 0.021 cc/pulse.

11. Press to accept the calibration. Press

to cancel the calibration and retain the previous

K-factor.

86 332564B

Color Change

Color Change

Color Change Module Kits are available as an

accessory. See manual 333282 for complete

information.

Single Color Systems

1. Follow the procedure under

Flush the System, page 23.

2. Load the new color. See

Prime and Fill the System, page 20.

3. Command the system to Mix to start spraying.

Multiple Color Systems

1. Command the system to Standby.

2. Enable manual override on

System Screen 5, page 71.

3. Select the new recipe on the

Spray Screen, page 62. This will change

colors in the pump and initiate a gun purge.

4. The system will purge material B then material

A out of the gun. Each material will purge for

the amount of time designated by the Flush

Sequence selected for each material on the

Recipe Screen, page 72.

5. Wait for the color change to complete. The

system automatically goes from Color Change to

Mix Fill and the remote mix manifold automatically

selects the correct color.

6. Trigger the gun to complete the Mix Fill.

NOTE: There is a 10 second delay without flow

before the system will fault.

7. Wait for the system to complete the Mix Fill

operation. Command the system to Mix and

begin spraying..

332564B 87

System Errors

System Errors

System errors alert you of a problem and help

prevent off-ratio spraying. There are three types:

Advisory, Deviation, and Alarm.

An Advisory records an event in the system, and will

clear itself after 60 seconds.

ADeviation records an error in the system but does

not shut down the equipment. The deviation must be

acknowledged by the user.

If an Alarm occurs, operation stops.

If any of the three types occur:

• Alarm buzzer sounds (unless in silent mode).

• Alarm popup screen shows the active alarm code

(see Error Codes, page 89).

• Status bar on the Advanced Display Module shows

theactivealarmcode.

• Alarm is saved in the date/time stamped log.

To Clear Error and Restart

NOTE: When a deviation or alarm occurs, be

sure to determine the error code before resetting

it. If you forget which code occurred, go to the

Errors Screen, page 65, to view the last 200 errors,

with date and time stamps.

If an alarm has occurred, correct the cause before

resuming operation.

To acknowledge a deviation or clear an alarm, press

on the Advanced Display Module. Users also

may acknowledge and clear errors via a network

device. INPUT REGISTER 08: Clear Active Alarm in

ProMix PD2K Network Inputs, page 36.

Gun Trigger Input Function

The Gun Trigger Input signals the controller when

the gun is triggered. The gun icon on the Advanced

Display Module shows spray when the Gun Trigger

Input is activated.

If a pump fails, pure resin or catalyst could spray

indefinitely if the unit does not detect the condition

and intervene, which is why the Gun Trigger Input

is so important.

If the unit detects through the Gun Trigger Input

signal that the gun is triggered, yet one or both of the

pumps are not running, a Flow Not Detected Alarm

(F8D1) occurs after 10 seconds (default) and the

system goes into Standby.

88 332564B

System Errors

Error Codes

NOTE: When an error occurs be sure to determine the code before resetting it. If you forget which code

occurred, use the Errors Screen, page 65 to view the last 200 errors, with date, time, and description.

Purge Errors

Code Type Description Problem Cause Solution

Air flow switch is stuck

in flow position.

Clean or replace switch.

Leak downstream in air

line or fitting.

Check for leaks and

tighten fittings.

F7P1 Alarm Air Flow

Switch On

The air flow switch is

indicating unexpected

atomizing air flow.

Air supply pressure

fluctuation.

Eliminate pressure

fluctuations.

Solvent flow switch not

working.

Replace switch.

Solvent flow is too low

to actuate the solvent

switch.

Increase solvent

pressure to drive a

high purge flow rate

Gun is not triggered. Operator must continue

flushing for configured

time, until the booth

control indicates purge

is completed.

SPD1 Alarm Gun Purge

Incomplete

Thesystemtimedout

without reaching the

user-specified volume

of solvent for a purge.

Mix manifold was not

set to flush position,

blocking solvent flow to

the spray gun.

Setmanifoldtoflush

position.

Mix Errors

Code Type Description Problem Cause Solution

Solvent flow switch is

stuck in flow position.

Clean or replace switch.F7S1 Alarm Flow

Detected

Solvent

Gun

The solvent flow

switch is indicating

unexpected solvent

flow. There is a leak through

the solvent cutoff valve.

Check for leaks and

repair valve.

Purge process was not

completed.

Make sure purge

process is completed.

QPD1 Alarm,

then

Devia-

tion

Potlife

Expired

Potlife time has expired

before the system has

moved the required

amount of material

(potlife volume) through

the mixed material line.

Solvent supply shut off

or empty.

Verify solvent supply

is available and on,

supply valves are open.

Mix manifold not set to

spray position.

Set manifold to spray.

Spraygunwasnot

triggered.

Allow flow through gun

during fill process until

the fill complete LED

stops flashing.

SND1 Alarm Mix Fill

Incomplete

The system timed out

before the mix fill cycle

loaded the gun with

mixed material.

Restrictions in mixer,

manifold, or spray gun.

Fix restrictions.

332564B 89

System Errors

Pumping Errors

NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the

applicable component number, which can vary. The unit’s display will show the applicable number as the

last digit in the code. For example, the F1S# code listed in this table will be displayed as F1S1 if the affected

component is pump 1, F1S2 for pump 2, and so on.

Code Type Description Problem Cause Solution

System has a leak

or open valve that is

allowing unrestricted

flow.

Inspect system for

leaks.

Pump is cavitating,

cycling without

restriction.

Verify that the pump

is being supplied with

material.

Viscosity of material is

too thin for nozzle size.

Reduce nozzlesizeto

create more restriction.

Reduce paint pressure

to lower the flow rate.

DA0# Alarm Exceeded

Maximum

Flow Pump

#

Pump was driven to

its maximum allowed

speed.

System pressure or

Flow Setpoint is too

high (causing the pump

to work too hard).

Reduce the pressure or

the Flow Setpoint.

No material in the pump

or line.

Make sure the pump

and down stream color

line areloadedwith

material.

DE0# Alarm Leak

Detected

Pump #

This is a manual stall

test failure when the

pump cannot build

pressure to the target

“Stall Test Pressure.”

Will fault after 30

seconds.

Leak in the system. Determine if leak is

external or internal

by visually inspecting

the system for fluid

leakage. Fix all loose

or worn hoses, fittings,

and seals. Inspect

all valve seats and

needles for wear, and

replace worn piston or

throat seals.

DF0# Alarm No Stall Up

Pump #

Pump failed the stall

test; did not stall on the

upstroke.

Valve failure, seal

failure, worn rod or

cylinder.

Replace inlet and outlet

valve and seal for

up stroke. Replace

piston and throat

seals. Replace rod and

cylinder as necessary.

DG0# Alarm No Stall

Down Pump

#

Pump failed the stall

test; did not stall on the

downstroke.

Valve failure, seal

failure, worn rod or

cylinder.

Replace inlet and outlet

valve and seal for

down stroke. Replace

piston and throat

seals. Replace rod and

cylinder as necessary.

90 332564B

System Errors

Code Type Description Problem Cause Solution

DH0# Alarm No Stall

Pump #

Pump failed thestall

test; did not stall on

either the upstroke or

the downstroke.

Valve failure, seal

failure, worn rod or

cylinder.

Replace inlet and outlet

valve and seal for up

and down strokes.

Replacepistonand

throat seals. Replace

rod and cylinder as

necessary.

DK0# Alarm Position

Pump #

Pump was detected to

be out of position.

Re-enable pump power

to reset pump. Make

sure inlet supply

pressure is not too

high.

EBH# Rec-

ord

Home

Complete

Pump #

Record of pump homing

is complete.

An indication on the

display that the pump

completed the home

function

No action required.

Pump dose valves did

not actuate.

Verify airpressure

to solenoid valves.

Verify the valves are

actuating.

Motor could not drive

pumps and linear

actuator.

Verify motor is driving

the pump.

EF0# Alarm Timeout

Startup

Pump #

Pump tried but was not

abletomovetothe

home position within

a specified amount of

time.

Pump stroke length

is shortened by

mechanical system

tolerance.

Verify correct assembly

of linear actuator and

pump piston rods. See

pump manual.

Pump dose valves did

not actuate.

Visually inspect valves

to ensure they are

operating properly;

verify they have air

pressure above 85 psi

(0.6 MPa, 6.0 bar).

EF1# Alarm Timeout

Shutdown

Pump #

Pump tried but was not

abletomovetothe

park position within a

specified amount of

time.

Pump is filled with thick

paint and could not

drive piston to end of

stroke. Motor or drive

is worn or damaged.

Observe motor and

drive assembly to

verify that the motor is

generating force.

332564B 91

System Errors

Code Type Description Problem Cause Solution

There is a restriction on

the outlet side of the

pump or color stack.

Make sure there are no

restrictions in the color

stack and that the dump

valve is actuating.

Thick viscosity paint

requires more pressure

to pump.

Increase non-mix

pressure if necessary

to create flow during

the fill function.

F1F# Alarm Flow Low

Fill Pump #

There has been no flow

or low flow during a

pump fill operation.

The pumps do not

have to move for the

system to build enough

pressure to meet the

setpoint.

Increase non-mix

pressure if necessary

to create flow during

the fill function.

F1S# Alarm Flow Low

Purge Pump

#

There has beennoflow

or low flow during a

pump purge operation.

Restriction in the outlet

side of the pump or

color stack resulting in

the solvent flow being

too low.

Make sure there are

no restrictions in the

system. Increase

non-mix pressure if

necessary to create

flow during the purge

function.

F7D# Alarm Flow

Detected

Pump #

Thepumpflow

exceeded 20 cc/min

flowcomingintoIdle

mode.

There is a leak in the

system or the gun was

open when the system

went into Idle mode.

Verify there are no

leaks in the system.

Make sure the air flow

switch is actuating

properly. Do not

trigger the gun without

atomizing air.

F8D1 Alarm Flow Not

Detected

No flow while mixing. Restriction in the outlet

side of the pump or

color stack.

Make sure there are

no restrictions in the

system.

F9D# Alarm Flow

Unstable

Pump #

Thepumpflowrate

did not stabilize while

entering Idle mode.

Potential leak in the

system.

Check the system for

leaks and run manual

stall test.

SAD1Alarm Atomizing

Solvent

Air flow switch is

active while solvent,

diluted material, or an

unknown material is in

the gun.

Atomizing air supply

was not shut off before

purging or filling spray

gun.

Make sure atomizing

air is shut off before

purging or filling the

spray gun. Use an

AA cutoff valve on the

atomizing air supply.

92 332564B

System Errors

Pressure Errors

NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the

applicable component number, which can vary. The unit’s display will show the applicable number as the

last digit in the code. For example, the P6F# code listed in this table will be displayed as P6F1 if the affected

component is pump 1, P6F2 for pump 2, and so on.

Code Type Description Problem Cause Solution

F6F# Alarm Press.

Sens.

Removed

Inlet #

No inlet pressure

transducer is detected

when the system is

expecting one.

Disconnected

transducer.

Verify transducer is

connected properly.

Replace if reconnecting

does not eliminate the

alarm.

P1F# Alarm Pressure

Low Inlet

Pump #

The inlet pressure on

pump # is less than

the user-entered alarm

limit.

Increase inlet pressure.

P2F# Devi-

ation

Pressure

Low Inlet

Pump #

The inlet pressure on

pump # is less than the

user-entered deviation

limit.

Increase inlet pressure.

P3D# Devi-

ation

Pressure

High Outlet

Pump #

The outlet pressure

on pump # is greater

than the user entered

deviation limit.

Relieve system

pressure.

P3F# Devi-

ation

Pressure

High Inlet

Pump #

The inlet pressure

on pump # is greater

than the user-entered

deviation limit.

Decrease inlet

pressure.

P4D# Alarm Pressure

High Outlet

Pump #

Theoutletpressureon

pump # is greater than

the user entered alarm

limit.

Relieve system

pressure.

P4F# AlarmPressure

High Inlet

Pump #

The inlet pressure on

pump # is greater than

the user-entered alarm

limit.

Decrease inlet

pressure.

P6D# Alarm Press.

Sens.

Removed

Outlet #

No outlet pressure

transducer is detected

when the system is

expecting one.

Disconnected

transducer.

Verify transducer is

connected properly.

Replace if reconnecting

does not eliminate the

alarm.

P9D# Alarm Press.

Sens.

Failed

Outlet #

Outlet pressure

transducer has failed.

Outlet pressure

transducer has failed or

the pressure is above

the readable range.

Relieve system

pressure. Verify

connections, or replace

if reconnecting does

not eliminate the alarm.

332564B 93

System Errors

Code Type Description Problem Cause Solution

P9F# Alarm Press.

Sens.

Failed Inlet

#

Inlet pressure

transducer has failed.

Inlet pressure

transducer has failed or

thepressureisabove

the readable range.

Relieve system

pressure. Verify

connections, or replace

if reconnecting does

not eliminate the alarm.

There is a leakonthe

B side.

Check the system

for internal and

external leaks on all

catalyst manifolds and

plumbing.

QADX Alarm Differential

Pressure A

Over B

Low differential

pressure. This alarm is

active only during Mix

mode.

The B side pump is

cavitating.

Check paint supply on

the B side, increase

paint supply pressure.

There is a leak on the

A side.

Check the system

for internal and

external leaks on all

color manifolds and

plumbing.

QBDX Alarm Differential

Pressure B

Over A

High differential

pressure. This alarm is

active only during Mix

mode.

The A sidepumpis

cavitating.

Check paint supply on

the A side, increase

paint supply pressure.

94 332564B

System Errors

System Errors

Code Type Description Problem Cause Solution

EB00 Rec-

ord

Stop Button

Pressed

Recordofastopbutton

press.

Indicates system stop

key on ADM was

pressed.

n/a

EC00 Rec-

ord

Setup

Value(s)

Changed

Record of changing

setup variables.

Indicates date and time

when setup values

were changed.

n/a

EL00 Rec-

ord

System

Power On

Record of power cycle

(ON).

Indicates date and

time when system was

started.

n/a

EM00 Rec-

ord

System

Power Off

Record of power cycle

(OFF).

Indicates date and

time when system was

turned off.

n/a

EMIX Advi-

sory

Pump Off The pumps are not

powered and are

unable to move.

Pump powerwas

turned offoranerror

occurred.

Start pumps by

pressing pump start

key on Advanced

Display module.

ES00 Advi-

sory

Factory

Defaults

Record of defaults

being loaded.

n/a

Communication Errors

NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the

applicable component number, which can vary. The unit’s display will show the applicable number as the last

digit in the code. For example, the CAC# code listed in this table will be displayed as CAC1 if the affected

component is color change board 1, CAC2 for board 2, and so on.

Code Type Description Problem Cause Solution

CA0X Alarm Comm. Error

ADM

System does not

detect the Advanced

Display Module

(ADM).

This communication

error indicates that

the Network has lost

communication with

the Advanced Display

Module.

Check CAN cable

connecting ADM to

the EFCM.

CAC# Alarm Comm. Error

Color Change

#

System does not

detect the Color

Change Module #.

This communication

error indicates that

the network has lost

communication with

the Color Change

Module #.

Check CAN cable

connections to

the Color Change

Module # and any

interconnected

modules.

CADX Alarm Comm. Error

Fluid Module

System does not

see the Enhanced

Fluid Control Module

(EFCM).

This communication

error indicates that

the Network has lost

communication with

the EFCM.

Check CAN cables

connecting ADM to

the EFCM. Replace

Cable or EFCM as

necessary.

332564B 95

System Errors

Code Type Description Problem Cause Solution

CAGX Alarm Comm. Error

Gateway

System does not

detect a CGM that

was registeredas

being connected at

power up.

CDC# Alarm Duplicate

Color Change

#

System detects two or

more identical Color

Change Modules.

More than one Color

Change Module with

thesameaddress

is connected in the

system .

Check the system

and remove the extra

color change module.

CDDX Alarm Duplicate

Fluid Module

System sees two

or more identical

Enhanced Fluid

Control Modules

EFCM).

More than one EFCM

is connected in the

system.

Check the system

and remove the extra

EFCM.

96 332564B

System Errors

USB Errors

Code Type Description Problem Cause Solution

EAUX Advi-

sory

USB Busy USB drive is inserted,

download is in

progress.

Indicates USB port

is uploading or

downloading data.

Wait for USB Idle.

EBUX Record USB Drive

Removed

USB drive was

removed while

downloading or

uploading.

Downloading/upload-

ingdataonUS

Bwas

interruptedbythe

USB device being

removed.

Replace the USB

device and begin

process again.

EQU0 Advi-

sory

USB Idle USB download

completed, drive

may be removed.

Data transfer is

completedtothe

USB device.

Remove USB device

from ADM.

EQU1 Record USB Sys.

Settings

Downloaded

Settings were

downloaded to USB

drive.

User installed USB

device in ADM USB

port.

n/a

EQU2 Record USB Sys.

Settings

Uploaded

Settingswere

uploadedfromUSB

drive.

User installed USB

device in ADM USB

port.

n/a

EQU3 Record USB Custom

Lang.

Downloaded

Custom language

was downloaded to

USB drive.

User installed USB

device in ADM USB

port.

n/a

EQU4 RecordUSB Custom

Lang.

Uploaded

Custom language

was uploaded from

USB drive.

User installed USB

device in ADM USB

port.

n/a

EQU5 Record USB Logs

Downloaded

Data logs were

downloaded to USB

drive.

User installed USB

device in ADM USB

port.

n/a

EVUX Advi-

sory

USB Disabled USB drive has

been inserted,

downloading is

disabled.

Configuration of

system is blocking

data transfer.

Change configuration

to enable USB

download function.

MMUX Advi-

sory

Maint. USB

Logs Full

USB memory is more

than 90% full.

Configuration

parameter on

system is enabled

to generate this

advisory.

Complete download

to ensure no data is

lost.

WSUX Advi-

sory

USB Config.

Err.

USB configuration

file does not match

expected; checked

on startup.

Asoftware update

was not completed

successfully.

Reinstall software.

332564B 97

System Errors

Code Type Description Problem Cause Solution

WXUD Advi-

sory

USB

Download Err.

An error occurred

while downloading to

the USB drive.

User installed

incompatible USB

device in ADM USB

port.

Repeat process with

compatible USB

device.

WXUU Advi-

sory

USB Upload

Err.

An error occurred

while uploading from

the USB drive.

User installed

incompatibleUSB

device in ADM USB

port.

Repeat process with

compatible USB

device.

98 332564B

System Errors

Miscellaneous Errors

NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the

applicable component number, which can vary. The unit’s display will show the applicable number as the last

digit in the code. For example, the B9D# code listed in this table will be displayed as B9D1 if the affected

component is pump 1, B9D2 for pump 2, and so on.

Code Type Description Problem Cause Solution

B9A0 Advi-

sory

Volume

Rollover A

Current

Batch counterfor

material A rolled over.

The totalizer has

reached maximum

capable value and

started over at zero.

n/a

B9AX Advi-

sory

Volume

Rollover A

Lifetime

Grand total counter

for material A rolled

over.

The totalizer has

reached maximum

capable value and

started over at zero.

n/a

B9B0 Advi-

sory

Volume

Rollover B

Current

Batch counter for

material B rolled over.

The totalizer has

reached maximum

capable value and

started over at zero.

n/a

B9BX Advi-

sory

Volume

Rollover B

Lifetime

Grand total counter

for material B rolled

over.

The totalizer has

reached maximum

capable value and

started over at zero.

n/a

B9D# Advi-

sory

Volume

Rollover

Pump #

Grand total counter

forpump#rolled

over.

The totalizer has

reached maximum

capable value and

startedoveratzero.

n/a

B9S0 Advi-

sory

Volume

Rollover

Solvent

Current

Batch counter for

solvent rolled over.

The totalizer has

reached maximum

capable value and

started over at zero.

n/a

B9SX Advi-

sory

Volume

Rollover

Solvent

Lifetime

Grand total counter

for solvent rolled

over.

The totalizer has

reached maximum

capable value and

started over at zero.

n/a

WX00 AlarmSoftware

Errors

An unexpected

software error has

occurred.

Call Graco technical

support.

332564B 99

System Errors

Calibration Errors

NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the

applicable component number, which can vary. The unit’s display will show the applicable number as the last

digit in the code. For example, the ENT# code listed in this table will be displayed as ENT1 if the affected

component is pump 1, ENT2 for pump 2, and so on.

Code Type Name Description

END# Record Calibration Pump # A calibration test was run on the pump.

ENS0 Record Calibration Solvent Meter A calibration test was run on the solvent

meter.

ENT# Record CalibrationStallTestPump

#

A stall test was completed successfully

on pump #.

100 332564B

System Errors

Maintenance Errors

NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the

applicable component number, which can vary. For example, the MAD# code listed in this table will be

displayed as MAD1 if the affected component is pump 1, MAD2 for pump 2, and so on.

Because some components are assigned a 2–digit number, the last digit of the code is displayed as an

alphanumeric character. The second table below correlates the alphanumeric digit to its component number.

For example, code MEDZ represents outlet valve 30.

Code Type Name Description

MAD# Advisory Maint. Outlet Pump # Maintenance is due on pump.

MAT# Advisory Maint. StallTest

Pump #

Maintenance stall test is due on pump.

MEB# Advisory Maint. Valve Catalyst

(B) #

Maintenance is due on catalyst valve.

MED# Advisory Maint. Valve Outlet # Maintenance is due on outlet valve.

MEF# Advisory Maint. Valve Inlet # Maintenance is due on inlet valve.

MEG# Advisory Maint. Valve Gun # Maintenance is due on gun valve.

MES# Advisory Maint. Valve Solvent

#

Maintenance is due on solvent valve.

MFF# Advisory Maint. Meter Flow # Maintenance is due on flow meter.

MFS0 Advisory Maint. Meter Solvent Maintenance stall test is due on solvent meter.

MGH0 Advisory Maint. Filter Fluid Maintenance is due on fluid filter.

MGP0Advisory Maint. Filter Air Maintenance is due on air filter.

Alphanumeric Last Digits

Alphanumeric Digit Component Number

11

22

33

44

55

66

77

88

99

A10

B11

C12

D13

E14

F15

Alphanumeric Digit Component Number

G16

H17

J18

K1

9

L20

M21

N22

P23

R24

T25

U26

V27

W28

Y29

Z30

332564B 101

Maintenance

Maintenance

Preventive Maintenance Schedule

The operating conditions of your particular system

determine how often maintenance is required.

Establish a preventive maintenance schedule by

recording when and what kind of maintenance is

needed, and then determine a regular schedule for

checking your system.

Flushing

• Flush before changing fluids, before fluid can dry

in the equipment, at the end of the day, before

storing, and before repairing equipment.

• Flush at the lowest pressure possible. Check

connectors for leaks and tighten as necessary.

• Flush with a fluid that is compatible with the fluid

being dispensed and the equipment wetted parts.

Cleaning theADM

Use any alcohol-based household cleaner, such as

glass cleaner, to clean the ADM.

102 332564B

Technical Data

Technical Data

Positive Displacement

Proportioner

U.S. Metric

Maximum fluid working

pressure:

AC1000 Air Spray

Systems

300 psi 2.1 MPa, 21 bar

AC2000 Air-Assisted

Spray Systems

1500 psi 10.5 MPa, 105bar

Maximum working air

pressure:

100 psi 0.7 MPa, 7.0bar

Air supply: 85–100 psi 0.6–0.7 MPa, 6.0–7.0 bar)

Air filter inlet size: 3/8 npt(f)

Air filtration for air logic

(user-supplied):

5micron(minimum) filtration required; clean and dry air

Air filtration for atomizing

air (user-supplied):

30 micron (minimum) filtration required; clean and dry air

Mixing ratio range: 0.1:1 — 50:1, ±1%

Fluids handled: one or two component:

• solvent and waterborne paints

• polyurethanes

• epoxies

• acid catalyzed varnishes

• moisture sensitive isocyanates

Viscosity range of fluid: 20–5000 centipoise

Fluid filtration

(user-supplied):

100meshminimum

Maximum fluid flow: 800 cc/minute (depending on material viscosity)

Fluid outlet size: 1/4 npt(m)

External power supply

requirements:

90 - 250 Vac, 50/60 Hz, 7 amps maximum draw

15 amp maximum circuit breaker required

8 to 14 AWG power supply wire gauge

Operating temperature

range:

36 to 122°F 2 to 50°C

Storage temperature

range:

—4 to 158°F —20 to 70°C

Weight (approximate): 195 lb 88 kg

Sound data: Less than 75 dB(A)

Wetted parts: 17–4PH, 303, 304 SST, Tungsten carbide (with nickel binder),

perfluoroelastomer; PTFE, PPS, UHMWPE

332564B 103

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.

To place an order, contact your Graco Distributor or call to identify the nearest distributor.

Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505

All written and visual data contained in this document reflects the latest product information available at the time of publication.

Graco reserves the right to make changes at any time without notice.

For patent information, see www.graco.com/patents.

Original Instructions. This manual contains English. MM 332564

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revision B, September 2014